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Hydro 10 & 15 (00756179S)

1. 2 item 5 The base end of the cylinder will now be open See figure 3 Remove the cylinder head figure 3 item 9 Pull the cylinder rod out from inside barrel approx 2 inches by pulling on the cylinder rod clevis figure 3 item 3 Using a brass soft metal hammer tap the barrel side of the cylinder head figure 3 item 9 Cylinder head will slide out of barrel when the shoulder of the cylinder head comes out of the barrel pull the cylinder clevis figure 3 item 3 The cylinder rod clevis cylinder rod cylinder head piston and piston nut will all pull out as an assembly when pulled from the barrel see figure 4 Remove the plastic plug figure 3 item 13 from the cylinder head With cylinder head piston cylinder rod and cylinder rod clevis assembly removed from the barrel the barrel can be removed from the vise the drain pans can be set aside see figure 3 Clamp the cylinder rod cylinder head and piston assembly into the vise see figure 4 When clamping the cylinder rod clevis into the vise make certain to clamp it as shown figure 4 the clevis must be clamped as shown or the clevis could be damaged by bending the ears of the clevis Slide a block ofwood figure 4 wood support block between cylinder rod and work bench insert a material between block figure 4 soft non scratching material and the cylinder rod this will protect the cylinder rod from damage Use a strap wrench to hold the cylinder rod figure 4 strap wrench to hold
2. A newsealis required for rebuild of the spindle Remove the bearing and check itfor damage or excessive wear Figure 13 gt HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 4 4 SPINDLE ASSEMBLY SERVICE amp REPAIR 10 Use a suitable drift punch to remove the bearing races BE CAREFUL NOT TO DAMAGE THE SPINDLE HOUSING figure 14 Remove and inspectthe vent and filler plugs and passageways Be sure the ventis free from clogs due to debris or paint Always install the vent plug above the filler plug figure 15 SPINDLE HOUSING INSPECTION Inspectthe bearings and bearing cups for nicks pitting discoloration and wear lfany exist replace the bearing and bearing cup Inspectthe housing for cracks wear atthe bearing cup bores orimpact damage Replace if necessary Inspectthe spindle shaft for pulled boltthreads cracks adjusting nut thread damage or machined surface damage Replace if required SPINDLE HOUSING ASSEMBLY Always install cups and cones toghter if new bearings are being used DO NOT mix used and new bearing components When installing the bearing cups make sure that they are properly seated into the housing DONOT DRIVE AGAINST THE BEARING SURFACE All parts should be thouroughly cleaned The bearing nut the lower seal and the motor flange seal cannot be reused Therefore replacements shouldbe ordered figure 16 er l 2 w HYDRO 15 Service Manual 09 06 2006 Alamo In
3. Clamp cylinder to work bench DO NOT over tighten clamp and bend or distort the shape of the barrel only tight enough to hold cylinder Place a drain pan under cylinder head to catch any oil that may leak out Pullthe Cylinder Rod Clevis Weldment figure 2 item 3 outward at least 3 inches This will allow the Cylinder Head figure 2 item 4 to be unscrewed from Barrel figure 2 item 5 using a commercially available two point spanner wrench figure 13 The cylinder head will screw counter clockwise out until it is away from the cylinder barrel Hold the Cyl rod figure 2 item 3 as straight as possible when cylinder head is unscrewed Keep drain pan under open end of barrel to catch oil that may drain from barrel Pull the Cylinder Rod Clevis Weldment figure 2 item 3 outward it will pull the piston out of the barrel figure 2 item 6 When pulling the rod and piston out do it slowly the amount of resistance should be about the same all the way out if you encounter a spot where the piston pulls easier than others make a mark on the OD of the barrel approx where the piston is in the barrel These loose places may indicate a worn are that will need to be checked later Pull the rod out slowly holding the rod as straight as possible until the piston figure 2 item 6 and cylinder rod weldment pulls completely out of barrel figure 2 item 5 Be careful not to bump the threads on the cylinder head or damage them Clamp cylinder rod clevis weldment in a
4. Coil As Solenoid Return Stem Logic Port Outlet Cartridge Manifold Block Plugged Manifold Block P coe os ie Port Port End TT Plugged A 2 Cover Port J Pressure Gear J Port Inlet Housing a Case Shaft End Drain FRONT OF Cover Fitting La MOWER Case E A i 7 Drain TT i g na A FRONT OF MOWER Figure 11 Figure 12 LH WING MOTOR RH WING MOTOR HYDRO 15 Service Manual 09 06 Section 3 9 Return Port Outlet Motor Asy Pressure Gear Port Inlet Housing 2006 Alamo Industrial MOTOR SERVICE amp REPAIR IMPORTANT CENTER MOTOR Mark all Sections of Motor with a Number or Symbols that will serve as a guide to all sections being re installed the same way they were removed Example if the numbers marks do not line up 1 2 38 4 as they were marked the Motor is not being assembled correctly Check this all through the assembly process The Motor will rotate in the wrong direction if connected wrong NOTE The manifold block will always mount with the relief valve on the same side as the pressure inlet Ifinstalled wrong the motor will not function properly because the relief valve will not work Center Motor Only Check Valve Cartridge Back Side Not Seen Relief Valve 3000 psi Manifold Block Center Motor a Plug 1 Split Flange Return A 1 Spli Lil plit Flange Outlet Side EL tend 7 a Pressure inlet Side Port End Cover Gear Housing Service Technic
5. Make certain the ports are clean and free of debris o a Straight Edge CLLLL LLL LLL LLL LLL LLP LPL LLP SSI SSI SSI SSI SSI SSI SSI SSI ST ST Z ER ee A TTT A E AA AS Figure 4 With the cylinder rod weldment still clamped in vice figure 5 slide the cylinder head figure 5 item 4 off the rod Inspect and clean the cylinder rod check the cylinder rod for any bend scratches metal flaking rust spots or pitting Use a straight edge figure 4 to check for bends in rod Check rod clevis mounting pin hole for wear or distortion Check the threads and piston seat surface If rod has been cleaned and is dry make certain to coat it with a light coat of oil Inspect the cylinder head general condition and the threads where it screws into the barrel figure 5 When working on the cylinder head never clamp it in a vice as it is made of aluminum and could be damaged be careful when removing old seals not to damage thread on OD of cylinder head Remove the Seals from the Cylinder Head First remove the O Ring and back up washer figure 5 item 4A when removing these note that the back up washer is on the outward side with the O Ring inward toward ID of Barrel Second remove the snap in rod wiper seal figure 5 item 4B make a note of the lip on seal thatit is pointing outward to enable the lip to wipe the dirt from rod Third remove the inner Rod seal figure 5 item 4C by prying
6. Over All Cutting Width 15 Ft Model 180 Center amp Wings Overall Cutting Width 10 Ft Model 124 1 2 Center amp Wing Overall Cutting Width Cutting Height 2 Down to 15 Up w 700 15 Pneumatic Tires Cutting Height will vary with tire amp Wheel sizes 2 Down to 12 Up w 12 Tires Cutting Height will vary with tire amp Wheel sizes Carrier Cutting Width Center amp Wing Center Section 69 Carrier Cutting Width Overlap Left Wing 63 1 2 Carrier Cutting Width Overlap Right Wing 63 1 2 Carrier Cutting Width Overlap Blade Over Lap Between Wing and Center 8 total overlap 4 center overlap amp 4 Wing overlap Carrier Options Pan or Bar Carrier Bar Carrier Size Bar Carrier 1 1 4 X 6 Bar Size Pan Carrier Size Pan Carrier 3 16 thick X 2 1 2 high X 37 1 4 dia pan w 1 1 4 X 6 steel bar w cross bar brace Carrier Mounting Bolts Direct to Blade Spindle f Under Side Qty 4 Allen Head Bolts 400 ft lbs Use Thread Lock Compound Qty 4 Fan 1 2 thick X 3 5 wide X 22 1 4 long measure blade length from center of bolt hole to end of blade Rotation CCW rotation Center amp LH Wing CW RH Wing Bolt Type Bolt On W Locknut Construction Cold Forged and Hardened w 1 1 8 square Shank Shoulder 1 2 High X 1 1 2 dia Shoulder w 1 RH Thread Bolt Head 2 7 16 Round Flat Head Bushing 2 OD X 1 1 2 ID X 1 1 2 Long Welded into Blade Bar Washer amp Nut 1 Structural Steel Flat Washer amp Toplock Locknut 300 ft l
7. The basic mounting design of the connecting blade carriers to the spindles are the same and will follow the same directions even with the fact some of the components are different Bar Carrier HEN Carrier Retaining Bolts amp Lockwashers Pan Carrier 7 Al A Carrier Retaining Bolts 8 Lockwashers Figure 1 Blade Carrier Spindle Mounting Bolts These bolts hold the blade bar onto the spindle and must be torqued when being installed These are high strength Allen head bolts figure 2 and should be replaced with the proper length of bolt never install a longer bolt than was removed If longer bolts are installed damage will occur Always replace the lockwasher figure 2 when reinstalling the bolts it is not recommended to use the lockwashers twice When changing or installing a blade bar place one drop of Loctite on threads of each bolt before installing it in place Tighten the bolts diagonally in an X pattern to assure that the blade bar pulls up evenly Torque the bolts to 400 ft lbs figure 3 in increments example 300 ft Ibs then 350 ft lbs then the last to 400 ft lbs This will help to make certain the blade carrier is pulled up evenly to the spindle Lockwasher a Allen Head Bolt HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 9 2 Blade amp Blade Carrier Service amp Repair Blade Bolts There is the square shanked blade bolt that is currently being used
8. This must be done equal all the way across the face of the machine surface to keep it level figure 26 ALL part must be cleaned and dried if stone is used it If deep scratches or excessively un level the section needs tobe replaced make certain this is checked before continuing installation of other components Replace the parts with machined surfaces if required Check comp onents for wear or damage now before continuing i Insertthe shaft end cover in the vise with the machined surface up figure 27 If the bushings figure 28 are to be replaced with new ones After the old ones have been removed Inspectthe holes where the new bushing will be pressed in If there are burrs or rough edges atthe tops of the holes they can be de burred by using your finger and emory cloth Keep the emory cloth on an angle and only around the top of the bore figure 28 Do this to each hole for the bushing that are to be replaced IMPORTANT Bushing must be pressed in with an arbor press DO NOT drive them in with a hammer F Note Steps 5 6 7 amp 8 apply to Shaft End Cover and Port End Cover figure 15 Any bushing removed from the shaft end cover portend cover or bearing end cover should be assembled in the drive bores with the grooves to the top of unit 12 O clock Assemble the bushings in the driven bores with the groove to the bottom ofthe unit 6 O clock The Grooves refer to the bearing seam figure 29 Bushings should be pressed into
9. angled chisel parallel with and into one of the staking slots in the threaded section of the shaft Using a hammer drive the chisel downward until the bent part of the staking flange on the adjusting nut is bentoutward andis free ofthe slot andthreads ofthe shaft This procedure is done in two places on the shaft A new nut will be required for reassemble figure 5 If the Spindle is equipped with a tabbed locking washer use a chisel to bend the locking tang until it is free from the slot in the nut Use a four pronged socket or a suitable punch and hammer to remove the shaft nut figure 6 Insert the original blade bar or pan bolts into the threaded spindle shaft Turn bolts until they contact the bearing ring Rotate each boltin a clockwise pattern 1 4 turn at a time for 2 amp 1 2 revolutions figure 7 Remove the original bolts and replace them with 4 shanked bolts In a clockwise pattern rotate each bolt 1 4 turn at a time until the spindle shaft is free from the housing figure 8 In some cases it may be necessary to use a drift punch and hammer to fully dislodge the shaft Care should be taken to avoid damage to the shaft or housing figure 9 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 4 3 SPINDLE ASSEMBLY SERVICE amp REPAIR Place the housing in a suitable vise with the motor flange facing down as shown Use a flat blade screwdriver to remove the seal retaining ring Pry out the lower seal
10. qty 4 and the hex nuts aty 8 onto the tie rods The hex nuts must be screwed on at the same rate and on each end try to keep the same amount of threads sticking out the nuts on both ends of the tie rods Snug the nuts down an all 4 tie rod evenly and alternating as to keep the same torque evenly Torque tie Rod nuts to 80 ft lbs based on 1 2 tie rod Install theHydraulic Elbow Adapters into the cylinder head ports figure 9 item 8 amp 9 Hydraulic Elbow Adapters 6 amp 7 cyl head clevis cyl rod amp piston asy Wood or other soft material LES Bench Vise Work Bench Figure 9 12 Install the cylinder on mower Mount cylinder with the base end figure 9 item 8 to the deck lug Mount cylinder head rod end figure 9 item 9 to the axle lug HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 29 OPTIONAL AXLE LEVEL LIFT CYLINDER REPAIR Cylinder Connections on Mower Axle Level Lift Cylinders Optional 1 The re phasing cylinders are connected together starting with the largest and going to the smallest 10 ft model will not use a 3 bore cylinder These cylinders MUST be connected in this order The cylinders will need to be purged of all air this can be done by powering cylinder to the full extend position and hold them there until the oil flows through the first cyl to the second cyl second cylto the third cyl and third cyl back to the optional remote control valve or tr
11. 1 Flange Qty Each Kit Bolt Hex Head Qty Each Kit Lockwasher Qty Each Kit Hose Asy 1 Hose amp Flange Pressure to Wing Motors Hose Asy 1 Hose amp Flange Pressure to Center Motor 5 Hose Asy 1 1 2 Hose 8 Flange Suction Hose for Center Motor Figure 9 Hose Asy 1 1 2 Hose amp Flange Suction Hose for Wing Motor HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 2 8 PUMP SERVICE amp REPAIR Pump Component Schematic VO 9 3 eS Description Description Snap Ring Dowel Pins Bearing Outboard Gear Housing Seal Input Bearing Carrier Shaft End Cover Connecting Shaft Plug Gear Set Matched Bushings Gear Housing Channel Seal Port End Cover Thrust Plate Studs Integral Drive Shaft and Gear Set Lockwasher Gasket Seal Nuts Lockwasher HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 9 J O O1 BR CO D o hb AR HROHHH HH OH PUMP SERVICE amp REPAIR IMPORTANT Mark all Sections of Pump with a Number or Symbols that will serve as a guide to all sections being re installed the same way they were removed Example if the numbers marks do not line up 1 2 3 4 8 5 as they were marked the pump is not being assembled correctly Check this all through the assembly process 1 1 2 Split Flange __ 1 Split Flange Suction Inlet Side Pressure outlet Side Port End Cover Service Technician Makes Alignment R
12. 1 1 2 dia steel ball a 1 1 2 ball peen ball end of a hammer can be used for this figure 28 when striking ball peen hammer flat end put a piece of cloth over itto prevent chips from flying off of hammer DO NOT use hammer direct to hit plugs Note Steps 5 6 7 amp 8 apply to Shaft End Cover figure 10item 4 Bearing Carrier figure 10 item 13 and Port End Cover figure 10 item 17 Any bushing removed fromthe shaft end cover portend cover or bearing end cover should be assembled in the drive bores with the grooves to the top of unit 12 O clock Assemble the bushings in the driven bores with the groove to the bottom of the unit 6 O clock The Grooves refer to the bearing seam figure 29 F HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 17 PUMP SERVICE amp REPAIR Bushings should be pressed into the bores one at a time Use the special installation tool figure 5 Tools recommended list and an arbor pres Be sure thatthe groove or seam are positioned as stated in step 5 previously Be sure to support casting so they are square and level to the arbor press and the bushings are straight before attempting to press them in The bushing mustbe pressed into the bores flush with the casting face figure 30 Repeat steps 1 and 2 after busings are installed See steps 1 amp 2 Just as earlier if the stone is used parts it is used on MUST be washed and dried Make certain bushings are flush with castings a
13. 1 2 bore RH wing 3 1 4 bore and LH wing 3 bore The hydraulic hose s are routed to largest bore medium bore and then to the smallest bore cylinder The hose routing must be this way to work properly The system has cylinders that have bypass grooves in the top end of the barrels to allow the hydraulic oil to pass from one cylinder to the other The return hose is connected to the return valves return hose this is recommended connection as this puts the return hose at hydraulic oil level and helps prevent air from accumulating in the cylinders during use If optional Valve is not used and cylinders are connected direct to tractor the return hose should be connected below hydraulic oil to keep hose full of oil Tractor connections must have the detent positions HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 4 WING LIFT FOLD OPTIONAL AXLE LEVEL LIFT CYL S 10 FT OPTIONAL HYD LEVEL LIFT AXLE W STD WING LIFT FOLD Option Remote Control Valve Shown Valve Inlet Pressure from E gt y Valve Outlet Return Tractor Hyd System to Tractor Resevoir Z 3 4 Large Bore Cyl Center Axle Medium Bore Cyl RH Wing Axle l N N N Smo SN H SS z O E a 5 2 E SN SS Wing Lift amp Fold Cyl RH Wing
14. 2 Electrical Volt Meter with variable settings and Ohm Meter 3 Electrical Test Light 4 Wrenches Socket Wrenches Open and Boxed End Wrenches Flow Testing the Pump figure 1 1 Use a Flow Meter that is rated to 6000 PSI and 60 GPM Minimum This applies to the gear type pump and motor type only 2 the area around the hoses motor flow meter mustbe clean of all debris and dirt NO contamination can be allowed to enter the system or its components Make certain there is nothing in flow meter from previous use that will contaminate the hydraulic system dirty and contamination in test equipment hoses and valves can cause a failure to occur Disconnect the hydraulic return hose from the motor Connect the hoses to the flow meter as shown above recheck all connections to make certain they are connected correctly and fittings have been check for tightness Completely open the pressure valve on the flow meter HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 3 MOTOR SERVICE amp REPAIR Record all the readings during the test Start the system run at 540 PTO speed which will run pump at required speed until the Oiltemperature reaches at least 110 F before starting test Check the flow GPM at 0 psi or no load Slowly close the pressure control valve valve on flow meter until the gauge pressure reaches 500 psi andrecord the readings pressure temperature and flow GPM Continues this at 500 psi incr
15. Axcess Hole Figure 5 Blade Inspections the blades should be closely examined each morning before start up figure 5 The Blade should be free of deep chips cracks or abnormal bends Ifthe blades are sharp they will require less power while moving Blades should be replaced when they become excessively worn bent or deformed Blade are designed to turn the direction of cut as according which way the blade carrier turnsas decided by the hydraulic motors direction of travel CW or CCW Make certain that the blades are i nstalled on the correct blade carrier to match the direction of rotation Make certain the holes in the blade carrier are not deformed or damaged If any holes in carrier are not in serviceable condition bolts will not stay tightened DO NOT operate the mower with damaged holes in blade carriers CAUTION Blades should always be replaced in pairs Blades of different weights can cause serious imbalance and damage to the machine and personnel When replacing the blades also replace the blade bolt nuts and washers Once the nut has been removed from the blade bolt it will not fasten tightly on the bolt again Never weld or modify the blades The blades are made of a high strength steel and heat treated to give maximum strength and resistance to chipping and wear Any welding or surfacing applied to the blades can severely reduce its strength A blade failure could result in a blade segment being thrown at high speeds o
16. Carborundurn Stone Seal removal Tool figure 6 Oiland Grease Snap Ring Pliers Prick Punch Bushing Installation Tool figure 5 Scale 1 32 or 1 64 graduations Small Screw Driver Torque Wrench in lbs ft lbs Vise with 6 minimum opening Barfor Lip Seal Installation For Center or Wing Motor use 2 1 2 dia X 2 Bar e Special Steel Sleeve figure 7 Figure 5 E T Figure 4 Bushing Installation ToolA S 18620 Bearing Qaulity Steel Heat treated A 30 GrindRelief Allowable Motor A B Cdia D dia Seal Removal Tool Easily 000 made from old screw driver Wing Motor 1 47 1282 Heat the tip and bend as 002 shown Grind the tip to fitthe Gannon 1 73 1492 000 1750 notch behind the shaft seal 1 625 n Special Steel Sleeve The special steel sleeve is used to insert the Figure 6 1 4 gt drive shaft through the lip seal without damage and can be made from bar stock For the center motor use a 1 1 2 dia X 4 5 8 bar Forwing motor use a 1 3 8 dia X 4 5 8 bar The drawing and cgart C ey z Hole Drill through give details for making this special tool Motor A B C Rad D Rad E dia F Chamfer Wing Motor 3 3 8 4 1 2 9 16 1 290 ae 1 250 002 015 X60 000 3 8 4 1 2 9 16 000 002 eee Center Motor 3 3 8 4 1 2 1 377 002 1 250
17. DO NOT start pump until looking at pump installation service repair start up in structions NEVER use Teflon tape on any hose or Ce New siyle fittings connections only thresd sealer on pipe con nections FIGURE 13 Splined Pump Shaft Adapters HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 7 13 NOTES HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 6 14 Section 8 HYDRO 15 Tire Wheel Hub Service amp Repair Section 8 1 Tire Wheel Hub Service amp Repair Tires amp Wheels When Removing wheels and or Hubs the mower should be supported under the main as well as the axles The deck and the wings in the lowered to the ground position There are options as the type wheel that may be on the mower A Laminated Sectional Tire and wheel Very heavy with small OD tire is made up of sections cut out of tires and is flat proof These tires and wheels are very heavy Use caution when lifting these tires and wheels B Pneumatic Tires and Wheels there are different tires available as an option on this model Phnuematic tires with 15 in Wheels The customer can purchase tires and wheels or wheels only and furnish his own tires sothe type pneumatic tires and wheels may not have been the manufacturers part The Used Airplane tire and wheel is offered as pneumatic foam filled and as recapped Pneumatic tires These tires and wheels are also heavy use cau
18. INSTRUCTIONS CAN CAUSE SERIOUS BODILY INJURY OR EVEN DEATH TO OPERATOR AND OTHERS IN THE AREA 2 NO RIDERS 3 USE SAFETY SHOES 4 BLOCK UP SECURELY NO CHILDREN OPERATORS HARD HAT SAFETY BEFORE WORKING pS GLASSES SEAT UNDER BELTS 4 ROPS Ad A 1 Study andunderstand operstor s manual safety signs and Instructional decals for tractor and Implement lo preven misuse abuse and accidents e Learn how lostop engine suddenly ln an emergency Be alert for passerby and especialiy chi dren 2 Mlow no chien on cenear implement or tractor Aiownonders on tractor andimplement Falingof mey cause senou s injury or death from being run over by tractor or culler or contact with rotating blades 3 Operate ontywith tractor having Roll Over Protectrve Structure ROPS ancwith seatbelt fastened securely and snugly to prevent mjury and possible death from falling off or tractor overturn Personal Protective Equipment such as Hard Hat Safet y Glasses Safety Shoes and Ear Plogs are Recommended 4 Elock up or support raised machine and allliftied components se curely before putting hands or feet under or working underneath a ny Medcomponents toprevent crusting Injury or death from sudden dropping or inadvertent operation of controls Make certain areas clear beforelowenng or folding Before transporting put Lift Lever in detent or full if positon Secure the mplement for transport by installing Cytinder Stops or Transport Pin on Pull type implement c
19. NOT use any abrasive materials at all and DO NOT bang the gears together Keep the gears inthe same sets as they were remove as they are a matched set and must remain as a set See next two pages for wear identification F HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 13 PUMP SERVICE amp REPAIR Wear Tolerance for Pump amp Motor This is suggested Wear Tolerance to Keep Assemblies operating as efficient as possible Not Complete failure rate Your Pumps and or motors may not be exact same as discussed here Gear Housing Gear type Pump and Motor Wear in excess of 007 cut out necessitates replacement of the Gear Gear Housing Housing Place a straight edge across the Bore in the cut out area If you can slip a 007 feeler gage under the straight edge in the cutout area Replace the Gear Housing Pressure pushes the Gears against the Housing on the Low Pressure side As the Hubs and Bushings wear the cutout becomes more pronounced Excessive cutout wear in short period of time indicates excessive pressure or Oil contamination If the relief Valve Settings are within prescribed limits check for shock pressures or tampering Withdraw Oil Samples and check it and tank for Cut Out Area dirt Where cut out is moderate 0 007 or less gear housing is in good enough Gear Wear Area condition and may be reused understand if you are at 0 007 you are at the upper limits and will not be at peak performance A pump sh
20. QU i CHILI MINI Note Hydraulic Axle Lift Option This has two axle cylinders one center and one wing These cylinder are different bore size the center is 3 1 2 bore and RH wing 3 1 4 bore The hydraulic hose s are routed to largest bore then smallest bore cylinder The hose routing must be this way to work properly The system has cylinders that have bypass grooves in the top end of the barrels to allow the hydraulic oil to pass from one cylinder to the other The return hose is connected to the return valves return hose this is recommended connection as this puts the return hose at hydraulic oil level and helps prevent air from accumulating in the cylinders during use If optional Valve is not used and cylinders are connected direct to tractor the return hose should be connected below hydraulic oil to keep hose full of oil Tractor connections must have the detent positions HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 5 NOTES HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 6 WING LIFT amp FOLD CYLINDER REPAIR WING LIFT AND FOLD CYLINDERS SERVICE amp REPAIR HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 7 WING LIFT amp FOLD CYLINDER REPAIR 2 Figure 1 x 27 LLLLL LLL LLL LLL SSI SSI SSI SSI SSI SSI SSI SSI SSI SSI TT Cylinder Removal LH or RH Wing Cylinder 1 Make Certain Wings are in the lowere
21. Return Filter amp Gauge Center Motor Return Pressure Bulk Head Fitting to Wing Motor Motor Asy Center Sction Motor Return Center Motor to Wing Cooling Tube Return Wing Tube to Center Cooling Tube Return Center Coolingg Tube to Fiter Tank z 3 J O O1 BR D O HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 6 PUMP SERVICE amp REPAIR Recommended Tools Bushing Puller The bushings in the pump may be Listed below are some of the toolds that removed from tier bores using blind hole collet type bushing are recommended for the dis assembly and re pullers similar to those manufactured by Owatonna Tool Co The assembly of the pump forthe HYDRO 15 Mower Table below illustrates the modification necessary to adapt the 1 Arbor Press OTC collets to this task Equivalent pullers from other suppliers 2 Awl may be modified in a similar fashion 3 1 1 2 Dia steel ball Make 4 Bearing Puller Owaonna Tool Co Pump A B C f OTC MD 956 or equivalent Collet No Bushing Remover Tool figure 4 Wing Supply 980 875 100 33863 Clean lintless Cloth o l Pump 970 Ref 090 Deburing Tool an old file with cutting Center Supply 1 382 1 260 100 33865 teeth ground off 1500 Machinest Hammer Pump 1 372 1 120 SoftHammer Gala 015 R Maximum Permatex Aviation Form A Gasket No 3 non hardening sealant or equal Medium Grit Carborundurn Stone Seal
22. age tothe replacement pumpin the eventthe relief valve has been set to high Before connecting any lines hoses to the pump fill all the ports with clean oil to provide initial lubrication on start up fillthe suction hoses with oil This is particularly import ant if the pump is located above the reservoir Use thread sealant on all fittings and hose threads DO NOT USE Torque to TEFLON TAPE 200 ft Ibs Make certain the oil reservoir is full of clean oil Test oil before running areplacement pump Contaminated oil will damage a replacement pump even oil ran a minute or so Review the type of failure that had occurred and investigate any damage that may have been caused due to that failure DO NOT runthe replacement pump ifthe cause of the failure has not been corrected Any oil added to or to fill reservoir PEN Torqueto mustbe ran through a 100 micron screen before going into SAE N 250 ft Ibs tank See the tank fill section for available equipment for this ib purpose After connecting the lines hoses and mounting the replacement pump operate the pump at least two minutes at no load and at low RPM 400 rpm During this break in period the mower should run free no load and notdevelope an excessive amount of heat If the unit operates properly speed and pressure can then be increased to normal operating settings See Specification Section Resetthe main relief if needed to its proper setting while the pump is running at ma
23. and a snap ring This splined adapter pushes into the speed increaser before the pump is bolted on the snap ring prevents the splined adapter from sliding inward and outward inside speed increaser is in operation DO NOT use without the snap ring on splined adapter failure will occur figure 2 B New Style Splined Adapter See figure 1 drawing B The new style splined adapter WILL NOT have a snap ring groove and WILL NOT use a snap ring to keep adapter stationary during operation The new style used a tube type spacer that is slid into the speed increaser splined adapter is inserted This tube spacer will keep the splined adapter from sliding DO NOT use without the tube spacer installed failure will occur figure 2 Old Style v A v Splined Spacer With Snap Ring Groove and Snap Ring New Style vv E VV Splined Spacer Without Snap Ring Groove and Tube Spacer HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 7 4 Speed Increaser Service amp Repair 13 Grease the splined shaft of the pump insert it into the splined adapter in the speed increaser The pump should slide into the speed increaser up to the machined flange on the pump The ridge on pump will slide into speed increaser with out excessive force If it will not slide together by pushing it in when the pumpis aligned with the speed increaser DO NOT use the pump mount bolts to force the pump into speed increaser check to find what is wrong p
24. away from speed increaser The open cover will have a seal figure 4 item 10 in it remove the seal Inspect the cover and the seal OD for damage that may have been caused by cover being damaged There is a gasket that should be on this cover figure 4 item 24 check to see if on cover or housing half There is a spacer ring figure 4 item 35 under cover and against bearing cup HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 7 8 Speed Increaser Service amp Repair To split the housing halves remove the 8 bolts lockwashers and nuts figure 4 item 31 32 amp 33 This will allow the two housing halves figure 4 item 15 amp 16 to be separated If it is necessary to pry the housing halves apart use extreme caution notto damage the machined surface ofthe housing halves Pry in alternating areas so the halves are separated as evenly around as possible There are two dowel pins figure 4 item 17 used to align the housing halves this usually where the housing are the most difficult to pull apart With the gears and shafts figure 4 item 2 amp 5 exposed pull them up and out of the housing half figure 4 item 15 amp 16 The bearing cones figure 4 item 14 amp 20 should stay on the gear shafts the bearing cups figure 4 item 13 8 19 should stay in the housing halves The bearing cups will be rather simple to remove from the pump side housing half remove any snap rings figure 4 items 35 and the bearing cups can be pr
25. back filter and the wings return through the front filter Each filter will have a return pressure gauge figure 4 amp 5 le Clean The Machine The deck and hydraulic tank should be cleaned off at least once a day Remove all foreign material from the deck Tank and structural members Never allow collected grass and dirt to remain in the deck or around the hydraulic tank This material will decompose forming ammonia compounds which will erode the paint and metal deck it will also prevent the tank amp oil cooling tubes from dissipating heat efficiently This material is also a source of contamination any time the hydraulic a system is opened or service Keep the Return Filters el 2 deck area clean and always clean before Filler Cap a pP A O Late l TT starting any service or repairs 2 To change filter cartridge it is not re quired to unbolt filter assembly from tap It will require the removal of the filter housing cover figure 6 by unbolting the filter cover bolts figure 6 There is a spring under the cover that presses down against the filter 7 cartridge hold down on the filter cover as Sight Gauge you unboltit Liftthe cover off and the spring under it Hold a small drain pan as close to A the filter housing as possible this will allow FIGURE 4 NC you to pull the filter cartridge straight up out FIGURE 4 REX of housing and move it over the drain pan as il quickly as possible This will limit the amount oil lea
26. completely cleaned around the gasket shim area Make certain the mounting surface is flat and undamaged This is important to assure the covers seal when installed later Install seals into covers there are three seals figure 4 item 10 these seal are all the same and can be install in either ofthe two open covers figure 4 item 9 or in the pump mount flange figure 4 item 6 The seals will install figure 6 with the flat side outward The hollowed side will install inward toward the gears Coatthe ID ofthe seal with clean light coat of grease Coat the OD side figure 6 of seal with Locktite TM 801 sealer or equal this will help keep seal from leaking figure 6 Use the proper dia seal driver to install the seal Set the covers with the seals installed aside for now Install Bearing Flange Mount figure 7 with new seal already installed to the housing half with the Allen head 5 16 NC X 3 1 4 Gr 5 bolts amp lockwasher figure 4 item 29 amp 30 There are total of 24 of these bolts used on speed increaser they are the same size and length bolts Make certain the housing half the one open cover and the pump mount flange are clean and free of the old gasket Install new gaskets figure 4 item 24 to the covers use light gasket sealer when installing the covers Only the one open cover and the Goar ar seal wiin light coat of Coat out side dia of Seal w Locktite TM pump cover flange can be installed and torqued to the housinf
27. figure 4 and the round keyed shanked Fo hanked ae Square Shanked bolt that was used in earlier ion fig Bolt say IS buik into Blade Bolt Current production fig bolt shank Old Style ure 4 Both bolts will have the same torque y Style rating Both bolts need to be lined up with the blade bolt hole when being installed and tightened The Keyed blade boltis very criti cal that the key be aligned with the keyway in the hole If keyed bolt is not aligned it will damage the bolts and or the hole The Sq shanked bolt is important that it be aligned with the hole when tightening Changing the blades is usually a two man job Access to the blade bolt Nut is through the access hole thatis covered ontop of the deck The easier method is to use an air impact It will usually require you to turn the blade carrier to align bolt with hole figure 5 Torque Blade Bolts to 300 ft lbs Blade Bolt Axcess Hole Blade Condition The condition of the blades blade bolts and other blade carrier components are very critical Never mix new and used blades on same carrier blades on the same carrier must be closely matched for weight or they will cause a un balance vibration If the mower has a vibration do not run the mower until the cause of the vibra tion has been corrected A vibration ina mower will cause metal fatigue and welds to crack The amount of time it takes to show Align Blade Bolt up depends on the severity of the vibration with
28. important DO NOT install them wrong 23 Make certain the bushings are OK or have been replaced correctly see step 5 6 amp 7 Place the port end cover overthe gear housing making certain your alignment marks figure 23A are aligned and the gear journals of the gearsethave a light coat of grease on them Recheck the gasket seal figure 10 item 10 is still in place Tap the portend cover lightly in the center make certain that the dowel pins are F aligned cover should fit flush on gear housing figure 46 24 Thread the bolts amp lockwashers in through shaft end cover andgear housing until threads are started into bearing housing Alternately tighten the bolts in increments that will make the three components pull down evenly figure 47 Torque the bolts in increments until the bolts qty 4 are torqued to 200 ft Ibs 25 Review all assembly steps to make certain the assembly is correct Wipe and clean any grease that may be on the outside of pump Reconnect hoses to pump figure 9 Figure 45 Ene HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 21 PUMP SERVICE amp REPAIR Recommended Start Up Procedure For New Or Rebuilt Pump Important Steps 26 through 30 26 Before installing a new or rebuilt pump back off the main relief valves until the spring tension on the adjusting screw is relieved See Specification section for relief valve settings This will avoid the possibility of immediate dam
29. it out on one side until it is across the ID of the cylinder head push the seal on out of the head using a nylon plastic rod and a light hammering on end of rod Clean and inspect cylinder head Check the ID of the cylinder head to make certain it is still round and without excessive wear Inspect the general condition of the piston figure 5 item 6 Remove the U Cup Seal figure 5 item 6C from the piston make a note of which way the U Cup seal came off the piston Insect the groove for the seal make certain it is not scratched or worn Make certain the piston has nut been struck and is deformed Check the OD of the piston to make certain it is not scored or worn ID Inspect the threads of the locknut figure 5 item 7 ifthey appear to be damaged take a second look at the threads on the cylinder rod clevis weldment figure 5 item 3 It is recommended that the piston locknut figure 5 item 7 be replaced and not re used HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 10 WING LIFT amp FOLD CYLINDER REPAIR Piston 4A Cyl Rod Piston Locknut N LT Cyl Head Clevis QI Weldment amp Clevis Figure 5 3 Weldment Cylinder Re Assembly LH or RH Wing 1 With all components inspected and in usable condi tion or replaced sort the part out and make certain all are clean and free of rust The barrel figure 6 item 5 will need to be prepared for for re assembly It barr
30. not slipped out Insert the 8 hex bolts figure 4 item 31 into the 8 holes in the housing halves from the PTO side figure 11 Install the Lockwashers and Hex Nuts figure 4 item 32 amp 33 onto the 3 8 bolts Tighten the bolts and nuts in an alternating pattern and in increments until bolts are snug Torque the bolts in the same pattern until they are torqued to 21 to 25 ft lbs Install the bearing Cups figure 4 items 13 amp 19 the bearing cone item 13 is smaller than the other 1 and will only fit the PTO side of the small gear shaft Bearing cups should be seated against bearing cone at gear figure 11 Use only soft hammer and light force to install bearing cups in housing half Install the bearing Spacer figure 4 item 11 amp 35 The smaller bearing spacer ring goes on the small gear shaft figure 11 The larger bearing spacer ring goes on the large gear shaft figure 11 Install the second open cover figure 4 item 9 and the closed cover figure 4 item 7 Make certain the ID of the seal in the open cover is coated with a light coat of grease The closed cover and the open cover will require that the shims figure 4 items 21 22 23 24 25 26 27 amp 28 The amount of shims required will vary It is recommended to try to start with the amount that was removed during dis assembly The purpose of the shims is to set the end play in the bearings and gear shafts Add or remove shims as required until the end playin the gear shaft L
31. off and the system Open always keep sytem closed when possible Avoid any oil contamiantion figure 4 y La Wu PER 8 Avoid Hydraulic Contamination by filtering the Hyd FIGURE 4 q qKEO __Q0Q _ Oil while filling the Hydraulic Tank Filter buggies or carts are commercially available for Hydraulic system clean up and Oil transfer These consist of high capacity filter a Circulating Pump a Drive Motor and hoses for connecting to the units hydraulic system When adding Oil always use Clean new Oil from a sealed container If you suspect the Oil of being contaminated don t use it figure 5 amp 6 It is best to always use a filter system when adding even new oil 4 When adding Oil in the field keeping it clean is critical do not use dirting funnels or hoses Do Not open Hydraulic tank or any contaners unless the openings have been cleanedfirst The outside of the containers must be clean If a windy dusty day do not fill and allow dirt to blow into oil Always add Oil using a pump systemwith at least a 10 Micron filter system figure 7 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 6 4 Fill Hydraulic Tank Fill Hydraulic Tank with Oil 5 Fill Tank Fillthe Hydraulic Tank figure 7 Filltank tillthe Oilis visable in the sight Gauge figure 8 9 amp 11 This will filltank for the start but it will have to filled again later 6 Fill Suction Hose with Oil Remove the Suction
32. old and new bearing cups and cones be mixed Inner Outer Bearing Bearing Inner CUP Cup Washer If hub and components are washed with solvent or similar Cotter Pin substance The component should be dried with clean filte Bearing y red compressed air DO NOT spin bearing with compressed air to dry them as this damages the bearing surface The inside of the hub must be cleaned after cleaning hub pump small amount Outer Slotted Nut Dust Cap of grease grease through grease Bearing fitting and make certain it is clean WheelHub Cone and free of solvent when itcomes FIGURE 5 w Studs out Dry all solvent and clean all grease from hub ID Lay all the components out as inspected replace components as need figure 5 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 8 4 Tire Wheel Hub Service amp Repair Wheel Hub Re Assembly Important Note There are two types of hubs figure 3 amp 4 that have been used these are best Identified by the seal type The earlier type has a one piece seal figure 3 Seal Seal Seal The later type has a three piece seal seal inner seal Adapter Protector adapter and outer seal protector If the hub you are working on has a one piece seal it must be re assembled using the components of the one piece seal hub If it is a three piece seal figure 4 it must use components for three piece seal hub The parts for the two different hubs bearings or seals won t inter
33. rd cyl the rod end of the 3 rd cylinder has a goove machined into the rod end which allows the hydraulic oil to bypass and return thr hydraulic resrvoir of the tractor Figure 6 HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 27 OPTIONAL AXLE LEVEL LIFT CYLINDER REPAIR Cylinder Re Assembly Axle Level Lift Cylinders Optional 1 Clamp cylinder rod clevis into bench vise figure 6 item 3 see figure 7 Make certain the old nylon seal protector has been removed before attempting to screw cylinder rod into clevis figure 6 item 2 Using a strap wrench if needed screw the cylinder rod figure 6 item 4 into the clevis figure 6 item 3 tighten rod until it is screwed in flush with cylinder rod see figure 7 Important DO NOT install nylon thread protector or setscrew figure 6 item 2 into clevis at this time itis best to do this later after piston and piston nut has been installed Replace the seals in the cylinder head figure 6 item 9 base clevis figure 6 item 8 and piston figure 6 item 15 Make certain to put the seal on in the correct order figure 6 amp 7 Installing the Piston on the cylinder rod figure 6 amp 7 item 15 may require a press DO NOT try to press piston onto cylinder rod with the piston nut Use Locktite 271 or equivalent when pressing piston onto cylinder rod Make certain piston and rod are in alignment when pressing piston make certain piston and rod are protected fro
34. removal Tool figure 6 Oiland Grease Snap Ring Pliers Prick Punch Bushing Installation Tool figure 5 Scale 1 32 or 1 64 graduations Small Screw Driver Torque Wrench in lbs amp ft lbs Vise with 6 minimum opening Barfor Lip Seal Installation For Front Wing Supply Pump use 1 3 4 dia X 2 Bar e For Rear Center Supply Pump Figure 5 A use 2 1 2 dia X 2 Bar NS Grind Relief Allowable Special Steel Sleeve figure 7 t Figure 4 i Bushing Installation Tool A 1 S 18620 Bearing Qaulity Steel Heat treated Pump A B C dia D dia i Wing Supply 000 made from old screw driver 147 1 054 Heat the tip and bend as Pump 002 shown Grind the tip to fitthe Center Supply 1 73 1 492 000 4759 Seal Removal Tool Easily 1 250 notch behind the shaft seal Pump 002 n Special Steel Sleeve The special steel sleeve is used to insert the Figure 6 1 4 gt drive shaft through the lip seal without damage and can be made from bar stock For the center supply pump use a 1 1 8 to 1 1 4 dia X 4 5 8 bar For wing supply pump use a 1 1 2 dia X 4 5 8 bar C ey Ur Hole Drill through The drawing and cgart give details for making this special tool Pump A B C Rad D Rad E dia F Chamfer Wing Supply 3 3 8 4 1 9 1 6 1 065 000 1 002 002 01 5 X45 Pump 002 000 Cen
35. stated in step 7 amp 8 Rerun PTO one more time to check alignments Speed Increaser Speed Increaser Mount Plate Mount Plate To NJ Tractor Spacers Pa Sp _ m y A LO Speed Increaser To To Tractor PTO Speed Increaser To Mount Plate Bolts Down Mount Plate Bacers FIGURE 1 Generic Speed Increaser Mount To Tractor Illustration HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 7 3 zo i a A a a A ze A Mount Plate To Tractor Bolts P Ed a Speed Increaser Service amp Repair 12 The pump mounts to the speed increaser with a four bolt flange There is a splined adapter required to mate pump shaft splines to the internal splines of the speed increaser shaft figure 2 There have been two types Old Style amp new Style Either style will work or can be replaced with the other but at least one style has to be installed complete Always make a note of which type is used when removing pump from speed increaser Sometimes the splined adapter will stay in the speed increaser and sometime it will slide out with the pump shaft When installing the spline adapter make certain to put a good coat of grease on the splined adater and on the internal splines before inserting it into the speed increaser Make certain at least one of these styles is used to mount the pump A Old Style Splined adapter See figure 1 drawing A The old style splined adapter has a snap ring groove on the OD of it
36. the cylinder rod from turning while screwing the piston nut figure 4 piston nut off the piston nut is RH Thread locknut HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 25 OPTIONAL AXLE LEVEL LIFT CYLINDER REPAIR Wood ther soft material poe Bench Vise Drain Pan Figure 3 Wood Support Block Strap Wrench Bench Vise Soft Non Scratching Material eS Piston Piston Nut Cylinder Head Figure 4 Remove piston nut figure 4 amp 5 the Piston from the cylinder rod Move the support block and the strap wrench figure 4 amp 5 Slide the cylinder head down the cylinder rod and off figure 5 remove the setscrew from the cylinder rod clevis figure 4 clevis set screw There is a nylon thread protector under the setscrew to protect the thread on the cylinder rod it will most likely stay in the threaded hole see figure 5 The cylinder rod will screw out of clevis it has RH threads if it cannot be turned by hand DO NOT use any type of tool that will damage the cylinder rod Use a strap wrench that only uses the strap to grab the rod see figure 48 5 Screw the cylinder rod completely out of the clevis Clean amp Inspect Cylinder Components Axle Level Lift Cylinder Optional 1 Clean and inspect parts figure 6 check cylinder components for wear operation damages condition of materials Make certain the piston cylinder rod barrel base clevis cy
37. the hydraulics always keep the hoses sealed by using temporary caps to plug them do not just leave them open to the elements DO NOT short any wires across or allow them to be shorted out on the electric components of mower Do not allow or attempt to jump across any wires or supply them with alternate power source DO NOT install higher rated fuses than are recommended by manufacturer for any components DO NOT do any welding on unit unless the electrical components are unplugged first this is to preventa power surge going into switch and or solenoids THIS IS VERY IMPORTANT This could also apply to the tractor components Check Tractors repair guide for specific instruction about tractor model and type It is recom mended that mower be disconnected from tractor when being repaired DO NOT attemptto repair or adjust acomponentthat is notintended to be repaired example sealed components as there are no serviceable components inside 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 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 DO NOT re use old oil if it is contaminated re install dirty components or not completely clean the system after arepair if there is a possibility of oil contamina
38. tractor remote is used for cylinder supply control the return line should be connected direct to the oil reservoir and below the oil level to prevent air from enter the re phasing cylinder on the return side HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 23 OPTIONAL AXLE LEVEL LIFT CYLINDER REPAIR Cylinder Removal Axle Level Lift Cylinders Optional 1 Make Certain axles and wings are in the lowered position before disconnection any compo nent Make certain tractor is securely parked with brakes set Make certain tractor engine is in off position and key secured to prevent starting lt is recommended mower be disconnected from tractor and or battery cable be removed from battery while repairs are being made Front and rear of mower must be securely supported on strong jackstands before hydraulic lines or cylinder mounting pins of the axle hydraulic assembly are disconnected Make certain that all hydraulic pressure has been released from lines after wings and axles have been completely lowered This may require the tractor hydraulic controls and or remote control valve be worked to release hydraulic pressure NEVER disconnect any cylinder hydraulic hose s or fittings if all mower components wings and deck are not resting in the completely lowered to the ground position or supported on jackstand position Do not remove cylinder pressure hose before the cylinder is dismounted from deck Remove the cylinder
39. vice figure 3 on the clevis end as shown Clamp the 2006 Alamo Industrial Section 5 8 WING LIFT amp FOLD CYLINDER REPAIR Remove the 3 4 RH Thread Piston Retaining Locknut figure 3 item 7 The piston figure 3 item 6 will not slide off of the cylinder rod weldment figure 3 item 3 Care must be taken when removing the piston so as not to damage it DO NOT hammer on piston or cylinder rod The piston was pressed on cylinder rod using a loctite 271 or equivalent Piston WILL HAVE TO be pressed off of cylinder rod when pressing piston off make certain to support piston so as not to damage it and use something to protect the threads on cylinder rod from being damaged by press Support the cylinder rod while in press from falling and damaging piston nut threads A roer AA Figure 2 4 Cyl head screwed out f barrel Slide the cylinder head figure 3 item 4 off the cylinder rod figure 3 item 3 in the direction of the piston DO NOT hammer on cylinder head or cylinder rod Cylinder head should slide by hand with aminimum amount of effort if it will not slide by hand check the cylinder rod for damage scored or bent If cylinder head is forced over a damage area or bend it could damage cylinder head Cyl Head screwed out f barrel Cyl Rod Clevis Weldment 7 Figure 3 Clean amp Inspect Cylinder Components LH or RH Wing Cylinder 1 Ins
40. weldments used the same type that is removed is the type that should be replaced figure 4 1 amp 5 item 3 The function of these control rods is to M 2 1 2 5 1 8 keep the mower leveled from front to rear Inspect the tongue clevis figure 1 through 3 and the control rod components figure 4 amp 5 to make 7 7 8 certain the components are correct and the mower is connected to the tractor draw bar correctly figure 2 5 Figure 4 Item 3 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 10 3 D D D D 4 0 1 1 4 4 4 4 D D D D D D 2 22 Leveling Control Rods Service amp Repair Leveling Control Rods Assembly amp Adjusting Using the drawing in figure 4 locate and identify the control rod components The control rods will require the proper assembly order in order to be assembled to the mower The following step are to be used ifthe control rods need to be assembled to mower the reverse of this procedure will be used to dis assemble the control rod s of the mower DO NOT REMOVE OR INSTALL ANY CONTROL ROD COMPONENTS unless you first support the mower on Jack Stands in the front and rear When replacing any parts the new parts must be compared to the old existing part for comparison and should be the same MOWER amp TRACTOR MUST BE ON LEVEL AREA concrete or pavement preferred BEFORE LEVELING CAN BE DONE 1 From the
41. with a relief groove notch in it 3 Thrust plate smooth surface with relief notch will always face the gears the groove side for the channel seal side will always face the gear bearing journal bushings never the gears as the gear would destroy the channel seal The relief groove will face the High Pressure side or Outlet Side of the gear housing This is determined by the port bearing carrier or port end cap port size The Inlet suction Side port will have a bigger opening than the pressure side These thrust plates are very important to the way they are installed If they are installed wrong the pump will not function properly and other components could be damaged if operated with them wrong Gasket Seal HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 16 PUMP SERVICE amp REPAIR ump Check all the machined surfaces on all pump components to make certain they are level and free of scratches Minor scratches andslightun level conditions may be fixed by using a Medium Grit Carborundurn Stone This must be done equal all the way across the face ofthe machine surface to keepitlevel figure 25 ALL part must be cleaned and dried if stone is used it If deep scratches or excessively un level the section will need to be replaced so make certain this is checked before continuing installation of other components Re place the parts with machined surfaces if required Check components for wear or damage now before
42. 000 015 X60 Figure 7 All external surfaces MUST be free of scratches and burrs HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 7 MOTOR SERVICE amp REPAIR Motor Cleaning amp Removal Clean Motor Hoses and all connections before discon necting any components from the motors This will keep con tamination from getting into system in this illustration the mower is new clean and un used Some type of drain pan will be required to catch the oil that will drain out when hoses are dis connected The hoses will need to be capped plugged after being disconnected If cap is not leak proof then hoses must remain elevated above hydraulic tank to preventoil leak age from hose fittings The Center Motor and the Wing motors are built different and will look different The easiest way to ID which is which is by the four bolts that hold the motor together On center motor the bolts are inthe open as shown figure 9 onthe wing motors they are down inside a machined hole on the Port End Cover figure 10 11 amp 12 Gear Set Matched Set GearHousing Bolt amp Lockwashers 4 Bolt Mounting Flange Iron Housing Drive Gear w Shaft amp Driven Gear Shaft End Cover Port End Cover Splined Input Shaft Split Flange 2 on center motor 1 on each wing motor High Temperature Seals a Low Friction Bushing Casting CENTER SECTION MOTOR SHOWN Motor Information Ce
43. 000 psi If the flow rate is 85 or greater of beginning flow rate at no load the pumpis serviceable and functioning within specifications CAUTION Stop tractor engine and discontinue testing if hydraoulic oil temperature exceeds 220 F as temperatures above this could cause damage to components Example Recorded test results PSI GPM TEMP F PSI GPM TEMP F 0 500 1000 1500 2000 2500 3000 Shown Below is a Gear Pump Schematic Return Hose Flow Direction Manifold Block Pressure Gauge ri un o E a T as ps D a A oO HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 4 PUMP SERVICE amp REPAIR 15 FT PUMP 8 MOTOR HYDRAULIC SCHEMATIC Wing Supply Front Pump Half CAUTION NEVER Connect Pump Pressure Line direct to cooling tubes as it will damage the tubes Center Supply Rear Pump Half if 14 N A Center LH 8 RH Cooling Tubes Description Tandem Pump Asy Suction Tank to Wing Pump Suction Tank to Center Pump Pressure Pump to Bulk Head Fitting Pressure Pump to Bulk Head Fitting Pressure Bulk Head Fititng to Center Motor Pressure Bulk Head Fitting to Wing Motors Motor Asy Center Sction Motor Return Center Motorto Wing CoolingTube Return Wing Tubeto Cen
44. 10 06 O 2006 Alamo Industrial Section 5 19 STANDARD AXLE LIFT CYLINDER REPAIR Install the new Piston retaining locknut figure 6 amp 7 item 14 onto the cylinder rod Note it is not recommended that old locknut be reused Before tightening the locknut down make certain that piston is seated onto cylinder rod completely this can be done by visually inspecting back side of piston against shoulder of cylinder rod Torque Piston Locknut 300 ft lbs based on 1 locknut When tightening piston locknut if support for cylinder rod is needed see figure 4 Cylinder Head Piston Piston Nut vA Cylinder Rod Clevis Set Screw Chamfered side of piston Bench Vise Figure 7 Install the new nylon thread protector figure 6 item 2 into the cylinder rod clevis figure 6 item 3 Make certain the nylon thread protector is laying flat in the bottom of the threaded hole in the clevis Insert the setscrew figure 6 item 2 into the clevis figure 6 item 3 Tighten the clevis setscrew to 20 ft lbs Clamp the barrel figure 8 item 5 in vise using wood or other soft material to protect barrel see figure 8 DO NOT tighten vise so tight that the barrel becomes distorted Make note that the mark that was made to identify which end of the barrel was the rod end is verified Coat the inside of the barrel with hydraulic oil Coat the piston cylinder rod cylinder head seals with hydraulic oil Holding the rod clevis cylinder hea
45. AKING CERTAIN the marks made Channel Seal to keep the components in the same orientation when re Outward assembled are aligned figure 13 amp 14 Thread the bolts 8 lockwashers in through shaft end ThrustPlate cover of gear housing until threads are started into bearing housing Alternately tighten the bolts in increments that will make the three components pull down evenly figure 42 8 43 Torque the bolts in increments until the bolts qty 4 are torqued to 200 ft lbs Install the manifold block to top of the motor The manifold block onthe LH and RH wing are the same and will mountwith the return line toward the front ofthe mower The manifold block for the center motor will only work with the center motor and is installed with the relief cartridge toward the front on the LH side The Wing motors use two large O Rings and one small O Ring on each manifold The center motor uses two large O Rings to install manifold block When tightening the four retaining bolts they MUST be tightened evenly in increments so block remains un distorted DO NOT over tighten any one bolt it will distort aluminum manifold block Torque the 5 16 Gr5 bolts to 16 to 20 ft Ibs figure 45 46 amp 47 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 21 MOTOR SERVICE amp REPAIR F Seal Retainer Cup Channel Seal 2 Bushing 2 Snap Ring Input Seal Shaft 8 Thrust Plate 2 Gear Set Channel Seal Drive gear
46. 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 Inche Sizes Metric Sizes ALWAYS CHECK MARKINGS Not Used 10 14 Not Used 20 27 Not Used 35 47 55 75 85 115 130 176 142 170 230 251 300 407 217 445 603 339 670 908 1030 1396 447 910 1234 1460 1979 651 1250 1695 2060 2793 ON HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 1 5 SPECIFICATIONS HYDRO 15 FLEX WING 15 FT PUMP 8 MOTOR HYDRAULIC SCHEMATIC CAUTION NEVER Connect Pump Pressure Line direct to cooling tubes as it will damage the tubes 14 Center LH amp RH Cooling Tubes Description Tandem Pump Asy Suction Tank to Wing Pump Suction Tank to Center Pump Pressure Pump to Bulk Head Fitting Pressure Pump to Bulk Head Fitting Pressure Bulk Head Fititng to Center Motor Pressure Bulk Head Fitting to Wing Motors Motor Asy Center Sction Motor Return Center Motor to Wing Cooling Tube Return Wing Tube to Center Cooling Tube Return Center Coolingg Tube to Fiter Tank HYDRO 15 Service Manual 09 06 K A 410 Description 13 Case Drain R Wing Moto
47. Asy 3 piece Seal item 5 off axle spindle shaft HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 8 3 Tire Wheel Hub Service amp Repair Pull the hub item 1 out slightly while holding your hand against end of spindle at attaching nut end this will allow you to catch the outer bearing cone Item 6 Continued to pull outward on the hub and the hub item 1 will slide off with inner bearing cone item 7 and wheel seal figure 3 amp 4 item 8 staying in hub Wheel Seals there are two different types Old type 1 piece seal figure 3 item 8 which consist of the standard type seal as shown in figure 3 amp 5 New style 3 piece seal figure 4 item 8 consist of 1 inner seal adapter 1 inner seal and a outer seal protector which drives onto the spindle figure 4 amp 6 The same type seal thatis removed from the hub must be the type that is replaced Parts between these two hubs will not interchange identify which hub you have by the type seal in it before ordering replacement parts The 3 piece seal components seal adapter seal and seal protector are not available as individual pieces they can only be ordered as part of the replacement seal assembly Remove Seal from Hub seal use a soft pin wood or plastic to drive into the hub from the front side and against the inner bearing cone this will drive the inner bearing cone and seal out If working with the three piece seal the seal adapter should come o
48. Cup only for now wa F ss Figure 29 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 4 8 SPINDLE ASSEMBLY SERVICE amp REPAIR At igure 30 ES 14 Install the spindle to the mower deck to where the fill plug and vent plug are pointing to the rear or the front of the mower this should allow easy access to the plug for service figure 32 Make certain a new gasket has been in stalled to spindle Re Install the motor onto the spindle making certain that the motor is facing the correct direction and none ofthe hoses are twisted or kinked figure 32 BLADE CARRIERS ae te Figure 32 There are 2 blade carrier options Blade Bar or Blade Pan figure 33 The carrier are bolted to the of spindle with 4 socket head bolts these bolts length are to be used with a particular carrier option ALWAYS use the same length and quality bolt that was removed when changing bolts Damage will result if wrong bolts are used refer to the replacement parts manual for correct bolt numbers to match the carrier option being used Install the blade bar or pan using the correct 4 bolts amp lockwashers Use a suitable locktite on the bolts Torque the bolts to 400 ft lbs using a progressive torque and staggered tightenin pattern figure 33 Bar Carrier HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 4 9 SPINDLE ASSEMBLY SERVICE amp REPAIR 3 Mount Motor onto Spindle T
49. ES HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 26 Section 4 HYDRO 15 Spindle Asy Service amp Repair SPINDLE ASSEMBLY SERVICE amp REPAIR o 3 Qty Description 11 12 13 1 Housing 1 Spindle 1 Bearing Ring 1 Lower Seal Seal 1 Snap Ring 1 1 1 1 1 6 6 6 SKIS SES NI DNA Lower Bearing Cup and Cone Upper Bearing Cup and Cone Stake Nut Plug Pressure Relief Fitting Grease Fitting Plug Locknut mount Spindle to Deck Bolt mount Spindle to Deck Washer mount Spindle to Deck Grease NLGI EP 2 NO UP ND HT ES Za SZ Fill with NLGI EP 2 Lithium Based Grease Alamo Industrial P N 00900000 Fill until Grease is forced out of top bearing while on work bench after re assembly TA UL Clean the deck motor and spindle area of debris before beginning any dis assembly When removing the spindles it WILL NOT require the removal or dis connecting of any hydraulic lines hoses Remove the Blade Bar or Pan Assembly figure 2 Use caution make certain blade carrier is sup ported before removing the 4 socket head bolts in the center of the blade carrier Itis recommended a hoist with sufficient rating for weight be used to hold blade carriers for wing Center section blade carrier should be supported by jackstands at least 3 jackstands while being unbolted and lowered with ajack that has alarge top surface area CAUTION Measure the le
50. H Wing Note Standard Hydraulic Axle Lift This has one axle cylinder on center axle only This cylinder is 3 bore The hydraulic hose is routed to the base end of cylinder The hose routing must be this way to work properly There is NO return hose connected to gland end of center axle cylinder only a vent plug this vent plug allows cylinder to move freely without creating a vacuum inside cylinder barrel If optional Valve is not used and cylinders are connected direct to tractor it will need at least two remotes It is also recommended these remotes have detent on them to allow wing to float or damage to deck could occur The wing axles are adjusted manually using the mechanical lift screws HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 3 WING LIFT FOLD OPTIONAL AXLE LEVEL LIFT CYL S 15 FT OPTIONAL HYD LEVEL LIFT AXLE W STD WING LIFT FOLD Option Remote Control Valve Shown Valve Inlet Pressure from l P Valve Outlet Return Tractor Hyd System to Tractor Resevoir Small Bore Cyl Large Bore Cyl Medium Bore Cyl C Axl LH Wing Axle PA Center Axle RH Wing Axle N 7 N N N N Wing Lift amp Fold Cyl LH Wing Wing Lift amp Fold Cyl RH Wing MI Note Hydraulic Axle Lift Option This has three axle cylinders one center and one each wing These cylinder are different bore size the center is 3
51. HYDRO 15 FLEX WING MOWER INDUSTRIAL Published 09 06 Part No 00756179S 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 or Alamo Industrial Inc ALAMO INDUSTRIAL 1502 E Walnut A OF THE Seguin Texas 781 55 rage THE CUTTING EDGE 830 379 1 480 2006 Alamo Industrial TO THE OWNER OPERATOR DEALER Allimplements 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 YOUSTART Read the safety messages on the implement and shown in your manual Observe the rules of safety and common sense FAILING TO FOLLOW SAFETY MESSAGES AND OPERATING
52. Hose atthe Tank figure 9 andfillthe hose with cleanoil Pressure THIS IS A MUST DO The Suction Hose must be filled Gauge with Oil to prevent Dry strat up of Pump Dry start up of PUMP will damage the Pump After filling suction Hose reinstall it and tighten down Hose Clamp figure 10 Sight Gauge FIGURE 9 if Return Filters y Filler Cap es amp pa WA WO To Vis JA 4 _ LL _ J V4 Sfght Gauge 22M sRetun Pressure Gauges e y y FIGURE 11 ae AT HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 6 5 NOTES HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 6 6 Section HYDRO 15 Speed Increaser Service amp Repair Speed Increaser Service amp Repair Attach Mount Plate Speed Increase and Pump To Tractor Important To attach the Speed Increaser and pump to the tractor will require a mount kit designed for the type tractor that unit is being connected to There is a universal mount kit available that will need to be modified to fit a particular tractor These modifications will require the service technician to determine what modifications are needed Modifications to the universal kit will be at customers expense and design Shown in this section are the general instructions to mount the speed increaser to the tractor some of the tractor specific mount kits may need modification because of tractor accessories or options Wh
53. Inquiries HOW YOU CAN HELP Make sure the call is necessary Most of the calls received may not be necessary if the Dealer Service Technician would do the following 1 Check the Service Information at your Dealership provided by Alamo Industrial This would include Service Bulletins Information Bulletins Parts Manuals Operators Manuals or Service Manuals many of these are available via the Alamo Industrial Internet site Alamo Industrial Com Attempt to diagnose or repair problem before calling 2 If a call to Alamo Industrial is needed Certain Information should be available and ready for the 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 3 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 get the information and call back Most recommendations for repairs will be based on the procedures listed in the Service Manual Trouble Shooting Guide CONTACT ALAMO INDUSTRIAL Alamo Industrial 1502 E Walnut St
54. N Front Side of Motor 8 Mower Motor 8 Mower Figure 14 RH Side of Motor amp Mower Shown HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 11 MOTOR SERVICE amp REPAIR Seal Retainer Cup Channel Seal 2 Snap Ring Bushing 2 SquareHousingSeal Input Seal Shaft amp Thrust Plate 2 Gear Set Channel Seal Drive gear z amp Driven Shaft End Cover Retaining Bolt amp Washers 4 Fiaure 15 Gear Housing Dowel Pins 4 Port End Cover Shown above figure 15 is a general breakdown ofthe motor components The motors are basicaly the same in design and replace componetn procedure Each motor will asemble different as some of the compo nents are different Refer back to figure 15 for later motor assembly information Motor Dis Assembly CAUTION Important information read before dis assembly Y If prying off sections becomes necessary take extreme care not to mar or damage machined sur faces Excessive force while prying can result in mis alignment and seriously damage parts If sections of motor are difficult to come apart during dis assembly tap gently with a soft hammer never usean iron hammer Gears are closely matched therefore they must be kept together as sets when removed from the pump Handle gears with care to avoid damage to journals or teeth Avoid touching gear journals Never hammer bushing into bores always use Figure 16 an arbor press m8 HYDR
55. O 15 Service Manual 09 06 O 2006 Alamo Industrial Section 3 12 MOTOR SERVICE amp REPAIR Motor Dis Assembly 1 Placethe motor in a vise withthe drive shaftpointing down Caution DO NOT grip on or near any machined surfaces of motor during assembly or dis assembly Mark all sections of the motor figure 13 14 amp 15 these marks must be done in a manner that will not wash off These marks are to identify the orientation ofthe component of the motor later for re assembly Itis recommended that marks be done with metal stampsthatwill mark components for correct assembly order for amp during re assembly This is very important as if any ofthe sections of motor are installed in the wrong direction it could damage motorwhen re assembled orwhen motor is en gaged during operation figure 15 Removethe four boltsthat retain the manifold block to the top of the motor There are O rings under the manifold blocks check to make certain all of these are removed and not stuck to one of the components figure 13 amp 14 Use a socket Wrench or Boxed end wrenches Air impact wrenches are notrecommended for dis assembly Remove the four hex bolts and washers figure 16 This will allow for the removal ofthe port end cover ofthe motor Inspectthe bolts for thread condition If bad threads on bolts most likely the threads in that hole are bad mark the hole so it can be check later Lift the first port end cover figure 18 if pryingi
56. OLD CYLINDER REPAIR 12 Coat the O Ring amp Back Up Washer Seal figure 11 item 4 with light coat of hydraulic oil Holding the cylinder rod figure 11 item 3 straight slide the cylinder head down cylinder rod until the threads are at the threads of the barrel Important Apply a drop of locktite 242 in 3 places 120 apart on the first two threads of the cylinder head Making certain the cylinder rod is straight thread the cylinder head clockwise RH threads into the barrel This can be done by hand if the threads are in good condition once the threads are started straight a two pin spanner wrench figure 13 can be used to tighten cylinder head into barrel read step 14 about spanner wrench Tighten the cylinder head until it is fully seated against barrel the two pin holes for the spanner wrench should be straight up and down from the barrel ports as shown Figure 12 item 4 The cylinder head should be tughtened to what would be equal to 100 ft lbs of toque Using a new O Ring install the vent plug figure 12 in the base end cylinder barrel port Install the pressure hose and existing fittings using a new O Ring into the rod end of barrel figure 12 When first using the rebuilt and or new cylinder it is not unusual for a light amount of oil to be pushed out of the vent The amount is the amount that was used to oil components during assembly If excessive amount leaks through vent cylinder is not functioning properly Recheck the assem
57. Seguin TX 78155 Technical Service Dept PH 830 379 1480 HYDRO 15 Service Manual 09 06 2006 Alamo Group Inc Index 1 INDEX Section Page Section 1 Specifications 1 1 to 1 7 Do Not Do or Allow Items Read First Thing Mower Specifications Bolt Torque Specifications Chart Pump amp Motor Hydraulic Schematic 15 Foot Model Pump amp Motor Hydraulic Schematic 10 Foot Model Section 2 Pump Service amp Repair Pump Repair Preparation Procedures Pump Test Procedure Pump amp Motor Hydraulic Schematic 15 Foot Model Pump amp Motor Hydraulic Schematic 10 Foot Model Recommended amp Required Tools Pump Cleaning amp Removal Pump Component Identification Pump Dis Assembly Preparations Pump Dis Assembly Procedures Pump Component Wear Inspection Guide Pump Assembly Preparation Pump Assembly Procedures Pump Recommended Start Up Procedure Section 3 Motor Service amp Repair Motor Repair Preparation Procedures Motor Test Procedure Motor amp Pump Hydraulic Schematic 15 Foot Model Motor amp Pump Hydraulic Schematic 10 Foot Model Recommended amp Required Tools Motor Cleaning amp Removal Motor Identification Center amp Wings Motor Dis Assembly Preparation Center Motor Dis Assembly Preparation Wings Motor Component Identification Motor Dis Assembly Procedures Motor Component Wear Inspection Guide Motor Assembly Preparation Motor Assembly Procedures Motor Recommended Star
58. Wing Motor Electric Switches 1 Wing Motors are equipped with electrical solenoids located it the motor manifold blocks these are designed to function with magnetic switched on brackets that are connected to the wing lift cylinders The wings are designed through these solenoid switches to turn the motors off when the wing is raised to a set angle The motors are also equipped with hydraulic brakes that are designed to speed the time it takes to stop the motor these also work through the motor manifold block figure 48 LH Wing Shown The Center Section Motor is controlled by engaging or dis engaging the tractor PTO Any time motors are being started the tractor RPM should be reduced during start up of motors Cylinder Switch Brackets bolt to cylinder with a U Bolt and the cylinder mounting bolts figure 49 RH Wing Shown The switches and magnetic pickups will bolt to the cylinder bracket The Switch will have twowires a white wire anda black wire The wires will have a female spade connector on the black wire which will connectto the black white wire on the wire harness figure 50 The switch white wire will have a male spade connector which will connectto the white wire of the wire harness figure 50 The leads to the tractor are to be connected with the positive 12 voltnegative ground source thatis only activated when the tractors ignition key is on If it is connected to aconstant power source it will run the Continued Next Page H
59. YDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 24 MOTOR SERVICE amp REPAIR Continued from Previous Page battery down when tractor is parked and not running Whenrunning wire harness to tractor tie the Spacer Magnet Spacer Cylinder Slide Switch Mounting Weldment harness away form any object that might catch it and also leave enough slack that when turning the wire harness it notto short and pulls apart This will be ser vice technicians choice and responsibility as most trac tors are differentin de sign There arespacers that are used with the magnetic pickups figure 48 49 amp 50 Black Wire 1 LH amp 1 RH Ground To Tractor Female Spade Connector linsulated White Wire 2 LH Male Spade Male Connector Insulated BIk White Wire 2 LH 8 RH Ground Eai Stripe Wire 2 Not Used q Wire 1 Left Wing Not Used HYDRO 15 Service Manual 09 06 4 72 2006 Alamo Industrial Cylinder Mounting Bolt Tube End Switch Switch Mount Weldment RH Shown U Bolt Cylinder Mounting Bolt Tube End To Tractor 12 Volt Supply E __ 10 Amp Inline Fuse White Wire 2 LH amp RH ne sl Female Spade Connector linsulated White Wire 1 RH Male Spade Male Connector Insulated Blk White Wire 2 RH amp LH Ground Black White Stripe Wire 2 Not Used 3 Black Wire 1 X i Right Wing Not Used 90 Section 3 25 NOT
60. a smooth side and there is a grooved side The smooth side will always face the gears the grooved side will be for the channel seal figure 10 item 7 Inspectthe thrust plate for damage or wear at this time see wear tolerance chart for pump and motors inthis section this will help in looking for other wear or damage to other components and also enable you to start making a list of components that need replacing Carefully remove the drive gear and the driven gear figure 10 item 15 Avoid tapping the gear teeth together or against other hardened surfaces figure 15 Keep these gears together because they are a matched set Examine the gears for wear and or damage Note the dowels figure 15 that are in the gear housing sometimes these will come out and be inthe end cover or they may stay in the gear housing It willbe OK as long as the same components are to be reassembled but if some components are to be replaced and some are not then these dowel pins will have to be re moved and re inserted Remove the outer gear housing figure 10 item 16 Liftthe outer gear housing figure 16 up if prying is necessary take care not to damage machined surface Examine gear housing for wear and or damage See wear tolerance chart for pump and motors in this section When the gear housing is removed there will be another thrust plate and channel seal figure 10 item 7 amp 8 that was under the gears sometimes this thrust plate will come out
61. actor reservoir These cylinder do not work well as a double action system by connecting the return into the tractor remote return If connected this way they will work but tend ti get air in them as used over a period of time and may require the air to be purged from system ocasionally if wings cylinders start to droop chances are they have air in them and need to be purged Cylinder work best when return to where return line has a constant supply of non pressere hydraulic oil to allow the cylinder to draw the oil back into the cylinder as the cylinder is collapsed The return side ofthe remote three spool valve work very well for this If phasing cylinder will not work check that the cylinders are connected in the correct series hose routing according to cylinder bore diameter Make certain the cylinder were re assembled correctly with the machined groove in the ID of barrel atthe rod end of cylinder this can be checked by pulling the return line loose and putting it into a clean bucket to catch the oil run the cylinder all the way to the top Always keep control of hoses during testing to keep them in something to prevent the oil form spraying DO NOT test if oil is excessively hot if you cannot touch the hoses the oil is to hot Oil will come out of hose when cylinder is until cylinder is fully extended and keep coming out as long as the control valve is open From Remote Valve j or Tractor Remote Return To Remote Valve Return Lin
62. ad Fititng to Center Motor Return Filter amp Gauge Center Motor Return Pressure Bulk Head Fitting to Wing Motor Motor Asy Center Sction Motor Return Center Motor to Wing Cooling Tube Return Wing Tube to Center Cooling Tube Return Center Coolingg Tube to Fiter Tank z 3 J O O1 BR D O HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 6 MOTOR SERVICE amp REPAIR Recommended Tools Bushing Puller The bushings in the Motor may be Listed below are some of the toolds that removed from tier bores using blind hole collet type bushing are recommended for the dis assembly and re pullers similar to those manufactured by Owatonna Tool Co The assembly of the pump for the HYDRO 15 Mower Table below illustrates the modification necessary to adapt the 1 Arbor Press OTC collets to this task Equivalent pullers from other suppliers 2 Awl may be modified in a similar fashion 3 1 1 2 Dia steel ball Make 4 Bearing Puller Owaonna Tool Co Motor A B C f OTC MD 956 or equivalent Collet No Bushing Remover Tool figure 4 Wing Motor 1 122 1 000 072 33864 Clean lintless Cloth o l 1 122 0 990 062 Deburing Tool an old file with cutting Center Motor 1 382 1 260 100 33865 teeth ground off 1550 MachinestHammer 1 372 1 120 SoftHammer Gala 015 R Maximum Permatex Aviation Form A Gasket ve ae No 3 non hardening sealant or equal Medium Grit
63. ake certain that the insertion is on the same end as when it was removed Not required only recommended Make certain the port of the cylinder head figure 8 item 9 is pointing up as shown this will make certain of port alignment when base end of cylinder is installed Install the new nylon thread protector figure 6 item 2 into the cylinder rod clevis figure 6 item 3 Make certain the nylon thread protector is laying flat in the bottom of the threaded hole in the clevis Insert the setscrew figure 6 item 2 into the clevis figure 6 item 3 Tighten the clevis setscrew to 20 ft lbs base on 3 8 setscrew HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 28 OPTIONAL AXLE LEVEL LIFT CYLINDER REPAIR Wood or other soft material Bench Vise cyl head clevis cyl rod amp piston asy Work Bench Figure 8 Coat the cylinder base barrel seals figure 6 amp 9 item 8 with coat of hydraulic oil Install the cylinder base end into the barrel see figure 9 If plastic plug is installed in base end as shown see figure 9 it will allow the insertion of the base end into the barrel if plug is removed Make certain that the ports on the base end are aligned with thew cylinder head as shown see figure 9 item 8 amp 9 the ports must be aligned this way Install cylinder tie rods figure 9 item 6 amp 7 make certain that the hex nuts that were left on the tie rod is loose Insert the tie rods
64. al Outward are aligned figure 23A f Figure 38 Place the thrust plate figure 10 item 7 amp 8 into the gear housing as per step 14 Coat the journal ofthe drive gear and the driven gear insert the drive gear aligning the splined shaft end overthe splined connecting shaft Insert the driven gear into the gear housing aligning gear teeth with the drive gear DO NOT force the gears in they must slide in smoothly and mesh together figure 44 Make certain the gears are seated completely down and againstthethrustplate face Smooth Figure 41 HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 2 20 PUMP SERVICE amp REPAIR 21 Check the plug in the port end housing figure 10 item 5 These plugs do not have to be removed unless the port end housing figure 10 item 17 is being replaced or someone has removed the plug The plug must be installed on the correct side to function properly If plugs need to be installed removed or re installed refer to steps 3 amp 4 in the assembly instructions on correct way to install plugs figure 27 28 amp 45 22 Genily slip the thrust plate figure 10 item 7 amp 8 into the gear housing and into place onthe shaft end figure 46 The channel seal from should face the portend cover The relief groove in the thrust plate should face the outlet side of the pump see figure 23A amp 24 The correct installation of the thrust plate and channel seal are very
65. amp Driven Shaft End Cover Retaining Bolt amp Washers 4 Gear Housing Figure 44 Dowel Pins 4 PortEnd Cover 18 Review all assembly steps to make certain the assembly is correct Wipe and clean any grease that may be on the outside of motors Review the illustration to determine the motors were assembled cor rectly Fill motors with clean oil through the pressure ports this will assist motor during first start up IF PUMP was replaced see start up procedure in pump repair section If only the motor is being replaced make certain not to start system if oil is warm and motor is cold If motor is cold and oil is warm start and stop system until motor and oil is temperature is equaled Warm oil and cold motor could damage motor HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 3 22 MOTOR SERVICE amp REPAIR 19 Mount Motor onto Spindle The motorboltstothe Manifold Block spindle with 1 2 grade 8 bolts Install a new gasket between motor and spindle Torque the 1 2 bolts to mount motor to spindle to 95 ft lbs Mount Spindle to deck use 3 4 bolts with lock nuts Torque the 3 4 bolts to 350 ft lbs IMPORTANT See Step 18 for proper installation of motor manifold blocks itis criticalthatthese be installed correctly and properly torqued to prevent leakage or distortion figures 45 46 amp 47 Manifold Block Mnt Bolts ni 2000 psi TN 800 psi Manifold Block RH Wing Motor L
66. arge and Small is from 007 to 011 The open cover and the closed cover retaining bolts will need to be torqued 12 to 15 ft los Torque these in an alternating pattern figure 11 Open Cover w Seal Installed Closed Cover Insert Hex Head 3 8 Bolt Insert Hex Head 3 8 Bolt varous shims Various Shims Washer Washer amp Nut amp Nut Bearing Spacer Bearing Cone Bearing Cone PTO Side Housing Half Sitting on Block to Make it Sit on Table Level HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 7 12 Speed Increaser Service amp Repair 11 Reinstall the plugs bag into the correct holes that they were removed from see Part Manual for holes to be plugged Use pipe sealer for plug DO NOT use teflon tape 12 Refill speed increaser with oil Check the Oil level in the speed changer Use a recommended grade of oil A recommended grade is SAE 90W oil with E P Additive Most speed increaser are installed where the pump will mount above the PTO figure 1 but in some case it may require the pump be mounted below the PTO shaft height If this is the case the breather plug will need to be installed in a different location on one of the side plugs Normal fill level is the setscrew plug about 1 3 of the way up on the side of the housing If Speed in creaser is turned to the bottom opposite what is shown in figure 1 the level plug will be the one that was on the bottom before and would be just below the
67. ase engagement of PTO shaft Make certain the PTO shaft is not bottomed out in speed increaser if it is the spacers are to short Check the grease level in the speed changer before operating the tractor PTO Use a recommended grade of oil Arecommended grade is SAE 90W oil with E P Additive Most speed increaser are installed where the pump will mount above the PTO figure 1 but in some case it may require the pump be mounted below the PTO shaft height If this is the case the breather plug will need to be installed in a different location on one of the side plugs Normal fill level is the setscrew plug about 1 3 of the way up on the side of the housing If Speed increaser is turned to the bottom opposite what is shown in figure 1 the level plug will be the one that was on the bottom before and would be just below the center line of the bearings figure 3 Run the speed increaser on the unit prior to mounting the pump on the speed increaser Make certain the speed changer runs smoothly and is not binding in any areas The bearings located around the PTO shaft should be cool and free of any noise If vibration or noise exist shut tractor off Loosen the mount plate bolts to tractor slightly to allow speed increaser to seek its on center line do the same with the four bolts mounting the speed increaser to the mounting plate Retighten bolts snugly and run PTO again to see if vibration and or noise has gone If no noise or vibration re torque the bolts as
68. be Return Wing Tubeto Center Cooling Tube Description Case Drain R Wing Motor to Cooling Tube Wing Motor Asy R Wing Return Pressure f R Wing to L Wing Motor Return Center Cooling Tube to Filter Tank Return Filter amp Gauge Wing Motors Return Return Filter amp Gauge Center Motor Return Return L Wing Motorto Cooling Tube Case Drain L Wing Motorto Cooling Tube Wing Motor Asy L Wing Return L Wing Tubeto Center Cooling Tube OONOOOBRWND Return Center Coolingg Tube to Fiter Tank HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 5 MOTOR SERVICE amp REPAIR 10 FT PUMP amp MOTOR HYDRAULIC SCHEMATIC Wing Supply Front Pump Half 1 Center Supply Rear Pump Half CAUTION NEVER Connect Pump Pressure Line direct to cooling tubes as it will damage the tubes he Dp a 14 LR _ Center LH amp RH Cooling Tubes Description Description Tandem Pump Asy Case Drain R Wing Motor to Cooling Tube Suction Tank to Wing Pump Wing Motor Asy R Wing Suction Tank to Center Pump Return R Wing Motor to Cooling Tube Pressure Wing Pump to Bulk Head Fitting Return Center Cooling Tube to Filter Tank Pressure Center Pump to Bulk Head Fitting Return Filter amp Gauge Wing Motor Return Pressure Bulk He
69. bly steps for possible assembly error x Cylinder Ports and two pin holes Vent Plug my in cylinder head are aligned Pressure Hose WU straight up CLL LLL LLL LLL L777 Figure 12 14 A Spanner wrench figure 13 can be pur chased commercially or it can be built by the repair technician The Pins will need to be the same size and width as the two holes in the cyl head The opening in the center must be large enough not to hit the cylinder rod The wrench must be built of material thick enough it will withl stand the pressure and handle is long enough to give the leverage needed when turning cylinder head When using aspanner wrench it is recom mended that the cylinder rod be covered well by wrapping and taping cardboard around it to protect the rod or wrap a cloth around rod Figure 13 HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 14 STANDARD AXLE LIFT CYLINDER REPAIR STANDARD AXLE LIFT CYLINDER SERVICE amp REPAIR HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 15 STANDARD AXLE LIFT CYLINDER REPAIR Cylinder Removal Axle Lift Cylinder Standard 1 Make Certain axles are in the lowered position before disconnection any component Make certain tractor is securely parked with brakes set Make certain tractor engine is in off position and key secured to prevent
70. bs Tip Speed Blade Tip Speed Based on Max Pressure amp RPM Center Section Blade Tip Speed 18 262 FPM Operating Speed Wing Section Blade Tip Speed 13 194 FPM Operating Speed Spindle 1 On Center Section amp 1 On Each Wing Spindle Bearing Type Adjustable Roller Bearing Cup amp Cone Spindle Seal Replaceble Round Seal Bottom amp Gasket Seal Top Spindle Lubrication NLGI EP 2 Grease Grease w Grease Gun Spindle Bearing Preload Required Adjustable 12 to 15 in lbs of rolling resistance HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 1 3 SPECIFICATIONS HYDRO 15 FLEX WING Blade Spindle Speed Measured RPM at Spindle Shaft Center Section Spindle Tip Speed 731 RPM Operating Speed Wing Section Spindle Speed 881 RPM Operating Speed Spindle to Deck Mounting Bolts 3 4 Grade 8 Toque to 350 ft lbs Hydraulic Pump Tandem Front1 2 of Pump f Wing amp Rear 1 2 pump of f Center Pump Type Tandem Gear Type PTO Driven Via Speed Changer Pump Displacement Center 2 95 C I D Wing 3 6 C I D 145 HP Dual Stage Gear Type 1 RPM Input X 4 RPM Output Increase 540 RPM Required 2160 RPM Operating 2750 RPM Max Pump Pressure 3000 PSI Operating 3600 PSI Max at Max RPM Pump GPM Front 1 2 Wing Motors 28 GPM Operating 35 GPM at Max RPM Rear 1 2 Center Motor 24 GPM Operating 35 GPM at Max RPM Hydraulic Motor Center amp Wing 1 amp 2 on 15 ft Model 1 amp 1 on 10 ft Model Motor Type Gear Type Motor HP Rati
71. cal Screw Lift Adjustment Optional Wing Axle amp Center Axle Hydraulic Lift Adjustment Mower Wing Lift and Fold Standard Hydraulic Cylinder 1 each Wing Optional Cable Winch and Stand Wing Lift amp Fold Hydraulic Standard Wing Lift Range 22 Down amp 90 Up Wing Winch Stand Bolt on Weldment Wing Winch Manual Operated Cable Lift Winch Mower Wing Transport Welded Bracket and Pin Assembly Hydraulic Control Valve Remote 3 Spool 15 ft or 2 spool 10 ft w Detent Hydraulic Control Valve Type Open or Closed Center Wing Deck Side Skirts 10 3 8 High 1 4 thick HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 1 4 SPECIFICATIONS HYDRO 15 FLEX WING Skid Shoes Standard Center amp Wings Replaceable Bolt on Deck Material Thickness 10 ga Steel with formed channel reinforcement Deck Reinforcement Hydraulic Oil Cooling Tubes welded to deck 6 Standard or 4 Optional Wheel Type Standard 6 00 X 9 Std Qty 6 Wheel Type Option 15 Wheel less tire 15 Wheel amp Pneumatic Tire Asy Used or Recapped Airplane Tire amp wheel Asy Foam Filled Airplane Tire Asy Wheel Spacing Center Axle 56 Center Inner Wheel to Center Inner Wheel Chain Guards 5 16 Double Row Standard Front amp Rear Tractor Drawbar Setting 14 to 16 f end PTO Shaft to Clevis Pivot Bolt Drawbar Safety Chain Standard TORQUE VALUES BOLTS Maximum Torque per Bolt Size and Grade Ft Ibs amp Nm IMPORTANT Listed below IS BOLT TORQUE and NOT
72. cannot be turned by hand DO NOT use any type of tool that will damage the cylinder rod Use a strap wrench that only uses the strap to grab the rod see figure 4 amp 5 Screw the cylinder rod completely out of the clevis Piston Nut Pist Cylinder Head iston Clevis Set Screw Cylinder Rod TP Bench Vise Figure 5 HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 18 STANDARD AXLE LIFT CYLINDER REPAIR Clean amp Inspect Cylinder Components Axle Lift Cylinder Standard 1 Clean and inspect parts figure 6 check cylinder components look for wear operation damages condition of materials Make certain the piston cylinder rod barrel base clevis cyl head rod clevis tie rods and nuts clevis set screw cylinder rod Remove the old seals and seal components figure 4 5 amp 6 Inspect the tie rods and the tie rod hex nuts The tie rods may need the threads cleaned and or straightened All components cleaned and inspected replace any damaged parts The Piston Locknut figure 6 item 14 is recommended that itbe replaced with new locknut of same rating Make a note of which way the seals are installed and in what order Remove all old seals and replace them with new ones see figure 6 The nylon thread protector will need to be removed from the rod clevis and replaced figure 6 item 2 After the seals have been removed inspect all of the grooves where seal seat for
73. center line of the bearings figure 3 y IA ay DA 13 Install the splined pump shaft adapter There are two types of splined pump adapters that were used While either style can be used the components of each style can not be mixed or left out Make note of which style that is being used A Old Style Splined adapter See figure 1 drawing A The old style splined adapter has a snap ring groove on the OD of it and a snap ring This splined adapter pushes into the speed increaser before the pump is bolted on the snap ring prevents the splined adapter Re Assembled from sliding inward and outward inside speed increaser is in operation DO NOT use with out the snap ring on Speed Increaser splined adapter failure will occur figure 2 amp 13 This FIGURE 12 will only fit with the snap ring outward B New Style Splined Adapter See figure 1 drawing B The new style splined adapter WILL NOT have a snap ring groove and WILL NOT use a snap ring to keep adapter stationary during operation The new style used a tube type spacer that is slid into the speed increaser and then the splined adapter is inserted This tube spacer will keep the splined adapter from sliding DO NOT use without the tube spacer installed failure will occur figure 2 813 This must be installed with the spacer tube insert first and then the splined adapter to Ao work properly B 14 Connect Pump to Speed increaser See pump repair service section
74. change Check which you have before ordering parts See figure 3 amp 4 for items referenced in the steps of dis assembly Inspect the wheel hub and hub components figure 3 amp 4 item 1 through 14 they should not have noticeable wear One Piece Seal Three Piece Seal or wearthatin any way would make them un serviceable Bearing Cones and cups must be replace together do not FIGURE 6 use a used bearing part against a new bearing part the bearings will fail as bearings wear on the cones and cups to match each other Lay all the new and or serviceable parts Roller Cage out on a clean surface figure 5 Install new bearing cups items 9 amp 10 into hub if needed Ifthe cups need to be replace they should be pressed in or installed with a driver designed for bearing Grease must be cup installation figure 3 8 4 lt ake certain the bearing pressed between cups are fully seated into the hub squarely and completely rollers andinner figure 8 race and it must be pressed out Pack Wheel bearing Cones items 6 amp 7 This can be around rollers done with a bearing packing tool or it can be done by hand Grease must be pushed through the roller cage figure 7 all the way around and completely If grease is not pushed in to bearings around rollers and out the top and around rollers FIGURE 7 of bearing cones they are not properly packed with grease this is important Lay the Hub with the outer bearing opening down a
75. condition make certain none are bent or distorted they should not have any damage or wear severe enough to damage seals Check for wear the ID of the barrel figure 6 item 5 OD of the piston figure 6 item 15 ID of the cylinder head figure 6 item 9 Figure 6 Cylinder Re Assembly Axle Lift Cylinder Standard 1 Clamp cylinder rod clevis into bench vise figure 6 item 3 see figure 7 Make certain the old nylon seal protector has been removed before attempting to screw cylinder rod into clevis figure 6 item 2 Using a strap wrench if needed screw the cylinder rod figure 6 item 4 into the clevis figure 6 item 3 tighten rod until it is screwed in flush with cylinder rod see figure 7 Important DO NOT install nylon thread protector or setscrew figure 6 item 2 into clevis at this time itis best to do this later after piston and piston nut has been installed Replace the seals in the cylinder head figure 6 item 9 base clevis figure 6 item 8 and piston figure 6 item 15 Make certain to put the seal on in the correct order figure 6 amp 7 Installing the Piston on the cylinder rod figure 6 7 item 15 may require a press DO NOT try to press piston onto cylinder rod with the piston nut Use Locktite 271 or equivalent when pressing piston onto cylinder rod Make certain piston and rod are in alignment when pressing piston make certain piston and rod are protected from damage HYDRO 15 Service Manual
76. continuing Ifthe bushings figure 10 item 6 were removed and new ones need to be replaced Inspect the holes where the bushing will be pressed in If there are burrs or rough edges atthe tops ofthe holes they canbe de burred by using your finger and emory cloth Keep the emory cloth on an angle and only around the top ofthe bore figure 26 Do this to each hole for the bushing that are to be replaced IMPORTANT Bushing must be pressed in with an arbor press DO NOT drive them in with a hammer Insert the shaft end cover in the vise with the machined surface up figure 27 Examine the plug in the surfaced area Itis NOT required to remove this plug un less the shaftend housing is being replaced This pump PGP PGM 365 Series has one plug and it is installed on determines the direction oftravel ofthe pump DO NOT change the location of this plug un less you want to change travel direction If plug is changed by error the pump will be damaged when Ml engaged it will most likely blow the shaft seal out of it and itmay damage othercomponents in the mowers hydraulic system This plugged is change by using a screw driver if need be If new plugs are to be installed coat the threads of the plug with locktite TM thread sealant If new plugs have been Ml installed they needto be screwedin tightly Stake the plug with a prick punch at both ends of the screw drive slot and around the edges Peen the edge of the hole 1 32 to 1 16 with a
77. cylinder base Figure 1 Cylinder Dis Assembly Axle Lift Cylinder Standard 1 This is a Tie Rod construction type cylinder the four tie rods figure 1 item 6 and the 8 hex nuts figure 1 item 7 bolt the cylinder together When these tie rods are unbolted the cylinder will come apart with minimum effort but DO NOT unbolt tie rods until later It is recommended that the barrel of the cylinder be marked as to which end isthe cylinder rod end and which is the cylinder base clevis end Place the cylinder in a bench vise figure 2 use pieces of wood or other soft material between vise jaws and cylinder barrel DO NOT over tighten vise and distort the shape of the barrel vise only needs to be tightened enough to hold cylinder Place drain pans under cylinder to catch hydraulic oil that may still be in cylinder figure 2 Drain Pans Using ratchet w sockets or boxed end wrenches repair technicians choice remove the tie rod hex nuts figure 2 item 7 The tie rods have a hex nut on each end figure 2 item 7 not all the hex nuts will screw off on the same side The hex nut with the least amount of resistance is going to screw off This is OK as the tie rods can be pulled out from either direction When a hex nut has been removed from each tie rod it will not matter which end of tie rod pull the tie rods out from the cylinder base and cylinder head figure 2 item 6 There are a total of 4 tie rods that will need to be r
78. d and piston as an assembly see figure 7 slide the assembly into the barrel Make certain that the insertion is on the same end as when it was removed Not required only recommended Make certain the port of the cylinder head figure 8 item 9 is pointing up as shown this will make certain of port alignment when base end of cylinder is installed Wood or other soft material Bench Vise cyl head clevis cyl rod amp piston asy Work Bench Figure 8 HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 20 STANDARD AXLE LIFT CYLINDER REPAIR Install the new nylon thread protector figure 6 item 2 into the cylinder rod clevis figure 6 item 3 Make certain the nylon thread protector is laying flat in the bottom of the threaded hole in the clevis Insert the setscrew figure 6 item 2 into the clevis figure 6 item 3 Tighten the clevis setscrew to 20 ft lbs base on 3 8 setscrew Coat the cylinder base barrel seals figure 6 amp 9 item 8 with coat of hydraulic oil Install the cylinder base end into the barrel see figure 9 If plastic plug is installed in base end as shown see figure 9 it will allow the insertion of the base end into the barrel if plug is removed Make certain that the ports on the base end are aligned with thew cylinder head as shown see figure 9 item 8 amp 9 the ports must be aligned this way Install cylinder tie rods figure 9 item 6 amp 7 make certain
79. d position before disconnection any component Make certain tractor is securely parked with brakes set Make certain tractor engine is in off position and key secured to prevent starting It is recommended mower be disconnected from tractor or battery cable be removed from battery while repairs are being made Make certain that all hydraulic pressure has been released from lines after wings and axles have been completely lowered This may require the tractor hydraulic controls and or remote control valve be worked to release hydraulic pressure NEVER disconnect any cylinder hydraulic hose s or fittings if all mower components wings and deck are not resting in the completely lowered to the ground position Remove the cylinder mounting pins figure 1 item 1 this allows the cylinder to be raised upward off the wing lug and outward from the cylinder mount of the winch stand Before disconnecting the base end hose figure 1 item 2 form the wing cylinder put a drain panunder the hose connection at the base end of the cylinder Begin to loosen the hose slowly If any hydraulic pressure is in the hose STOP and reread step 2 above If no Hydraulic pressure continue removing the hose from the base end of the cylinder while keeping the hose and cylinder over the drain pan When hoseis removed hold cylinder over drain pan until oil has drained from cylinder Install a cap onto the cylinder hose to seal it Cylinder Dis Assembly LH or RH Wing Cylinder 1
80. d which is the cylinder base clevis end and the barrel reassembled on the same end as removed Place the cylinder in a bench vise figure 2 use pieces of wood or other soft material between vise jaws and cylinder barrel DO NOT over tighten vise and distort the shape of the barrel vise only needs to be tightened enough to hold cylinder HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 24 OPTIONAL AXLE LEVEL LIFT CYLINDER REPAIR Place drain pans under cylinder to catch hydraulic oil that may still be in cylinder figure 2 Drain Pans Using ratchet w sockets or boxed end wrenches repair technicians choice remove the tie rod hex nuts figure 2 item 7 The tie rods have a hex nut on each end figure 2 item 7 not all the hex nuts will screw off on the same side The hex nut with the least amount of resistance is going to screw off This is OK as the tie rods can be pulled out from either direction When a hex nut has been removed from each tie rod it will not matter which end of tie rod pull the tie rods out from the cylinder base and cylinder head figure 2 item 6 There are a total of 4 tie rods that will need to be removed see figure 3 Wood or other soft material 13 Drain Pan Figure 2 Work Bench Remove the cylinder Base end cap figure 2 ltem 8 To remove the cylinder base end cap use a small brass soft metal hammer tap the base end cap until it slide out ofthe cylinder barrel figure
81. dustrial Section 4 5 SPINDLE ASSEMBLY SERVICE amp REPAIR It is recommended to apply Loctite 5900 Silicone Gasket Sealer around the Shaft or athin coat of silicone on the inside tapered side of the bearing ring but Place the bearing ring on the spindle shaft The tapered surface should face downward to fitthe contour of the spindle shaft Use a piece of 2 3 4 16 gauge tubing 8 long to drive the bearing ring down on to the spindle until the bearing ring bottoms out against the spindle Remove any excess silicone from the spindle shaft and bearing ring Turn the housing upside down so that the bearing seal and retaining ring may be installed Lubricate the seal prior to installation 2 3 4 16 gauge tubing 8 long Installthe lower Bearing Cup lower bearing race Drive the lower bearing cup into the lower end of housing Use a Bearing driver to seat the bearing cup into the housing make certain the cup is completely seated The lowering bearing cone must be packed with grease use a bearing grease packer or the properhand packing technique Install the lower bearing Cone packed with grease into the lower bearing cup Install the seal to approximately 1 4 from the edge of the Spindle Housing Seal must be even with lower edge of lock ring groove in spindle housing Place the Retaining Ring in the housing on top of the seal Using a suitable driver press the seal and retaining ring into the housing until the retaining r
82. e or Tractor Reservoir Center Level Lift Cylinder 3 1 2 Bore RH Wing Level Lift LH Wing Level Lift Cylinder 3 1 4 Bore Cylinder 3 Bore Hydraulic Pressure Figure 10 Flow Direction HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 30 Section 6 Repair Fill amp Service Fill Hydraulic Tank Inspection Service amp Repair Hydraulic Fluid Maintaining the proper level and cleanliness of the oil is very important for the continued trouble free operation of the mower and should be checked each morning before the mower is started Check for any leaks and tighten any fittings which may be loose 1 Clean The Machine The deck should be cleaned off at least once a day Remove all foreign material from the deck and structural members Never allow collected grass and dirt to remain in the deck This material will decompose forming ammonia compounds which will erode the paint and metal deck This material is also a source of contamination any time the hydraulic system is opened or service Keep the deck area clean and always clean before starting any service or repairs 2 Proper Oil Level Maintain the oil level within the sight gauge located on the front of the reservoir Never fill the tank above the sight gauge level A space is maintained above this sight gauge to allow forthe expansion ofthe oil figure 1 Oilis added throu
83. e smooth side of thrust plates are against gears Gently slip the thrust plate figure 10 item 7 amp 8 through the gear housing andinto place onthe shaft end cover figure 39 Thechannel seal from step 13 should face the shaft end cover The relief groove in the thrust plate should face the outlet side of the pump see figure 234 Coatthe driven gearjournal with light coat of oil Slide the driven gear figure 10 item 9 through the housing and into the bushing in thew shaft end cover figure 40 Coat the drive gear figure 10 item 9 splined shaft end with light coat of grease insert shaft into the o special steel sleeve figure 7 recommended tools list Lightly coat the steel sleeve with grease Place the lightly greased drive gear Figure 34 CS shaft inside the sleeve and slide both through shaft end cover with a gt twisting motion until the integral gear rest against thrust plate Avoid damaging double lip seal Remove steel sleeve squirt clean oil over gears figure 40 Note purpose of sleeve is to prevent splines onthe shaft from dam aging double lip seal F HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 19 PUMP SERVICE amp REPAIR 16 Slip the next thrust plate with the channel seal installed figure 10 item 7 amp 8 over the gear journals and into the housing bore The flat side of the seal should face up with the relief groove of thrust plate facing the outle
84. e with the splined side up figure 34 Before inserting the new lip seal into the shaft end cover Coat the outer edge of the lip seal with Permatex Aviation Form A Gasket No 3 non hardening sealant or equivalent figure 33 With the metal side of the seal up press itinto the mounting flange side of the shaft end cover with anarbor press and bar see recommended tools list Be careful not to damage the lip seal Press the lip seal in until flush with the recess wipe off excess sealant Install the Seal Retaining Cup figure 15 guide the Seal Retaining Cup into the recess in the shaft end cover This is alight press fit and can be pressed in with the arbor press or it can be lightly tapped into the bore DO NOT use excessive force to insert retaining cup ifit will not go with light force check for size error or other reason Forcing an over size bearing in will damage bearing and casting figure 15 amp F 44 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 19 MOTOR SERVICE amp REPAIR Using the snap ring pliers as shown Install the snap ring into the flange side of the shaft end cover figure 35 Lightly tap the snap ring with a small punch and hammer to make certain it is seated into the snap ring groove ofthe shaftend cover Remove the shaft end cover figure 36 from the vice and turnitover 180 and re insertit into the vise with the splined side down and re insert it into the vise Grease t
85. e wrong place could to extreme damage to the hydraulic system and or to the mower deck cooling tubes The pressure side of the pump hydraulic flow MUST NEVER be sent directly to the deck cooling tubes as the excess pressure will damage them The hydraulic oil flow can only be sent through the deck cooling tubes when it is being returned to the tank with little or no resistance Some components of hydraulic system are not meantthe be repaired only replaced Do Not dis assemble acomponent if it is a part intended for replacement only When storing a pump or its components for any reason it is recommended they be stored in a clean area and covered to protect from any dust components that have been washed be coated which oil if they are made of material that may rust HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 2 MOTOR SERVICE amp REPAIR Recommended To Test Hydraulic Pump before Motor is Removed Before Installing a New or Rebuilt Motor 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 until Pump failed from excessive pressure 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 Check Oil leve
86. eal with petroleum jelly vaselene on the OD of seal Slide the seal into the ID of the of the cylinder head figure 8 step 1 Press down and inward on seal until seal is seated in groove Figure 8 step 2 Check seal to make certain it was nut cut during installation Install cylinder head seal figure 8 step 1 item 4A Turn the cylinder head over as shown figure 9 step 1 Coat the back up ring with Push Down 8 Inward Here light coat of oil and slide it down over cylinder head NOTE some back rings have a round 4C depression in one side this side willbe mounted 4 __ Cyl Head up so the round O ring seal will fit in the depression Slide the back up ring down over pas 1 cylinder head until it is seated into the groove Clean Work Bench figure 9 step 2 item 4A Coat the O Ring figure 9 item 4A with oil and slide it down onto the cylinder head until it is seated into the Push Down amp Inward le Seal is seated in groove groove Figure 9 step 2 item 4A The Cylinder head is complete set it aside for now Install the Cylinder Head figure 10 item 4 onto the cylinder rod Coat the cylinder rod with ae a light coat ofoil and slide the cylinder head onto 2 it It should slide on with minimum effort but it must be slid on square and straight DO NOT Clean Work Bench use a hammer to force the cylinder head onto cylinder rod if it will not slide on by hand force Figure 8 check the components something is wrong and fo
87. ear Gear Housing Marks Here 1 Split Flange 1 1 2 Split Flange pil Ye Pressure outlet Side Suction Inlet Side Port Bearing Housing Front Gear Housing Service Technician Makes Alignment Marks Here Shaft End Cover See Figure 10 for Compo nent Item Number Speed Changer amp Figure 10A Tractor PTO HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 10 PUMP SERVICE amp REPAIR Pump Dis Assembly CAUTION Important information read before dis assembly as If prying off sections becomes necessary take extreme care not to mar or damage machined surfaces Excessive force while prying can result in misalignment and seriously damage parts If parts are difficult to come apart during dis assembly tap gently with a soft hammer never use an iron hammer Gears are closely matched therefore they must be kept together as sets when removed from the pump Handle gears with care to avoid damage to journals or teeth Avoid touching gear journals Never hammer bushing into bores always use an arbor press Pump Dis Assembly a Place the pump in a vise with the drive shaft pointing down Caution DO NOT grip on or near any machined surfaces of pump during assembly or dis assembly Mark all sections of the pump figure 10A these marks must be done in a manner that will not wash off and these marks are to identify the orientation of the component of the pump later for re assembly Iti
88. ear mea surementwas 17 from top of hinge pin to ground on rear The front measurement was 15 1 2 from top of hinge pin to ground This means the front is to low The ideal measurement would be rear 17 and front 16 to 16 1 2 the front should be run at least 1 2 to 1 lower in the front than rear Run lower in front will give cleaner cut and distribute cut grass better ae With 17 in rear and 15 1 2 in front means Figu re 9 a the mower needs to be raised in front Raising the front means shortening the control rod to do this screw the adjusting nut onto the control rod The RH control rod will raise the mower Note tightening the adjusting nut will raise the mower it will make adjusting easier if a floor jack is placed under mower and jack the mower up to the desired height of 16 to 16 1 2 Continue to raise mower until the desired height is reached Adjust the LH control rod on dual control rod models until the mower starts to lift Make certain the control rods have equal pressure on them best way to do this is watch the mower when the LH side adjustment starts to raise the mower it is starting to pick up the weight Install the jam nuts item 10 onto the control rods This will require two wrenches one to hold the adjusting nut so it won t turn and one to tighten jamnut against adjusting nut figure 6 Lock the adjusting nut securely with the jamnut to prevent the adjustment from changing This should keep the mower ad
89. ease Alamo Industrial PN 00900000 figure 28 The properlevel willbe uptothe upper bear cup bottom side for now do not fill with grease above the bottom of upper bearing cup if you do it will interfere with adjusting bearing preload Pack the upper bearing cone with grease completely Install upper bearing cone down over the top of the spindle shaft Bearing if needed use a bearing driver to seat Cup bearing cone into bearing cup Apply Locktite 277 to the spindle threads where the bearing nut screws on It may require grease to be cleaned off of threads to apply locktite figure 29 Start the New Locknut onto the shaft threads the nut should start by hand make certain it is started straight figure 29 Tighten the new Lock Nut with a 4 prong socket and hand ratchet until tight Back the nut off until 12 to 15 INCH POUNDS of rolling resistance is achieved figure 29 Use a punch to stake the bearing nut in place Be sure to stake the nut at both slot locations figure 30 Useing the grease fitting to the side of the spindle housinf pump grease in to spindle housing Watch the upper bearing cone when grease is being forced through the roller bearings of the upper bearing cone spindle is full figure 31 Install the new motor flange gasket Apply athin film of silicone to both sides of the gasket to ensure a good seal figure 31 Use Grease Gun to put Grease into Spindle Fill to bottom of Upper Brg
90. el has been replaced or the old barrel is being used it will need cleaning and a light coat of appropriate hydraulic oil applied Once done clamp the barrel done with only enough force to hold it Step 1 but_not so much as to damage it gt Clean Work Bench Barrel Nylon Plastic Rod Threads l Cyl Head SS EE E e e i a A a a a Step 2 4C lt Clean Work Bench 4 Cyl Head 4C Step 3 g S E A gt Clean Work Bench Figure 6 Figure 7 HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 11 WING LIFT amp FOLD CYLINDER REPAIR Install the cylinder rod seal into the cylinder head figure 7 item 4C Install the rod seal first coating the seal with petroleum jelly vaselene on the OD of seal Slide the seal into the ID ofthe of the cylinder head figure 7 step 1 Using a nylon plastic rod press down on seal light taps with small hammer will be ok providing you watch the bottom of the seal and make certain it is started in the seal groove and not being driven on through cutting seal Figure 7 step 2 drive seal in until it is seated into the groove Figure 7 step 3 Install the snap in cylinder rod wiper seal into the cylinder head figure 8 item 4B Turn the cylinder head over where the groove for the wiper seal is up ward Install the wiper seal first coating the s
91. ements until a maximum of 2000 psi If the flow rate is 85 or greater of beginning flow rate at no load the pumpis serviceable and functioning within specifications CAUTION Stop tractor engine and discontinue testing if hydraoulic oil temperature exceeds 220 F as temperatures above this could cause damage to components Example Recorded test results PSI GPM TEMP F PSI GPM TEMP F 0 500 1000 1500 2000 2500 3000 Shown Below is a Gear Pump Schematic Return Hose Flow Direction Manifold Block Pressure Gauge ri un o E a T as ps D a A oO HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 4 MOTOR SERVICE amp REPAIR 15 FT PUMP 8 MOTOR HYDRAULIC SCHEMATIC Wing Supply Front Pump Half CAUTION NEVER Connect Pump Pressure Line direct to cooling tubes as it will damage the tubes Center Supply Rear Pump Half if 14 N A Center LH 8 RH Cooling Tubes Description Tandem Pump Asy Suction Tank to Wing Pump Suction Tank to Center Pump Pressure Pump to Bulk Head Fitting Pressure Pump to Bulk Head Fitting Pressure Bulk Head Fititng to Center Motor Pressure Bulk Head Fitting to Wing Motors Motor Asy Center Sction Motor Return Center Motorto Wing CoolingTu
92. emoved see figure 3 HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 16 STANDARD AXLE LIFT CYLINDER REPAIR Wood or other soft material 13 Drain Pan 5 Drain Pan Figure 2 Work Bench Remove the cylinder Base end cap figure 2 Item 8 To remove the cylinder base end cap use a small brass soft metal hammer tap the base end cap until it slide out of the cylinder barrel figure 2 item 5 The base end of the cylinder will now be open See figure 3 Remove the cylinder head figure 3 item 9 Pull the cylinder rod out from inside barrel approx 2 inches by pulling on the cylinder rod clevis figure 3 item 3 Using a brass soft metal hammer tap the barrel side of the cylinder head figure 3 item 9 Cylinder head will slide out of barrel when the shoulder of the cylinder head comes out of the barrel pull the cylinder clevis figure 3 item 3 The cylinder rod clevis cylinder rod cylinder head piston and piston nut will all pull out as an assembly when pulled from the barrel see figure 4 Wood or other soft material j ood or other soft materia Bench Vise Drain Pan Figure 3 Work Bench HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 17 STANDARD AXLE LIFT CYLINDER REPAIR Remove the plastic plug figure 3 item 13 from the cylinder head With cylinder head piston cylinder rod and cylinder rod clevis assembly removed from the barrel the barrel can be rem
93. en making any modifications to the speed increaser mount kit the speed increaser must be kept in alignment with the PTO shaft of the tractor 1 Secure tractor in a safe area and secure tractor in a safe parked position see Tractor manufactures instructions for safely parking the tractor NEVER work on tractor with it running or any hydraulic components in the unsupported lifted position Read through the entire instruction section before attempting to install speed increaser or mounts The speed increaser mount plate needs to be mounted so that the existing bolts holes are centered around PTO Shaft Remove any existing shield support plates and center linkage arms or supports that are in the way Be sure and save all of these parts that are removed in case they are needed on the tractor in the future The mount plate should be mounted directly to the tractor using existing bolt holes or studs on the rear of the tractor These bolts or studs should be at least 1 2 in diameter in order to give full support Mount the speed increaser to the mount plate with the bolts and spacer provided Slip the assembly onto the PTO shaft Make certain the pump mount bracket of the speed changer is up and facing away from the tractor IF using a universal mount Kit Use transfer punches screwed into the mounting holes in the tractor to locate center of holes in mount plate A specific mount kit the mount plate should have a set of holes that align with the holes
94. enter axle and Vang Transport Locks on folding implements eA ach Safety Chain to cuter andtowing unit securely See Operator s Manual 5 Makecertain that the SMY sign Waming Lights and Reflectors are dearly visible Follow local traffic codes 7 Never operate wth Cutting Head mised Y passerby bystanders or tratic are in the area to reduce possibly of injury or deam fram Objects Mwrown by Blades under Guard or cuter structure Before Gsmounting secure implement in transport postion ar lower to ground Put Iractor in park or set he brake disengage PTO stop engine and remove key and wail until noise of rotation Has ceased loprevenl entanglement in rotating parts which can cause injury or death Never mount or dismount a moving venice Crushing rom runovermay cause injury ordeath 5 TRANSPORT SAFELY 6 USE SMV LIGHTS amp 7 DO NOT OPERATE 8 DO NOT MOUNT OR LOCK UP REFLECTORS WITH CUTTER OR DISMOUNT WHILE WING RAISED MOVING 00749117 WARRANTY INFORMATION Read and understand the complete Warranty Statement foundin 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 INTRODUCTION ABOUT THIS MANUAL The intent of this publications to provide the competent technician with the information necessary to perform the CORRECT repairs to the Alamo Industrial Product Th
95. ervice Manual 09 06 2006 Alamo Industrial Section 10 6 Section 11 HYDRO 15 Trouble Shooting Guide Trouble Shooting Guide TROUBLE SHOOTING GUIDE INTRODUCTION The following guides intended to help locate minor problems before they become major ones The basic procedures for maintaining the equipment properly are covered in the operators manual However any machine can have operating problems or need parts replacement under unusual conditions or severe use The following guide will help identify the most common problems and presents possible causes and solutions PROBLEM NOT CUTTING CLEAN DISHPAN HITTING CUTTER DECK BREAKING BLADE BOLTS BLADE WEARS TOO FAST POSSIBLE CAUSE Blades dull Blade Bent or damaged Blade rotation incorrect Using flat blades Carrier RPM too low Cutter not level Tires mashing down grass Ground speed too fast Blades locked back Blades riding up due to blade boltwear Blades hitting deck Blade carrier bent Nut that holds Blade Carrier on is loose Deck bent down Output Shaft on Gearbox bent Operating mower w loose blade bolts Worn blade bolts Cutting in sandy condition Cutting in rocky conditions Blades too soft HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 11 2 SOLUTION Sharpen or replace blades Replace with correct condition blades Use correct blade for carrier rotation check to make certain Hyd motors tur
96. ess at Gear contact area Thrust Plate 1 Check center of Thrust Plates where the Gears mesh Erosion here indicates Oil contamination 2 Pitted Thrust Plates indicate cavitation or Oil aeration 3 Discolored Thrust Plates indicate overheating probably insufficient Oil HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 16 MOTOR SERVICE amp REPAIR Thrust Plate CAUTION Figure 25 Important information read before assembly 1 Thrust Plates must not have scratches or excessive worn places on either side of plate 2 Thrust plates must be installed correctly The thrust plate has two surfaces one surface has a groove for channel seals and the other surface is smooth with two relief grooves notch in it Thrust plate smooth surface with relief notches will always face the gears the groove side for the channel seal side smooth with groove side will always face the gear bearing journal bushings never the gears as the gear would destroy the channel seal The relief grooves will face the both sides ofthe gear housing on the motor as both relief grooves are the same and will not make any difference which goes to which side Thrust plates are very important to the way they are installed If they are installed wrong the pump will not function properly and other components could be damaged if operated with them wrong Channel Seal Side Gear Bore Grooved Side Back Side GearHousing Not Shown Thrust Pla
97. essed out Make certain to support the housing half while pressing out bearing cup Turn the PTO housing halve overto remove the closed cover Figure 4 item 7 and the open cover figure 4 item 9 from the PTO side housing half figure 4 item 15 Remove the closed cover and the open cover by removing the 6 bolts and lockwasher that retain them Make a note as the amount of shims that are installed behind closed cover and open cover this will give fair indication of what is need during re assembly Remove bearing spacer figure 4 item 11 8 35 and press bearing cups out of housing half Remove the seal figure 4 item 10 from the open cover figure 4 item 9 Remove bearing cones figure 4 items 14 amp 20 from gear shafts figure 4 items 2 amp 5 the removal of the bearing cones will require a bearing puller When removing the bearing cones from the gear shafts use caution not to damage the bearing cone or the shaft surface Inspect and clean all components that have been dis assembled from speed increaser Inspect the seals that were removed Clean both housing halves Inspect all machine surfaces of housing for scratches and damage Wash all parts clean old gaskets off and air dry DO NOT SPIN DRY BEARING CONES WITH COMPRESSED AIR this will damage bearing cones Inspect old seals and seal openings Figure 5 for damage to old seals that may have been caused by covers and or plates One of the most common problems is damaged sone when the ori
98. est Identified by the seal type The earlier type has a one piece seal figure 3 The later type has a three piece seal seal inner seal adapter and outer seal protector If the hub you are working on has a one piece seal it must be re assembled using the components of the one piece seal hub If itis a three piece seal figure 4 it must use components for three piece seal hub The parts for the two different hubs will not interchange Check which you have before ordering parts See figure 3 amp 4 for items reference in dis assembly 2 steps NOTE Axle Spindles shown removed from axle as illustration only the spindles are actually welded to the axle arms and are not removable je 11 Whl Hub Asy 1 piece Seal Before removing the wheel from the hub item 1 make note of which way lug nuts are installed The laminated tire lug nut MUST be installed different than the other wheels see previous page if using laminated tires and wheels Clean all dirt and debris from dust cap and hub before attempting to remove dust cap Use a small wedge type tool to dislodge the dust cap item 2 from the hub dust cap will pry off usually with ease Remove the cotter pin item 3 It will require the cotter pin be un bent to remove it dis card the old cotter pin and replace it with new one during re assembly Remove the slotted retaining nut item 4 from the y spindle it has RH threads Slide the retaining nut washer FIGURE 4 whi Hub
99. front side of the center section deck slide eye end of the control rod item 1 into the hole of the channel on the deck the threaded end will be to the front Install the swivel bar figure 4 item 2 into the tongue if dual control rods there is one onthe LH side also that should be installed now figure 6 From the back side slide the control rod item 1 forwar toward tonge and into the hole of the swivel bar item 2 this will mot likely require two people The hole in the swivel block will be larger than the control rod diameter figure 4 8 6 Select the correct bushing weldment item 3 should be same as existing part slide the bushing weldment item 3 over the threaded end of the control rod item 1 and through the hole of the swivel bar item 2 until the shoulder in bushing weldment is against the swivel bar figure 4 5 amp 6 Start the adjusting nut item 4 on to the threads of the control rod item 1 only start the threads do not screw the adjusting nut on completely Push the control rod back toward the rear ofthe mower Install the rear control rod anchor bolt item 5 by aligning the eye on the control rod with the hole in the rear axle item 9 install the locknut item 6 onto the anchor bolt Tighten the nut untill the slack is out and the bolt will not slide in or out DO NOT over tighten the bolt and deform the plates on the axle or tighten bolts so tight the control rod is pinched between the plates of the axle figu
100. ft Adapter Spacer use w item 1A 1 Shaft 8 Gear Low Speed 72 Tooth 1 Pump Flange 1 Cover Closed 2 Cover Open 3 Seal 1 Spacer Ring 1 Breather Plug 1 Bearing Cup 1 Bearing Cone 1 Housing Half Non Breather Side 1 Housing Half Breather Side 2 Dowel Pin Upper or Lower 1 Gasket F Housing Halves 3 Bearing Cup 3 Bearing Cone AR Shim Aluminum 005 AR Shim Aluminum 007 Shim Aluminum 020 3 Shim Fibre 005 Shim Aluminum 005 Shim Fibre 005 Shim Aluminum 007 Shim Aluminum 020 Bolt Allen Head 5 16 NC X 3 1 4 Gr 5 Lockwasher 5 16 Bolt Hex Head 3 8 NC X 3 1 4 Gr 5 Nut 3 8 NC Lockwasher 3 8 Pipe Plug 1 plug is removed to install Breather Spacer Ring HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 7 7 Speed Increaser Service amp Repair Dis Assembly Prodedure Important It is assumed that the pump has been disconnected from speed increaser the speed increaser has been disconnected from the tractor mount plate lf not see the step previously instructing the mounting of speed increaser and pump The speed increaser has been cleaned and drained of oil Dis assemble amp Re assemble for Inspection Only 1 There are different ways to dis assemble the speed increaser If the purpose is to only inspect the components the housing halves can be unbolted figure 4 item 31 32 amp 33 allowing the two halve to come apart leaving the components in one housing half This will allow the in
101. g Wing Lift amp Fold Cyl RH Wing Note Standard Hydraulic Axle Lift This has one axle cylinder on center axle only This cylinder is 3 bore The hydraulic hose is routed to the base end of cylinder The hose routing must be this way to work properly There is NO return hose connected to gland end of center axle cylinder only a vent plug this vent plug allows cylinder to move freely without creating a vacuum inside cylinder barrel If optional Valve is not used and cylinders are connected direct to tractor it is recommended tractor have at least three remotes Itis also recommended these remotes have detent on them to allow wings to float or damage to deck could occur The wing axles are adjusted manually using the mechanical lift screws This can be used on tractor with only two remotes by connecting the wing cylinders together with a Tee fitting but if doing this you will lose the ability to decide which wing folds first The wing with the least resistance will fold first HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 2 WING LIFT amp FOLD STD AXLE LIFT CYLINDERS 10 FT STANDARD HYD AXLE LIFT W STD WING LIFT FOLD Option Remote Control Valve Shown Valve Inlet Pressure from Valve Outlet Tractor Hyd System Return to Tractor Resevoir Cylinder Center Axle Mechanical Lift Screw Wing Lift amp Fold Cyl R
102. gh the breather cap pressure valve located in the top ofthe tank Stand off to one side when removing the breather cap element to prevent possible injury Remove the breather cap slowly to release any excess air figure 2 Remove the pressure cap and add oil Use one of the following oils Exxon NUTO H 100 Gulf Harmony 100 AW or Shell Tellus 100 3 Oil Level Low Low oil level in the reservoiris caused by leakage of oil Locate the area of the leak and repair the leak atonce Loss of fluid can cause severe damage to the hydraulic pump and motors figure 1 NOTE After the first day of operation the mower may require more oil to bring the oil level back into the sight gauge This is normal Air trapped in the lines and tanks was displaced by the oil causing the oil level to go down figure 2 4 Filter Change After the first 25 hours of opera tion change the oil filters Replace the oil filters with anew one Thereafter replace these filters every FIGURE 3 500 hours The return gauges should always be in the green color of gauge figure 3 HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 6 2 Fill Hydraulic Tank Return Filters Service amp Repair Hydraulic Tank Hydraulic tank is bolt on assembly hydraulic tank houses return filters figure 4 amp 6 oil level sight glass and two return oil pressure gauges The filler cap is a breather type The center section returns through the
103. ginal seal or whena replacement was installed previously When installing seal there are a number of ways the damage can occur hitting opening with seal driver hitting opening with hammer or hitting opening when removing old seal The top opening is not chamfered and the metal will mash down and lay over the side this can usually be identified by scratches that run across the OD of the seal as shown in figure 5 This can be and should be fixed by using emery cloth and carefully removing these burrs on the outer edge only the burrs on the outer edge should be removed not material inside the ID of the opening Inspect bearings cups and cones housing halves gears and shafts covers bolts nuts and washers Replace any components that are not serviceable DO NOT mix old worn parts with new parts the worn parts will decrease the life of the repair parts Damaged burrs Seal opening in Seal Removed from Damaged cover burrs opening incover 1 i i Good Seal opening in cover Seal Removed form good opening in cover HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 7 9 Speed Increaser Service amp Repair Re Assembly for Replacement of Components IMPORTANT Make certain all components have been cleaned inspected and replaced as required All parts must be dry of any cleaning agents All covers should be cleaned of oil and or grease 1 Make certain the covers figure 4 items 6 7 9 are
104. good enough Gear Wear Area condition and may be reused understand if you are at 0 007 you are at the upper limits and will not be at peak performance A pump should always produce at least 85 efficiency Example if your Pump is rated at 37 GPM it should produce at least 32 GPM Gears Gear Teeth Any scoring on Gear Hubs necessitates Replacement Scoring Grooving or Burring of Outside diameter of Teeth requires replacement Nicking Grooving or Fretting of Teeth surfaces also necessitates replacement Drive Shaft with Built on Gear Gear Hubs If Gear Teeth and Gear Hubs are OK Inspect Splines on input end OD of Shaft and the Splines ID Output Coupler End Tandem Pump for condition and Wear Inspect Wear or damage to Seal Wear Area If damage at Seal are check for contamination Note Some Pumps and or Motors may have Keyway or Splines Either will have to be inspected for condition If Damage in any of these area the Shaft Gear will have to be replaced Splines Thrust Plate The Thrust Plate Seals the Gear Section at the sides of the Gears Wear will allow internal slippage which is Oil bypassing within the pump The Pump and Motor Thrust Plates are different even though they may look very similar They are built different They will not interchange A Maximum of 0 002 wear is allowable Replace Thrust Plates if they are scored eroded or pitted Wear can be checked usually by comparing thickness at outer edges with thickn
105. half figure 4 item 16 at this time figure 9 Coat the bolt threads with a thread light sealer The 5 16 bolts will torque 12 to 15 ft lbs These are to be torqued in a criss cross pattern figure 8 Do this in increments to keep the flange and cover m mounted square and prevent warpage The pump mount flange and the open cover mount and toque the same 12to 15 ft los After tightening the open cove and the pump mount flange make certain the ID of the seals are coated with light coat of grease Pump Mount Flange FIGURE 7 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Clean Grease 801 or Equal Sealer Flat side Outward This Side Inward Toward Gears Seal Install From Top Section 7 10 Speed Increaser Service amp Repair Correct Bolt Torque Pattern Install the bearing spacer figure 4 item 35 Installthe bearing spacer figure 9 now in the open cover end ofthe housing The bearing spacer is installed into the opening Dowel Pin Cover Gasket Pump Mount Housing Half Flange Breather half pump mount half Bearing Cups 5 16 Allen Head Bolts amp Lockwashers Housing Half befor the bearing cup is installed Make cer tain the bearing spacer is installed flat and seated againstthe open cover Cover Gasket LT Open Cover Installs here Bearing Spacer Installthe Bearing Cups into the housing pene half Use a bearing driver to install bearing cups figure 4 item 19 Install
106. he motor bolts to the spindle with 1 2 grade 8 bolts Install a new gasket between motor and spindle Torque the 1 2 bolts to mount motor to spindle to 95 ft Ibs figure 34 4 Mount Spindle to deck use 3 4 bolts with lock nuts Torque the 3 4 bolts to 350 ft lbs figure 34 Bar Carrier Shown Lf Na 3 Description Spindle Housing Assembly Motor Assembly Motor To Spindle Retaining Bolts Torque to 95 ft lbs Motor Spindle Gasket Spindle to Deck Retaining Bolts Torque to 350 ft Ibs Deck Mainframe Blade Bar or Pan Carrier Assembly Bar Shown Blades Blade Bolts Bolt Nut and Washer Torque to 400 ft Ibs Blade Bar Carrier Retaining Bolts amp Washers Torque to 400 ft Ibs lt BND 04 gt 2p It 1 2 3 4 5 6 7 8 9 1 o IMPORTANT NOTE BOLTS of different lengths are used for the installation of the blade bar or pan blade carrier attachement to the spindle shaft The required length is dependant on which carrier is used DO NOT change the length of the bolts on the carrier installation use only the length that came with the mower The spindle shaft and spindle componets can be damages if longer bolts are used as well as the blade carrier can not be torqued porperly See Parts Manual for correct part numbers figure 34 DO NOT mix old and new blades on same blade carrier Blades MUST be equal in weight to maintan carrer ba
107. he new Gasket Seals figure 15 and insert it in both sides of all gear housing Position the gear housing figure 36 onto the shaft end housing figure 35 aligning it with the holes for the dowel pins Tap it with a soft hammer until it rest tightly against the shaft end cover Be careful not to pinch the seal gasket figure 36 Assemble the channel seals figure 37 amp 38 into the grooves in the thrust plates with the flat side of the seal facing away from the thrust plates as shown figure 37 amp 38 IMPORTANT NOTE Channel seals will always be on side of thrust plate away from gears only the smooth side of thrust plates are against gears The channel Seals will be all around gear shaft journal opening on motors Gently slip the thrust plate figure 39 into the gear housing and into place on the shaft end cover figure 39 The channel seal from step 13 should face the shaft end cover The relief grooves inthe thrust plate should face the outlet gears figure 39 Coat the driven gear journal with light coat of oil Slide the driven gear figure 40 throughthe housing andinto the bushing in the shaft end cover figure 40 Coat the drive gear splined shaft end with light coat of grease insert shaft into the special steel sleeve figure 7 recommended tools list Lightly seal Remove steel sleeve squirt clean oil over gears figure 40 Note purpose of sleeve sto prevent splines on the shaft from damaging double lip seal Coat t
108. he steel sleeve with grease Place the lightly greased drive gear shaft inside the sleeve and slide both through shaft end cover with a twisting motion until the integral gear rest against thrust plate Avoid damaging double lip seal Remove steel sleeve squirt clean oil over gears figure 40 Note purpose of sleeve is to prevent splines on the shaft from damaging double lip seal HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 20 MOTOR SERVICE amp REPAIR 15 Slip the second thrust plate with the channel seal installed figure 41 over the gear journals and into the down over the gear shaft journals figure 41 The flat side of the seal should face down with the relief groove of thrust plate facing the gears Check the gear housing gasket seal figure 15 is still in place on gear housing figure 36 Channel Seal Lightly coat the gear journals with grease When eed AERO aoc aa Side Grooved Gear Side placing the Port end housing figure 42 over gears use Smooth caution so you don t hit and damage gear shaft journals Place the bearing carrier onto gear shaft journals of the drive and the driven gears Be sure to align the dowel pin holes over with dowel pins When the parts are parallel squeeze them together or alternately tap over each dowel untilthe parts are together DO NOT use excessive force to put housing together if light taping won t do it something Smooth Side is wrong figure 42 M
109. ian Makes Alignment Mark Here Shaft End Cover 4 Bolt Mounting Flange RH Side of TTS LH Side of Motor amp Mower Motor amp Mower Figure 13 Front of Motor amp Mower Shown HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 10 MOTOR SERVICE amp REPAIR IMPORTANT RH amp LH WING MOTOR Mark all Sections of Motor with a Number or Symbols that will serve as a guide to all sections being re installed the same way they were removed Example if the numbers marks do not line up 1 2 38 4 as they were marked the Motor is not being assembled correctly Check this all through the assembly process The Motor will rotate in the wrong direction if connected wrong NOTE The manifold block will always mount with the relief valve on the same side as the pressure inlet If installed wrong the motor will not function properly because the relief valve will not work RH 8 LH Wing Motor Relief Valve 3000 psi Relief Valve 800 psi Manifold Block Mounting pS l l Bolts Plug Logic Cartridge Solenoid Stem amp Coil Manifold Block RH Wing Motor Assembly bolts are notvisible under manifold block cut 1 Split Flange outview for Return Outlet Side illustation only LZ 1 Split Flange 2 Pressure inlet Side 1 Screw in Plug Y Port End Cover O Gear Housing Service Technician lt A Makes Alignment Marks Here Fo Ed Shaft End Cover ee oo Sead ae 1 a T
110. ice Manual 09 06 2006 Alamo Industrial Section 1 7 NOTES HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 1 8 Section 2 HYDRO 15 Pump Service amp Repair Section 2 1 PUMP SERVICE amp REPAIR Recommended Reading Before any Service Work Begins Le Read this section completely before starting inspection or repair to the mower hydraulic system to become familiar with its components Identify the model of the mower model number serial number and other information that may be needed to identify which components or options that may be on the mower Make certain the mower and tractor are secured in a safe and proper parked position hydraulic axle and wings lowered Tractor safely parked according to tractor manufacturers recommendations Clean the complete hydraulic system in the area of the repairs Dirt is the enemy of all hydraulic systems and all steps must be taken to keep hydraulic system from being contaminated Make certain the hydraulic oil is not hot from being operated or tested All hydraulic components including hydraulic oil temperature should not exceed ambient temperatures If temperature is high it must be allowed top cool before attempting any repairs of the hydraulic system Caution should be taken if mower is sitting in hot sun ona very hot day the temperature of the metal and oil can be hot test the temperature The drawing andillustrations in this section are to help under
111. in the tractor This procedure will insure that the speed changer is centered around the PTO shaft If drilling holes the holes should be 1 32 larger than the bolt or stud size to maintain concentricity DO NOT oversize holes more than 1 32 Over size holes will allow plate to slip off center to the degree it will not function properly and if ran this way will most likely damage the PTO or other components The mount plate can be altered if need be to fit tractor The use of a cutting torch to enlarge the center hole or remove excess plate from the sides or the bottom can be done BUT the technician must make the decision when cutting as to the amount that is cut off the technician must also make certain to leave enough material on the mountplate to allow it to maintain strength to support the pump and speed increaser It is recommended that the technician contact Alamo Industrial if the amount of material being removed is in question or severe enough to weaken mount plate If you can not mount the mount plate directly to the tractor use the spacer tubes figure 1 mount plate to tractor spacers These tubes should already be to length if a specific tractor mount kit has been ordered a universal mount kit will require modification which will be at a later time Check the ends of the spacer tubes to make certain the ends are cut square if they are not don t use them replace them with tubes that are square and to length The spacer tubes must be squa
112. ing snaps into place in the ring groove Be sure the retaining ring is in the groove all the way around and the sealis against the retaining ring Coatthe ID of the seal with a light coat of grease HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 4 6 SPINDLE ASSEMBLY SERVICE amp REPAIR Place the spindle shaft with the bearing ring installed into the spindle housing Turn the assembly over so that the housing is sitting upright and the spindle shaftis supporting the housing Make certain to support the spindle housing to keep it straight up as the lower bearing ring is being inserted into the seal as the lower bearing is being driven down onto the shaft Use the 2 3 4 16 gauge tubing to drive the lower bearing down onto the bearing ring If the bearing ring is not seated or if the bearing is not properly seated against the bearing ring the assembly will lose bearing preload and rapidly fail Remove the 2 3 4 16 gauge pipe from the spindle housing Checkto make certain the shaft bearing ring and lower bearing are seated properly Install the upper bearing cup using proper size driver Make certain the bearing cup is seated completely into the spindle housing 2 3 4 16 gauge tubing 8 long w Figure 25 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 4 7 SPINDLE ASSEMBLY SERVICE amp REPAIR Fillthe spindle housing with NLGI EP 2 gr
113. ion 11 Trouble Shooting Guide 11 1 to 11 3 Probable Cause amp Solutions 11 2to 11 3 HYDRO 15 Service Manual 09 06 2006 Alamo Group Inc Index 4 Section 1 HYDRO 15 Model Specifications SPECIFICATIONS HYDRO 15 FLEX WING READ THIS BEFORE BEGINNING ASSEMBLY REPAIRS OR TESTING The Hydro 15 has electric components The electric components can be damaged if care is not taken when performing repairs testing dis assembly or re assembly Mower must be maintained in a safe position at all times The hydraulic system must be protected from contamination at all times DO NOT DO NOT start any repairs testing or dis assembly before the mower is secured with the wings in the lowered position and the mower hydraulic axle system released to lower the mower completely If the Hydraulic axle cylinders or turnbuckles are to be removed or serviced make certain mower decks are securely supported by strong jack stands Make certain mower is in secure clean environment when working on hydraulic system If mower is connected to tractor must be securedto prevent someone from starting itand parkedin accordance with the tractor manufactures recommendation See tractor operators manual and or decals for parking tractor securely DO NOT open any hydraulic component on mower before the entire exterior of the mower and hydraulic components have been cleaned of all debris or any thing that would contaminate the hydraulic system When working on
114. is will in turn provide for complete customer satisfaction It is hoped that the information contained in this and other Manuals will provide enough detail to eliminate the need for contact of the Alamo Industrial Technical Service Dept However it should be understood that many instances may arrive wherein correspondence withthe Manufactureris 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 partto 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 Request for Technical Information or Specifications Mounting or Fitting Problem Special Service Problem Equipment Application Problems Tractor Problem
115. justed to the desired cutting height unless something changes Some things that will affect this is changing tractors to a different draw bar height The wear or distortion bending of the blades can change this Changing type of tires amp wheels used can change this Any time any of these things are changed the mower will require re adjusting HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 10 5 Leveling Wings Service amp Repair Leveling Wings L to R There are two different system for lifting of the wings the standard mechanical turnbuckle and the optional level lift hydraulic cylinder system leveling the wings should be done only after the mower has been leveled front to rear Leveling the mechanical turn buckle axle lift system This is done by lengthening or short ing the mechanical turnbuckle figure 10 Mea sure to the ground atthe inner rear edge of the top deck of wing and adjust the turn buckle until the top deck is the same height at the outer edge Dos this on both wings and mower should be level across left to right Leveling the optional hydraulic level lift fig ure 11 is done by the cylinders The cylinders are connected together and move together This system will level the wings themselves if they are connected and the air is bleed from them See the hydraulic axle level lift in a previ ous section of the service manual for operating instructions HYDRO 15 S
116. king down on tank and deck Retlp Pressure Gauges Filter Housing Cover Bolts 3 Return filter gauge is low pressure gauge It will FilterHousing read high in the red when oil is cold and unit is first Cover started Run unit at lower RPM until oil reaches normal FilterReturn operating temperature Recheck gauge the return Gage Port should be reading in the green if it is not check system for blockage or other problem restricting the return flow NEVER connect the pressure side direct to the colling tubes on deck this will damage them Filter Housing Filter Asy to Tank Gasket Vent Cut Off Filter Asy to Top Red Area Replace Filter Tank Bolts 16 psi to 60 psi Oil to Filter Asy Return Port Return Filter 1 4 NPT Cartrige Inside Filter Oil to Tank Return Green Area Good 0 psi to 15 psi Return Pressure Gauge FIGURE 5 Glycerin Filled HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 6 3 Fill Hydraulic Tank Fill Hydraulic Tank with Oil 1 DO NOT START TRACTOR until you have filled Hyd Oil Tank to a level as shown in Sight Glass gauge DO NOT perform any maintenance service or repairs to hyd system until the mower has been cleaned of all debris If new or rebuilt pump has been installed fill the Suction Hose to Pump with Oil 2 Remove Filler Cap Remove Filler cap only when ready to fill hydraulic Tank with Oil Do Notleave the Cap
117. l head rod clevis tie rods and nuts clevis set screw cylinder rod Remove the old seals and seal components figure 4 5 amp 6 Inspect the tie rods and the tie rod hex nuts The tie rods may need the threads cleaned and or straightened HYDRO 15 Service Manual 10 06 O 2006 Alamo Industrial Section 5 26 OPTIONAL AXLE LEVEL LIFT CYLINDER REPAIR Piston Nut Pist Cylinder Head iston Clevis Set Screw Cylinder Rod Bench Vise Figure 5 After components have been cleaned and inspected replace any damaged parts The Piston Locknut figure 6 item 14 is recommended that it be replaced with new locknut of same rating Make a note of which way the seals are installed and in what order Remove all old seals and replace them with new ones see figure 6 The nylon thread protector will need to be removed from the rod clevis and replaced figure 6 item 2 After the seals have been removed inspect all of the grooves where seal seat for condition make certain none are bentor distorted they should not have any damage or wear severe enough to damage seals Check for wear the ID of the barrel figure 6 item 5 OD of the piston figure 6 item 15 ID of the cylinder head figure 6 item 9 Make certain to inspect the ID of the cylinder barrel the will be a groove machend into the rod end of the barrel that will allow the hydraulic oil to bypass from the 1 st cyl to the 2nd cyl and onto the 3
118. l in reservoir fill to full level if needed Reservoir must have more Oil than the Pump GPM capacity 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 Operate the Pump for at least two minutes atno load and atlow 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 amountof heat Heat should not exceed 100 deg F above 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 Ifnormal 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 Ka Equipment Needed 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 connectto Hydraulic System
119. lamce If A vibration exist in the blade carrier the balance is off The problem causing the out of balance condition must be corrected If mower is run without correcting balance problem damage will be done to the deck and other components The extend and speed of the damage will increase with the severity of the unbalance problem HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 4 10 Section 5 HYDRO 15 Hydraluic Cylinder Service and Repair HYDRAULIC SCHEMATICS 1 WING LIFT amp FOLD CYLINDERS 2 STANDARD AXLE LIFT CYLINDER 3 OPTIONAL AXLE LEVEL LIFT CYLINDERS This section contains the procedures to service and or re pair the mower wing lift cylinders standard axle lift cylinder and the optional axle level lift cylinders Review the cylinder schematics to determine which axle lift system was installed on the mower The 15 foot Model and the 10 foot model are the same with the exception only one wing is used on the 10 foot model HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 1 WING LIFT amp FOLD STD AXLE LIFT CYLINDERS 15 FT STANDARD HYD AXLE LIFT W STD WING LIFT FOLD Optional Remote Control Valve Shown Valve Inlet Pressure from i Valve Outlet Return Tractor Hyd System B to Tractor Resevoir A Mechanical Lift i Screw Mechanical Lift Y Ar Screw Wing Lift amp Fold Cyl LH Win
120. late for damage atthis time see wear tolerance chart for pump and motors in this section Note Thrust plate can be re moved after gear housing if wanted figure 25 Remove the gear housing figure 22 Liftthe gear housing up if prying is necessary take care notto damage machined surface Examine gear housing for wear and or damage See wear tolerance chart for pump and motors in this section Remove shaft end cover figure 23 from vice and turn it180 over and re insertitinto vice Using snap ring pliers remove the snap ring figure 23 as shown Remove the seal retainer cup figure 15 The seal retainer cup should pull up out of the end shaft cover Ifit will not go on to step 12 and remove the retainer cup with the seal Remove shaft endcover figure 10 item 4 from vice and turn it 180 over and re insert it into vice Remove the double lip seal by inserting the special seal removal tool see figure 6 recommended tools Make note of which way Figure 22 sealis removed Inspect the shaftend cover seal seat area figure 24 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 14 MOTOR SERVICE amp REPAIR 13 Inspect allthe components that have been removed review steps 1 through 12 There are 2 gasket seals Square Seals figure 15 thatare installed one on each side of the gear housing Make certain the gasket seal have been removed and the gasket grooves are clean Wash and clean al
121. ll level if needed Reservoir must have more Oil than the Pump GPM capacity 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 Operate the Pump for at least two minutes atno load and atlow 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 amountof heat Heat should not exceed 100 deg F above 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 Ifnormal 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 Ka Equipment Needed 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 connectto Hydraulic System 2 Electrical Volt Meter
122. lthe components DO NOT use any material that will leave linton components it s best to air dry the components Use extreme caution when cleaning gear sets DO NOT use any abrasive materials at all and DO NOT bang the gears together Keep the gears inthe same sets as they were remove as they are a matched set and must remain as a set See next two pages for wear identification F HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 15 MOTOR SERVICE amp REPAIR Wear Tolerance for Pump amp Motor This is suggested Wear Tolerance to Keep Assemblies operating as efficient as possible Not Complete failure rate Your Pumps and or motors may not be exact same as discussed here Gear Housing Gear type Pump and Motor Wear in excess of 007 cut out necessitates replacement of the Gear Gear Housing Housing Place a straight edge across the Bore in the cut out area If you can slip a 007 feeler gage under the straight edge in the cutout area Replace the Gear Housing Pressure pushes the Gears against the Housing on the Low Pressure side As the Hubs and Bushings wear the cutout becomes more pronounced Excessive cutout wear in short period of time indicates excessive pressure or Oil contamination If the relief Valve Settings are within prescribed limits check for shock pressures or tampering Withdraw Oil Samples and check it and tank for Cut Out Area dirt Where cut out is moderate 0 007 or less gear housing is in
123. m damage Install the new Piston retaining locknut figure 6 amp 7 item 14 onto the cylinder rod Note it is not recommended that old locknut be reused Before tightening the locknut down make certain thatpiston is seated onto cylinder rod completely this can be done by visually inspecting back side of piston against shoulder of cylinder rod Torque Piston Locknut 300 ft lbs based on 1 locknut When tightening piston locknut if support for cylinder rod is needed see figure 4 Cylinder Head Piston Clevis Set Screw Piston Nut Cylinder Rod Chamfered side of piston Bench Vise Figure 7 Install the new nylon thread protector figure 6 item 2 into the cylinder rod clevis figure 6 item 2 Make certain the nylon thread protector is laying flat in the bottom of the threaded hole in the clevis Insert the setscrew figure 6 item 2 into the clevis figure 6 item 3 Tighten the clevis setscrew to 20 ft lbs Clampthe barrel figure 8 item 5 in vise using wood or other soft material to protect barrel see figure 8 DO NOT tighten vise so tight that the barrel becomes distorted Make note that the mark that was made to identify which end of the barrel was the rod end is verified Coat the inside of the barrel with hydraulic oil Coat the piston cylinder rod cylinder head seals with hydraulic oil Holding the rod clevis cylinder head and piston as an assembly see figure 7 slide the assembly into the barrel M
124. mo Industrial Section 5 21 NOTES HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 22 OPTIONAL AXLE LEVEL LIFT CYLINDER REPAIR AXLE LEVEL LIFT CYLINDERS OPTIONAL SERVICE amp REPAIR IMPORTANT NOTE SEE HYDRAULIC SCMATIC AT THE BEGINNING OF THIS SECTION This system will use a cylinder on the center axle and a cylinder on each wing axle These cylinder are connected in series and must be connected in a special way to function properly See hydraulic schematic for the hose connectors and cyl inder mounting sequence for this type of application These are rephasing cylinders and each cylinder is different bore size 15 foot model Center cylinder is 3 1 2 bore Right wing is 3 1 4 bore and Left wing is 3 bore 10 foot model center cylinder and right wing cylinder only Cylinder must be installed in this order and hydraulic lines must be connected in this order see hydraulic schematics on previous pages Cylinder barrels must be installed in the same direction as removed when re assembled The machined groove pressure bypass groove on the ID of the barrel must always be installed with machined grove on the rod end of cylinder Hydraulic lines must be connect to largest bore cylinder then medium sized then small cylinder Return line from smallest cylinder to hydraulic oil supply works best if the return line is connected to the optional auxiliary remote control valve pressure return line If
125. mounting pins figure 1 item 1 this allows the cylinderto be raised upward off the deck mounting lug and the axle lug Place a drain pan under the pressure hose to catch the hydraulic oil when hose is disconnected Drain cylinder and hose into drain pan Plug the pressure hose and cylinder to keep contamination out of them Plug all openings in cylinder before cleaning the cylinder Base end of cylinder figure 1 item 8 will have two ports Pressure in hose port figure 1 item 11 and second plugged port on side figure 1 item 12 which should still be in the cylinder base The other port on the cylinder head is the bypass pressure out port IMPORTANT These cylinders must be marked so the barrels will be rassembled with the bypass grooves in the rod end or the repair technician must keep in mind that the barrel end with the groove machined into the ID must always be assembled with groove to the rod end Pressure bypass Groove in ID of Barrel at the cylinder head end i an 7 D ram Figure 1 Cylinder Dis Assembly Axle Level Lift Cylinders Optional 1 This is a Tie Rod construction type cylinder the four tie rods figure 1 item 6 and the 8 hex nuts figure 1 item 7 bolt the cylinder together When these tie rods are unbolted the cylinder will come apart with minimum effort but DO NOT unbolt tie rods until later It is a must that the barrel of the cylinder be marked as to which end is the cylinder rod end an
126. nd insert the inner bearing cone that has 3 Piece Wheel Seal been properly packed with grease figure 8 Install wheel seal Now is when the correct seal must chosen and installed If old style 1 piece seal figure 5 amp 6 is used drive the seal in to the wheel hub using the correct seal driver Make Innser Bearing certain the seal ID has light coat of grease on it Cone with inner If new style 3 piece seal figure 6 amp 8 is used coat the bearing cup OD of seal adapter with a Locktite type sealer Drive the installed seal adapter into the hub with the open side up this open side is the recess for the seal Make certain seal adapter is seated into hub completely Insert the seal into the seal adapter and drive it into the adapter until itis seated figure FIGURE 8 8 Coat the ID of the seal with light coat of grease HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 8 5 Tire Wheel Hub Service amp Repair 5 Install wheel seal protector item 8 This will only apply to units with the new style three piece seal The three piece seal has a seal protector that drives onto the axle spindle figure 9 amp 11 An easy way to install the seal protector on to the spindle is with a driver that is hollow ID and Axle Spindle has the correct diameter to drive it on Another way is to heat the seal protector in an oven to about 250 to 300 then while still hot drive it on Use caution because it is hot make ce
127. nd motors in this section for wear and or damage Inspectall ofthe bushings for scoring or discoloration figure 10 item 6 qty 8 in the port end cap bearing carrier both sides and the shaft end cover If they need to be replaced use a bushing puller as shown figure 4 recommended tools list Removethe bushings with care notto damage housings figure 20 Remove shaft end cover figure 10 item 4 from vice and turn it 180 over and re insert it into vice Using snap ring pliers remove the snap ring figure 10 item 1 as shown figure 21 Removethe shaftbearing figure 10 item 2 using a bearing puller figure 22 Make certain to use the correct size bearing puller and that puller is inserted straight Remove shaft end cover figure 10 item 4 from vice and turn it 180 over andre insertitinto vice Remove the double lip seal by inserting the special seal removal tool see figure 6 recom mended tools Make note of which way sealis removed Inspect the shaft end cover seal seat area figure 23 Inspect all the components that have been removed review steps 1 through 13 There are 4 gasket seals figure 10 item 10 that are installed one on each side of the gear housing Make certain the gasket seal have been removed and the gasket grooves are clean Wash and clean allthe components DO NOT use any material that will leave lint on components it s best to air dry the components Use extreme caution when cleaning gear sets DO
128. nd there are NO burrs on the top ID of bushings figure 31 Check to make certain that the dowel pins are in place in any new castings and that the location corresponds with the mating casting Before inserting any dowel pins check to make certain holes are clean the top ofthe holes do not have burrs To insert dowels hold the dowel in alignment with the hole Gently startthe pin into the hole straight tap lightly with a soft hammer until dowel is seated into hole figure 32 Note as shown dowel pins have holes in the center this is for the studs to go through Remove the shaft end cover from the vice and turn it over 180 and re insertitinto the vise with the splined side up figure 34 Before inserting the new lip seal figure 10 item 3 into the shaft end cover Coat the outer edge of the lip seal with Permatex Aviation Form A Gasket No 3 non hardening sealant or equivalent With the metal side ofthe seal up press it into the mounting flange side ofthe shaft end cover with an arbor press and bar see recommended tools list Be careful not to damage the lip seal Press the lip seal in until flush with the recess wipe off excess sealant Install the outboard bearing figure 10 item 2 guide the bearing into the recess in the shaft end cover This is a light press fit and can be pressed in with the arbor press or it can be lightly tapped into the bore DO NOT use excessive force to insert bearing ifit will not go with light co
129. ng 75 HP 3000 PSI i 70 HP 2000 PSI Motor Displacement Center 6 300 C I D Wing 6 375 C I D Motor Relief Valve Setting Center 3000 PSI Wing 2000 PSI Motor Max Pressure Center 3600 PSI Wing 3000 PSI Motor HP Rating at Operating RPM Center 37 8 HP Wing 27 2 HP Motor Tip Speed at Operating RPM Center 731 RPM Wing 881 RPM Motor Cut Off Wing Decks Electric Cut Off Standard on Wings Center Deck Tractor PTO Shut Off For Center Deck Standard Motor Mounting Type Bolts Direct to Blade Spindle Asy Motor To Spindle Mounting Bolt Size 1 2 Grade 8 Torque to 95 ft Ibs Hydraulic Oil Type 100AW or Equivalent SAE 30 Weight Hyd Oil Hydraulic Oil Capacity Tank amp Cooling Tubes 35 Gals Hydraulic Tank Weldment Bolted to Center Section Hydraulic Filter 2 Micron Filter Replaceable Hydraulic Cooling Tube Type 3 X 8 Deck Length Weldments 2 each wing amp Center Hydraulic Reservoir Pressure 11 PSI Return Pressure Mower Deck Leveling Adjustment Mechanical f Front to Rear at Assembly Setup amp Self Leveling While Operating Mower Center Deck Control Rods Dual Control Rods Mower Hitch Self Leveling Axle Lifting Standard Hydraulic Cylinder Center Axle amp Lift Screws on Wings Optional Hydraulic Cylinder on Center Axle and Wing Axle Axle Lowering Height Stop Center Axle Clip on Spacers Set Center Cylinder Axle Shock Absorber Rubber Bump Pads Standard i Coil Springs each Wing Axle Standard Mower Wing Leveling Wing Axle mechani
130. ngth of the socket head bolts that mount the blade carrier to the spindle shaft Make certain not to use bolts that are longer that what was removed DO NOT screwthe bolts into shaft while the spindle assembly is completely assembled If longer bolts or the ones that came out are screwed in to far the spindle shaft bearing ring bearings or other components can be damaged Unbolt the hydraulic motor figure 3 Hoses amp Motor can be left connected to motor Remove the bolts attaching the motor to spindle Lift motor up and off of spindle Motor can be left sitting on deck with hydraulic lines attached but make certain not to sit motor in debris that may be on deck keep the motor shaft clean Figure 3 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 4 2 SPINDLE ASSEMBLY SERVICE amp REPAIR Remove the spindle assembly fromthe Mower Deck unbolt and remove the six spindle retaining bolts that mount the spindle to deck The spindle will pull up and away from deck Spindle Housing Dis Assembly 1 NOTE For illustrations only the spindle shown was not filled with grease If you are working on a spindle remove from the mower most likly the spindle has been filled with grease the grease cannot be cleaned out until til m after dis asy it may require you to wipe grease G out of the way to see components Inspect the housing for cracks or other damage which would deem it unusable figure 4 Place a 3 16
131. ning correct rotation Use fan blades for down grass Use correct PTO speed and check for correct speed increaser ratio Check for required hydraulic pressure through out hydraulic system Adjust machine Check for correct rotation Move tires out of cutter overlap area to clear 72 cutting width Reduce ground speed Free blades Replace blade bolts Blades Bent Mower hitting ground and blade deflecting upwards Replace dishpan Straighten dishpan Tighten Nut Straighten deck Replace Shaft Keep blade bolts tightened to 350 ft lbs Replace bolts Increase cutting height or try to mower when more moisture in ground Increase cutting height Replace blades with heat treated blades from the manufacturer Trouble Shooting Guide PROBLEM BLADE BOLTS WORKING LOOSE BLADES HITTING TOP DECK OR CUTTING TOO HIGH CUTTER VIBRATING CUTTER WINDROWING NOISY SPEED CHANGER OIL BLOWING OUT OF SPEED CHANGER WING BLADES DO NOT CUT CLEAN ON OUTER EDGES POSSIBLE CAUSE Bolts not tightened sufficiently Bolt hole elongated or oversized Locknut worn out Blades bent Blade bolt bushing broken loose Blade carrier bent Blades hitting ground Blades on upside down Blade broken Blade carrier bent Blade hub not properly seated on shaft New blade matched with worn blades Rotation of blades incorrect Cutting heavy material Ground Speed to fast Mower un level Rough gears Worn bearing Improper gea
132. nter Center motoris very differentfrom the wing motors in design The Housings are more square than the wings The manifold blocks are different the center is thinner and will not use the solenoids that the wings do The four assembly bolts on the center motor are visible under manifold block figure 10 The center motor is assembled to turn in a CW rotation which should be marked on the motor mounting flange from the factory The rotation is determined by standing onthe deck behind the motor facing forward Make certain which motor is being serviced Most parts will not interchange between the cent and wing motors RH Wing The RH wing motor is basically the same as the LH wing motor with the exception of the Port end cap is installed different figure 11 The wing motor the four assembly bolts are in a machined hole under the manifold block The manifold block will need to be removed to see them The RH Wing motor is assembled to turnin CW rotation which should be marked on the motor mounting flange from the factory The rotation is determined by standing on the deck behind the motor facing forward On the wing motor the fourassembly bolts are in a machined hole under the manifold block Make certain which motor is being serviced HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 3 8 MOTOR SERVICE amp REPAIR LH Wing The LH wing motor is basically the same as the RHwing motor withthe exception ofthe Portendcap is ins
133. ntinued next page Figure 31 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 18 PUMP SERVICE amp REPAIR continued from previous page force check for size error or other reason Forcing an over size bearing in will damage bearing and casting figure 34 Using the snap ring pliers as shown Installthe snap ring into the flange side of the shaft end cover figure 35 Lightly tap the snap ring with a small punch and hammer to make certain it is seated into the snap ring groove of the shaft end cover Remove the shaft end cover figure 10 item 4 from the vice and 4 y turnitover 180 andre insertitinto the vise with the splined side down we and re insert it into the vise Figure 32 gt Grease the new Gasket Seals figure 10 item 10 and insert itin both sides of all gear housings Position the first gear housing figure 10 item 12 onto the shaft end housing figure 10 item 4 aligning it with the holes for the dowel pins Tap it with a soft hammer until it rest tightly against the shaft end cover Be careful notto pinch the seal gasket also be sure that the large rounded core is on the inlet side figure 36 Assemble the channel seals figure 10 item 7 into the grooves in the thrust plates figure 10 item 8 with the flat side ofthe seal facing away from the thrust plates as shown figure 37 amp 38 IMPORTANT NOTE Channel seals will always be on side of thrust plate away from gears only th
134. occur Make certain all components are laid out so as not to damage the machined surfaces Make certain any replacement parts have been compared to the old parts to make certain they are correct Gears are closely matched there fore they must be kept together as sets when removed from the pump Handle gears with careto avoid damagetojournals or teeth Avoidtouching gear journals DO NOT mix new and old gears when reassembling pump Never hammer bushing into bores always use an arbor press Hammering will damage bushings and possibly the bores in the housing NOTE illustrations shown here are for a single pump the tandem pump is longer with more sections the disassembly will be basically the same with the exception tandem pump has two pump section instead of one See figure 9 amp 10 for reference to components Thrust Plate Gear Bore Relief Groove High Gear Housing Pressure Inlet y Suction Core Outlet Relief Groove High Opening pressure Pressure Core Opening Gear Side Smooth Side Channel Seal Side Grooved Side Thrust Plate Installed in Gear Figure 24 Housing Thrust Plate CAUTION Figure 24 Important information read before assembly A Thrust Plates must be in good condition no scratches or excessive worn places on either side of plate 2 Thrust plates must be installed correctly The thrust plate has two surfaces one surface has a groove for the channel seal and the other surface is smooth
135. ogic Cartridge ce Solenoid Return 7 Stem Port Outlet e Motor Asy Bolts 4 Port End Cover Pressure Port Inlet Housing Shaft End Cover Case Ay ra Drain Fitting FRONT OF Figure 46 HYDRO 15 Service Manual 09 06 RH WING MOTOR 2006 Alamo Industrial Mnt Bolts D Plug notseen Pressure Ny Port Inlet E Relief Cartridge 2000 psi A 800 psi Logic Cartridge Plugged Port Port End Gear Housing Case Section 3 23 Relief Cartridge 3000 psi Manifold Block Center Motor Cartridge Check Valve Manifold Block O Rings PortEnd Cover Return Port Outlet Gear Housing IS ee EL Ae Manifold Block Mnt Bolts Manifold Block LH Wing Motor Solenoid Stem amp Coil Return Port Outlet Manifold Block Pressure Port Inlet FRONT OF MOWER LH WING MOTOR MOTOR SERVICE amp REPAIR Recommended Start Up Procedure For New Or Rebuilt Pump amp Motor Important Steps 26 through 30 Before installing a new or rebuilt pump or motor back offthe main relief valves until the spring tension on the adjusting screw is relieved See Specification section for relief valve settings This will avoid the possibility ofimmediate damage to the replacement pump in the event the relief valve has been set to high Before connecting any lines hoses to the pump fill all the ports with clean oil to provide initial lubrication on start up fill the
136. ould always produce at least 85 efficiency Example if your Pump is rated at 37 GPM it should produce at least 32 GPM Gears Gear Teeth Any scoring on Gear Hubs necessitates Replacement Scoring Grooving or Burring of Outside diameter of Teeth requires replacement Nicking Grooving or Fretting of Teeth surfaces also necessitates replacement Drive Shaft with Built on Gear Gear Hubs If Gear Teeth and Gear Hubs are OK Inspect Splines on input end OD of Shaft and the Splines ID Output Coupler End Tandem Pump for condition and Wear Inspect Wear or damage to Seal Wear Area If damage at Seal are check for contamination Note Some Pumps and or Motors may have Keyway or Splines Either will have to be inspected for condition If Damage in any of these area the Shaft Gear will have to be replaced Splines Thrust Plate The Thrust Plate Seals the Gear Section at the sides of the Gears Wear will allow internal slippage which is Oil bypassing within the pump The Pump and Motor Thrust Plates are different even though they may look very similar They are built different They will not interchange A Maximum of 0 002 wear is allowable Replace Thrust Plates if they are scored eroded or pitted Wear can be checked usually by comparing thickness at outer edges with thickness at Gear contact area Thrust Plate 1 Check center of Thrust Plates where the Gears mesh Erosion here indicates Oil contamination 2 Pitted Thrust Plate
137. oved from the vise the drain pans can be set aside see figure 3 Clamp the cylinder rod cylinder head and piston assembly into the vise see figure 4 When clamping the cylinder rod clevis into the vise make certain to clamp it as shown figure 4 the clevis must be clamped as shown or the clevis could be damaged by bending the ears of the clevis Slide a block of wood figure 4 wood support block between cylinder rod and work bench insert a material between block figure 4 soft non scratching material and the cylinder rod this will protect the cylinder rod from damage Use a strap wrench to hold the cylinder rod figure 4 strap wrench to hold the cylinder rod from turning while screwing the piston nut figure 4 piston nut off the piston nut is RH Thread locknut Wood Support Block Strap Wrench Bench Vise Soft Non Scratching Material Clavie Set Screw Piston Piston Nut Cylinder Head Figure 4 10 Remove piston nut figure 4 amp 5 the Piston from the cylinder rod Move the support block and the strap wrench figure 4 amp 5 Slide the cylinder head down the cylinder rod and off figure 5 remove the setscrew from the cylinder rod clevis figure 4 clevis set screw There is a nylon thread protector under the setscrew to protect the thread on the cylinder rod it will most likely stay in the threaded hole see figure 5 The cylinder rod will screw out of clevis it has RH threads if it
138. pect the barrel check for scratches severe wear areas distorted tube dia If no serious damage is detected clean the Barrel figure 4 item 5 this can be done with solvent or with pressure Steam washer Inspect the tube closely look at the OD of the tube for any dents or bulges Inspect the ID of the tube for serious wear Inspect the base mount to make certain it is not worn or damaged Inspect the hose ports condition check the threads in these ports If water was used to clean the barrel make certain all water moisture has been dried off DO NOT se aoe ie Le lent ot dirt on it to dry the Barrel ID it is reco rnmiended that air be naed Put le iB a 10 06 O 2006 Alamo Industrial Section 5 9 WING LIFT amp FOLD CYLINDER REPAIR Using a straight edge figure 4 check the OD ofthe barrel in several places look for high or low spot in the tube Also use the straight edge top check the ID in several places check to make certain there are no over sized wear places in tube If the barrel has minor scratches or a glaze on the ID the barrel can by lightly honed useing a cylinder hone with the proper honing liquid the hone will need a long shank DO NOT over hone the ID of the Barrel and DO NOT damage the threads for the cylinder head with the hone If honeing the barrel the barrel will have to be cleaned again Inspect threads in hose ports figure 4 item 2 of barrel if O Ring Boss is used in ports insect the area machined to seat O Rings
139. r mesh Low on oil Vent plug defective or broken Oil level too high Vent Plug inserted wrong place Ground speed too fast Reverse rotation of wing blades HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 11 3 SOLUTION Tighten New Bolts to 350 ft lb torque Replace blade carrier Replace locknut Replace blades Replace bushing Straighten or replace blade carrier Blades Bent Mower hitting ground and blade deflecting upwards Change blades right side up Replace blade only in pairs Replace carrier Remove hub check key and replace Replace blade only in pairs Reverse rotation Use guards on the rear to reduce windrowing Reduce ground speed Check and re level mower Run in or change gears Replace bearing Change check repair or replace Fill with oil and check for damage Repair or replace as needed Replace with proper vent plug Lower oil level Check amp relocate vent plug Slow forward speed Reverse rotation wing motor and blade carrier NOTE This rotation of wing blades may tend to streak behind tractor tires NOTES HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 11 4 Hydro 15 Service Manaual 09 06 MUNN HYDRO 15 Hydro 15 Hydro 15 Service Manual 09 06 Late 2006 Alamo Industrial Inc P N 00756179S Printed U S A
140. r to Cooling Tube Wing Motor Asy R Wing Return Pressure f R Wing to L Wing Motor Return Center Cooling Tube to Filter Tank Return Filter amp Gauge Wing Motors Return Return Filter amp Gauge Center Motor Return Return L Wing Motor to Cooling Tube Case Drain L Wing Motor to Cooling Tube Wing Motor Asy L Wing Return L Wing Tube to Center Cooling Tube 2006 Alamo Industrial Section 1 6 SPECIFICATIONS HYDRO 15 FLEX WING 10 FT PUMP amp MOTOR HYDRAULIC SCHEMATIC CAUTION NEVER Connect Pump Pressure Line direct to cooling tubes as it will damage the tubes Center LH amp RH Cooling Tubes Description Description Tandem Pump Asy Case Drain R Wing Motor to Cooling Tube Suction Tank to Wing Pump Wing Motor Asy R Wing Suction Tank to Center Pump Return R Wing Motor to Cooling Tube Pressure Wing Pump to Bulk Head Fitting Return Center Cooling Tube to Filter Tank Pressure Center Pump to Bulk Head Fitting Return Filter amp Gauge Wing Motor Return Pressure Bulk Head Fititng to Center Motor Return Filter amp Gauge Center Motor Return Pressure Bulk Head Fitting to Wing Motor Motor Asy Center Sction Motor Return Center Motor to Wing Cooling Tube Return Wing Tube to Center Cooling Tube Return Center Coolingg Tube to Fiter Tank HYDRO 15 Serv
141. rcing it could damage head and seals A O Ring Seal 46 Back Up Seal Cyl Head AB 4 Cy A Cyl Head gt Clean Work Bench Clean Work Bench Figure 9 Installing the Piston on the cylinder rod figure 10 item 6 will require a press DO NOT try to press piston onto cylinder rod with the piston nut Use Locktite 271 or equivalent when pressing piston onto cylinder rod Make certain piston and rod are in alignment when pressing piston make certain piston and rod are protected from damage HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 12 WING LIFT amp FOLD CYLINDER REPAIR Install the U Cup Seal figure 10 item 6C onto Piston figure 10 item 6 The U Cup Piston seal is a directional seal and is designed to be used as a single action cylinder The U Cup seal should be installed so the U Cup side of seal is toward the pressure side of the piston which is the rod side on this cylinder The cylinder rod weldment is clamped into vice as shown figure 10 item 3 Clamp the rod with the mounting pin hole upward as shown See Rod Clevis Weldment figure 10 item 3 ifthe clevis is clamped with the hole the other way the clevis could be bent together and cause the clevis to be deformed Install the new Piston retaining locknut figure 10 item 7 onto the cylinder rod Note it is not recommended that old locknut be reused Before tightening the locknut down make ce
142. re 7 Tighten the adjusting nut item 4 until the slack is out of the control rod and the previous components are seated against each other as explained in previous steps figure 4 amp 6 The LH and RH control rods on dual control rods should be assembled as explained above F HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 10 4 Leveling Control Rods Service amp Repair Using the height control spacer figure 8 to set the center axle hydraulic cylinder at the gt height to begin adjusting this height is not a fixed Hyd Cyl Strok height it may vary depending on the type tires that are on mower This height will be measure from the center of the RH wing hinge pin in the rear to the ground make note of distance figure 8 Go to the front of the mower and measure the distance to the ground RH Side and measure distance to the ground make note of distance 2 Rear Wing Hinge Pin Su g ning Spacers A At this time the front of the control rod should have the adjusting nut item 4 screwed on until itis touching the bushing weldment figure 6 The jam nut item 10 can be on control rod or not if it is on it should be screwed out away from adjusting nut Front Use the measurements you got in step 7 to M in Wing Hinge Pin lt determine which way to turn adjusting nut Using y distance numbers that are as example only as the distance you got will be different R
143. re cut to keep the speed increaser perpendicular to the PTO shaft Use a lathe to cut or square the ends of the spacer if necessary Tubes MUST be of sufficient length when mounted between tractor and mounting plate that the PTO shaft will have a minimum of 2 inches of engagement into speed increaser This can be checked by performing measurements of spacers plate and speed increaser splined sleeve then calculating the distance required The bolts to install the mount plate to the tractor must be grade 8 they must be long enough to allow at least 1 thread engagement into tractor housing and make certain to use lockwashers on these bolts DO not tighten these bolts at this time on snug them When time to torque these bolts they are most likely 1 2 NC Gr8 bolts Torque them to 100 to 110 ft Ibs in increments use in an X pattern HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 7 2 Speed Increaser Service amp Repair Install the speed increaser to the mount plate using four 1 2 Gr5 bolts There are 4 short spacers that are used to mount between the speed increaser and the mount plate The mount plate will have thread holes in ti to screw these 4 bolts into use lockwashers on these bolts These 1 2 Gr 5 bolts will torque 65 to 75 ft lbs using an X pattern in increments as being torqued Check to make certain the speed increaser has at least 2 of engagement on the PTO Shaft If not the spacers will have to cut to incre
144. reventing it from sliding together If pump is force into speed increaser something will be damaged If pump is just being reconnected to speed increaser and pump has not been removed the hydraulic connections should already be connected to the pump If the pump is being replaced and the hydraulic lines need to be connected see the pump service repair section for hydraulic line connection instructions NOTE once the pump and hydraulic lines are connected do not start tractor until assembly has been completed DO NOT start tractor and engage PTO unless all hydraulic system has been connected and check Make certain Oil level is full and etc SEE START UP PROCEDURE IN PUMP SERVICE REPAIR SECTION Speed Increaserto Tractor mounting bolt holes qty 4 Tractor PTO Side 7 A Speed Increaserto Pump Side View Tractor mounting bolt holes qty 4 Side View HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 7 5 Speed Increaser Service amp Repair 31 32 33 25 26 27 28 29 30 13 14 29 30 21 22 23 24 N 31 32 33 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 7 6 Speed Increaser Service amp Repair Speed Increaser 1 4 Increase See Figure 4 Qty Description 1 Splined Shaft Adapter w Snap Ring Groove use w item 3 1 Splined Shaft Adapter w o Snap Ring Groove use w item 3A 1 Pinion Gear High Speed 18 Tooth 1 External Snap Ring use w item 1 1 Splined Sha
145. rtain that piston is seated onto cylinder rod completely this can be done by visually inspecting back side of piston against shoulder of cylinder rod Torque Piston Locknut 350 to 400 ft lbs Piston w U Cup Seal Installed Cyl Head Cyl Rod Clevis Weldment Piston Locknut Cyl Rod amp Clevis Figure 10 Weldment Coatthe piston figure 10 item 6 and ID of the barrel figure 11 item 5 with light coat of hydraulic oil Clamp the barrel down just enough to hold it being careful not to over tighten it or the barrel could be distorted Holding the cylinder rod straight slowly slide the piston into the barrel be careful at the front of the barrel when sliding piston across the threads in the barrel figure 11 Item 5 Threads so as not to damage U Cup seal on piston figure 11 item 6 When piston is being slid into barrel do it slowly feeling the resistance the resistance should remain about the same all the way in if not recheck barrel for wear Continued to slide piston in holding rod as straight as possible until it is in barrel approx 10 to 12 inches making certain the cylinder head figure 11 item 4 is not inside barrel O Ring amp Back Up Washer Seal 1 LLLLL LL LLL L777 es LLLLL LL LL 777777 X d AEE Cyl Head Figure 11 5 Barrel Cyl Head Threads Threads HYDRO 15 Service Manual 10 06 2006 Alamo Industrial Section 5 13 WING LIFT amp F
146. rtain to drive it on straight while it is still hot The seal protector allows the hub seal and seal adapter to be covered by the seal protector when completely assembled Make certain ID of seal has light coat of grease Slide Hub w Inner Bearing cone and seal installed into hub onto Axle Spindle for the 1 piece Seal spindle Slide Hub up until the hub inner bearing cone is against the machined area of the axle spindle figure 10 amp FIGURE 9 10A FIGURE 9 Insert outer bearing cone item 6 that has been packed with grease into the outer part of hub Support hub with your Drives Onto hand or the weight of the hub could push the outer bearing Spindle cone back out Insert the bearing adjusting nut washer item Axle Spindle Seal Protector 5 onto the shaft Screw the bearing adjusting nut item 4 onto spindle once the adjusting nut is started you will not have to supportthe hub as the outer bearing cone cannot slide out Adjusting wheel bearing The wheel bearing are a cup and cone type these type bearings require a preload setting Tighten adjusting nut item 4 until all end play in and out is eliminated on bearings DO NOT tighten adjusting nut so Axle Spindle for the 3 piece Seal tight the bearings are damaged Back off on adjusting nut 1 6 turn one flat spot of hex shape of nut When turning hub you should feel a drag on it but hub should turn with little effort FIGURE 9A Adjusting nut 1 6 turn at a time until adj
147. s a swinging clevis that is designed to be bolted to the draw bar figure 1 This Bolt Washers and Locknut was supplied with mower and should be replaced with same components it required The tongue clevis must be connected to the tractor draw bar using this bolt washer and lock nut figure 2 The tongue clevis will not operate correctly with using a drop pin figure 3 The drop pin will cause damage to the clevis and draw bar Some drawbars will have a hole that is larger than the bolt in the clevis itis recommended these holes be fitted with a connex bushing to adapt the draw bar hole to the size of the bolt to hold the clevis as parallel to draw bar as possible figure 2 The spring washers also act as wear washers the qty of washers will vary from tractor to tractor but all need to have washers between clevis and draw bar for wear figure 1 8 2 Tighten the Nut onto the Bolt 150ft lbs so that it holds the Clevis parallel with the draw bar figure 2 l Control rod options single or dual control rods Tongue Hitch Bolt item 1 The components are the same forthe LH or RH control rod Shown here is the RH control Rod 7 Clevis figure 4 The single control rod is longer 112 inches than the control rod used on the dual control rod 110 Spring Washers inches mowers these cannot be mixed on mowers To set the Mower cutting height and or level the Mower from front to rear position it on level ground Attach the Mower to the trac
148. s indicate cavitation or Oil aeration 3 Discolored Thrust Plates indicate overheating probably insufficient Oil HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 14 PUMP SERVICE amp REPAIR IMPORTANT Mark all Sections of Pump with a Number or Symbols that will serve as a guide to all sections being re installed the same way they were removed Example if the numbers marks do not line up 1 2 3 4 amp 5 as they were marked the pump is not being assembled correctly Check this all through the assembly process 1 1 2 Split Flange Suction Inlet Side Service Technician Makes alignment Marks Here 1 1 2 Split Flange __ Suction Inlet Side Bearing Housing Re taining Nuts amp studs Torque to 3000 in Ibs Service Technician Makes Alignment Marks Here Speed Changer amp Figure 23A HYDRO 15 Service Manual 09 06 Tractor PTO 2006 Alamo Industrial Section 2 15 __ 1 Split Flange Pressure outlet Side Port End Cover Rear Gear Housing 1 Split Flange Pressure outlet Side Port Bearing Housing Front Gear Housing Shaft End Cover See Figure 10 for Component Item Number KEEP THESE MARKS ALIGNED During Assembly PUMP SERVICE amp REPAIR Pump Assembly CAUTION Important information read before assembly Y All sections have been cleaned and inspected take extreme care not to allow the marring or damage to machined surfaces to
149. s nec essary be careful not to damage the machined surfaces figure 18 Dowel pins figure 19 will remain in either the port end cover or gear housing This will be OK because the components must be re assembled in the same direction and orientation as removed If one or more ofthe components are to be replaced as parts then it may require that the dowel pins be removed figure 19 Remove the thrust plate figure 19 Make a note how this was removed there is a smooth side and there is a grooved side The smooth side will always face the gears the grooved side will be for the channel seal figure 19 Inspectthe thrust plate for damage or wear atthis time see wear tolerance chart for pump and motors in this section this will help in looking for other wear or damage to other components and also enable you to start making alist of components that need replacing The channel seal will fit into a grove on the thrust plate this groove is all the way around and on both sides of the shaft Note a Pump channel seal in only on one side figure 20 The Thrust plate is flaton one side with two relief notches The flat side of the thrust plate with the relief notches will always face the gears The relief notches will be the same and can Figure 19 be installed with either notch to either port check to make certain when these are removed that they were installed cor rectly HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Sec
150. s recommended that marks be done with metal stamps that will mark components for correct assembly order for amp during re assembly This is very important as if any of the sections of pump are installed in the wrong direction it could damage pump when re assembled or when pump is engaged during operation figure 11 Use a socket Wrench or Boxed end wrenches Air impact wrenches are not recommended for dis assembly Remove the four hex bolts and washers figure 10 item 19 amp 20 This will allow forthe removal of the outward half of the pump The inward section is still connected together with the studs and nuts which will be removed in a later step Inspect the bolts for thread condition If bad threads on bolts most likely the threads in that hole are bad mark the hole so it can be check later Figure 14 Figure 15 HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 11 PUMP SERVICE amp REPAIR Liftthe first port end cover figure 10 item 17 if prying is necessary be careful not to damage the machined surfaces Dowel pins figure 10 item 11 will remain in either the port end cover or gear housing This will be OK because the components must be re assembled in the same direction and orientation as removed If one or more of the components are to be replaced as parts then it may require that the dowel pins be removed figure 13 Remove the thrust plate figure 10 item 8 Make a note how this was removed there is
151. section are to help understand the components of the pump This section is notintended to be a parts manual or operators manual although itis intended to be used with the other manuals Use caution if clamping any pump components in a vise or gripping them with any type of tools The jaws of a vise can damage the surface or it the shape of a component tools can scratch or damage the surface to renderthe componentun serviceable These pumps are designed to be assembled to be turned in the direction for which they were built clockwise or counter clockwise When the pump is dis assembled it is very important that you take notice of which components are where and which way they are installed in pump example Item 5 If these pumps are installed with componentin the wrong place and then turnedin the wrong direction the pressure will usually blow the input seal out and may damage other components When making repairs always make certain that the cause of the failure is identified and repaired Sometimes the cause ofthe failure is not corrected and another failure occurs rapidly because the cause of the failure is still there Make certain to use drain pans to catch all oil that may leak out during the testing and or repair steps Make certain to keep all hydraulic opening plugged or capped during repairs Never start the tractor and engage PTO to turn pump if any hydraulic components have been removed or disconnected line blockage or oil diverted to th
152. spection of the gears and the bearings The gears can be lifted up out of the housing to allow the inspection of the other side bearings If every thing is OK the two halves cane be bolted back together It is recommended that the gasket figure 4 item 18 be replaced The end play on the bearings should not change and if they were correct before they should be correct now Check the end play on the shafts figure 4 item 2 amp 5 it should be from 007 to 01 1 Ifnotthe shims will need to be added or removed to adjustthe end play this will be done on the PTO side closed top cover figure 4 item 7 and the PTO side open cover figure 4 item 9 Add or remove shims to adjust shaft end play as needed figure 4 item 21 22 23 amp 24 for open cover and items 25 26 277 28 for closed cover Refill speed increaser with oil Check the Oil level in the speed changer Use a recommended grade of oil recommended grade is SAE 90W oil with E P Additive Most speed increaser are installed where the pump will mount above the PTO figure 1 but in some case it may require the pump be mounted below the PTO shaft height If this is the case the breather plug will need to be installed in a different location on one of the side plugs Normal fill level is the setscrew plug about 1 3 of the way up on the side of the housing If Speed increaser is turned to the bottom opposite what is shown in figure 1 the level plug will be the one that was on the bottom before and
153. stand the components of the pump This section is notintended to be a parts manual or operators manual although itis intended to be used with the other manuals Use caution if clamping any pump components in a vise or gripping them with any type of tools The jaws of a vise can damage the surface or it the shape of a component tools can scratch or damage the surface to renderthe componentun serviceable These pumps are designed to be assembled to be turned in the direction for which they were built clockwise or counter clockwise When the pump is dis assembled it is very important that you take notice of which components are where and which way they are installed in pump example Item 5 If these pumps are installed with componentin the wrong place and then turnedin the wrong direction the pressure will usually blow the input seal out and may damage other components When making repairs always make certain that the cause of the failure is identified and repaired Sometimes the cause ofthe failure is not corrected and another failure occurs rapidly because the cause of the failure is still there Make certain to use drain pans to catch all oil that may leak out during the testing and or repair steps Make certain to keep all hydraulic opening plugged or capped during repairs Never start the tractor and engage PTO to turn pump if any hydraulic components have been removed or disconnected line blockage or oil diverted to the wrong place could to ex
154. starting It is recommended mower be disconnected from tractor or battery cable be removed from battery while repairs are being made Front and rear of mower must be securely supported on strong jackstands before hydraulic lines or cylinder mounting pins of the axle hydraulic assembly are disconnected Make certain that all hydraulic pressure has been released from lines after wings and axles have been completely lowered This may require the tractor hydraulic controls and or remote control valve be worked to release hydraulic pressure NEVER disconnect any cylinder hydraulic hose s or fittings if all mower components wings and deck are not resting in the completely lowered to the ground position or supported on jackstand position Do not remove cylinder pressure hose before the cylinder is dismounted from deck Remove the cylinder mounting pins figure 1 item 1 this allows the cylinder to be raised upward off the deck mounting lug and the axle lug Place a drain pan under the pressure hose to catch the hydraulic oil when hose is disconnected Drain cylinder and hose into drain pan Plug the pressure hose to keep contamination out of it Plug all openings in cylinder before cleaning the cylinder Remove the Vent Plug figure 1 item 10 and insert a plug plastic plugs will work Base end of cylinder figure 1 item 8 will have two ports Pressure hose port figure 1 item 11 andsecond plugged port on side figure 1 item 12 which should still be in
155. suction hoses with oil This is particularly important if the pump is located above the reservoir Usethread sealant on all fittings and hose threads DO NOT USE TEFLON TAPE Make certain the oil reservoir is full of clean oil Test oil before running a replacement pump Contaminated oil will damage a replacement pump even oil ran a minute or so Review the type of failure that had occurred and investigate any damage that may have been caused due to that failure DO NOT run the replacement pump if the cause of the failure has not been corrected Any oil added to or to fill reservoir must be ran through a 100 micron screen before going into tank See the tank fill section for available equipment for this purpose Never run hot oil through a cold pump or motor the hot oil will cause damage to the cold components Gradually warm components by turning pump on then off on then of until temperature is equalized After connecting the lines hoses and mounting the replacement pump operate the pump at least two minutes at no load and at low RPM 400 rpm During this break in period the mower should run free no load and not develope an excessive amount of heat If the unit operates properly speed and pressure can then be increased tonormal operating settings See Specification Section Reset the main relief if needed to its proper setting while the pump is running at maximum operating engine motor speed for the PTO rating See Specification Section
156. t side Check the gear housing gasket seal figure 10 item 10 is stillin place on gear housing figure 24 amp 41 Lightly coat the gear journals with grease When placing the Bearing housing figure 10 item 13 over gears use caution soyou don t hit and damage gear shaft journals Place the bearing carrier to align the dowel pin holes over with dowel pins When the parts are onto gear shaft journals ofthe drive and the driven gears Be sure parallel squeeze them together or alternately tap over each dowel until the parts are together DO NOT use excessive force to put housing together if light taping won t do it something is wrong figure 42 Insertthe 4studs 4Lockwashers amp 4Nuts See figure 23A that a connect the previous sections Tighten the stud nuts in alternating Figure 37 pattern until Torque of the nuts to 3000 in lbs 250 ft Ibs y3 Coat the connecting shaft figure 10 item 14 use light coatof Channel Seal Gear Side grease insert it into spline of drive gear Make certain that gasket Side Grooved seals are coated with clean grease andinstalled into second gear housing as instructed in step 12 Position and place second gear housing figure 10 item 16 making certain the dowel pins are kept aligned between two castings figure 43 amp 44 Housing should fit flush to bearing housing MAKING CERTAIN the marks made to Smooth Side keep the components in the same orientation when re assembled Channel Se
157. t Up Procedure Motor Electrical System wing Motors 3 24 to 3 25 Section 4 Spindle Repair 4 1 to 4 10 Spindle Component Identification Blade Carrier Removal Spindle Removal Preparation Spindle Housing Removal Spindle Housing Dis Assembly Spindle Component Inspection Part Condition Spindle Assembly Procedure Blade Carrier Installation HYDRO 15 Service Manual 09 06 2006 Alamo Group Inc Index 2 INDEX Section Page Section 4 Spindle Repair 4 1 to 4 10 Spindle Component Identification Blade Carrier Removal Spindle Removal Preparation Spindle Housing Removal Spindle Housing Dis Assembly Spindle Component Inspection Part Condition Spindle Assembly Procedure Blade Carrier Installation 4 9to 4 10 Section 5 Hydraulic Cylinder Repair amp Service 5 1 to 5 30 Wing Lift Cylinders Wing Lift amp Fold Cylinder Schematic 15 ft Wing Lift amp Fold Cylinder Schematic 10 ft Wing Lift 8 Fold Cylinder Removal Wing Lift amp Fold Cylinder Dis Assembly Wing Lift amp Fold Cylinder Re Assembly Standard Axle Lift Cylinder Standard 1 Cylinder System Axle Lift Cylinder Schematic Standard 1 Cylinder 15 ft Axle Lift Cylinder Schematic Standard 1 Cylinder 10 ft Axle Lift Cylinder Removal Standard 1 Cylinder Axle Lift Cylinder Dis Assembly Standard 1 Cylinder Axle Lift Cylinder Component Inspection Standard 1 Cylinder Axle Lift Cylinder Re Assembly Standard 1 Cylinder Optional Axle Lift Cylinder Optional 3 Cylinder Sys
158. t dust cap for any time at all the wheel hub should be removed cleaned and components inspected DO NOT just replace dust cap and keep running the hub bearings and spindle can be damaged IMPORTANT INFORMATION FOR Laminated Tire and Wheels Attach the wheels to the hubs If punc ture proof Laminated Sectional Tires and Wheels are used be sure the flat side of the nut is against the Wheel Tighten wheel bolts to 85 fi lbs This will apply only when using laminated tires and the lug nuts are installed with flat side sectionalTires against wheel Note direction of travel and Shown le curvature of rubber segments in tire and install as shown to give longest tire life See figure 2 If tires are mount to roll in the wrong direction the segments of the tire tend to open allowing dirt and mud to be wedged in between segments forcing the segments apart and making tire loose These are not high speed tires and should nut be run faster than 10 to 15 MPH max nor for long distances on hard ground HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 8 2 Tire Wheel Hub Service amp Repair 1 Direction of travel Place Flat Side of ee Nut against Wheel lt lt o S E gt O oS ented 2 LI i IMPORTANT INFORMATION FIGURE 2 For Laminated Tire and Wheels Wheel Hub Dis Assembly Important Note There are two types of hubs figure 3 amp 4 that have been used these are b
159. talled different figure 12 The wing motor the four assembly bolts are in a machined hole underthe manifold block The manifold block will need to be removedtoseethem LH Wing motoris assembled to turn in CCW rotation which should be marked on the motor mounting flange from the factory The rotation is determined by standing on the deck behindthe motor facing forward On the wing motor the four assembly bolts are in a machined hole under the manifold block Make certain which motor is being serviced Hydraulic Connections Center Motor The hydraulic connections are connectedtothe Motor for the inlet and outlet side with a 1 inch split flange connection figure 10 RH 8 LH Wing Motor The hydraulic connection for the Inletis con nected to the motor with a 1 inch split flange connection The outletconnectionis onthe manifold block with a 1 inch splitflange connection figure 11 8 12 Relief Cartridge Manifold Block Mnt Bolts Manifold Block Mnt Bolts Plug notseen Pressure Port Inlet E 10 Relief Cartridge Relief Cartridge 3000 psi Manifold Block Center Motor Cartridge Check Valve Manifold Block O Rings Port End Cover Return Port Outlet Gear Housing SK O ADR of Manifold Block Mnt Bolts 2000 psi 2000 psi Manifold Block Relief Cartridge 800 psi Manifold Block i Oe RH Wing Motor Relief Cart Solenoid Logic i 800 psi ry a Stem Ka e T amp
160. te Dowel Pin Holes Relief Groove Both Sides ena Opening Opening Side Gasket Seal Pump Assembly CAUTION Important information read before assembly la All sections have been cleaned and inspected take extreme care not to allow the marring or damage to machined surfaces to occur Make certain all components are laid out so as not to damage the machined surfaces Make certain any replacement parts have been compared to the old parts to make certain they are correct Gears are closely matched there fore they must be kept together as sets when removed from the pump Handle gears with care to avoid damage to journals or teeth Avoid touching gear journals DO NOT mix new and old gears when reassembling pump Never hammer bushing into bores always use an arbor press Hammering will damage bushings and possibly the bores in the housing NOTE illustrations shown here are for a single pump the tandem pump is longer with more sections the disassembly will be basically the same with the exception tandem pump has two pump section instead of one See figure 9 amp 10 for reference to components HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 3 17 MOTOR SERVICE amp REPAIR Motor Assembly 1 Check all the machined surfaces on all Motor components to make certain they are level and free of scratches Minor scratches and slight un level conditions may be fixed by using a Medium Grit Carborundurn Stone
161. tem Axle Lift Cylinder Schematic Optional 3 Cylinder 15 ft Axle Lift Cylinder Schematic Optional 3 Cylinder 10 ft Axle Lift Cylinder Removal Optional 3 Cylinder Axle Level Lift Axle Lift Cylinder Dis Assembly Optional 3 Cylinder Axle Level Lift 5 24 to 5 26 Axle Lift Cylinder Component Inspection Optional 3 Cyl Axle Level Lift 5 26 to 5 27 Axle Lift Cylinder Re Assembly Optional 3 Cylinder Axle Level Lift 5 28 to 5 30 Section 6 Hydraulic Tank Repair Fill And Service 6 1 to 6 5 Hydraulic Tank Fluid Level Hydraulic Tank Oil Return Filter Hydraulic Tank Oil Fill Procedure Section 7 Speed Increaser Speed Changer Repair amp Service Speed Increaser To Tractor PTO Mount Speed Increaser Component Identification Speed Increaser Dis Assembly For Component Inspection Speed Increaser Dis Assembly For Component Re Placement Speed Increaser Re Assembly For Component Re Placement 7 10 to 7 13 Section 8 Tire Wheel Hub Repair amp Service 8 1 to 8 7 Wheel Information Wheel Hub Dis Assembly Wheel Hub Re Assembly HYDRO 15 Service Manual 09 06 2006 Alamo Group Inc Index 3 INDEX Section 9 Blades amp Blade Carriers Service amp Repair Blade Carrier Service amp Repair Blade Bolt Service amp Repair Section 10 leveling Mower Service amp Repair Tongue Clevis Connection Leveling Rod Component Identification Assembling Control Rods Adjusting Control Rods Adjusting Wing Axles Leveling Mower 10 1 to 10 6 Sect
162. ter Cooling Tube Description Case Drain R Wing Motor to Cooling Tube Wing Motor Asy R Wing Return Pressure f R Wing to L Wing Motor Return Center Cooling Tube to Filter Tank Return Filter amp Gauge Wing Motors Return Return Filter amp Gauge Center Motor Return Return L Wing Motorto Cooling Tube Case Drain L Wing Motorto Cooling Tube Wing Motor Asy L Wing Return L Wing Tubeto Center Cooling Tube OONOOOBRWND Return Center Coolingg Tube to Fiter Tank HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 5 PUMP SERVICE amp REPAIR 10 FT PUMP amp MOTOR HYDRAULIC SCHEMATIC Wing Supply Front Pump Half 1 Center Supply Rear Pump Half CAUTION NEVER Connect Pump Pressure Line direct to cooling tubes as it will damage the tubes he Dp a 14 LR _ Center LH amp RH Cooling Tubes Description Description Tandem Pump Asy Case Drain R Wing Motor to Cooling Tube Suction Tank to Wing Pump Wing Motor Asy R Wing Suction Tank to Center Pump Return R Wing Motor to Cooling Tube Pressure Wing Pump to Bulk Head Fitting Return Center Cooling Tube to Filter Tank Pressure Center Pump to Bulk Head Fitting Return Filter amp Gauge Wing Motor Return Pressure Bulk Head Fititng to Center Motor
163. ter Supply 3 3 8 4 1 2 9 16 1 377 000 1 250 002 i 5 Pump Sn 002 000 015 X60 Figure 7 All external surfaces MUST be free of scratches and burrs HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 7 PUMP SERVICE amp REPAIR Pump Cleaning amp Removal Clean Pump Hoses and all connections before discon necting any components from the pump This will keep con tamination from getting into system Figure 8 shows the pump and hoses connected to the mower this mower is new clean and un used with the pump sitting on the ground ifthe hoses are to be dis connected the pump should mounted up and above the hydraulic tank on work bench hoist etc What ever the technician decides to mount pump on Some type of drain pan will be required to catch the oil that will drain outwhen hoses are dis connected The hoses will need to be capped plugged after removal being disconnected If cap is not leak proofthen hoses mustremain elevated above hydraulic tank to prevent oil leakage from hose fittings Figure 9 shows how the hoses are connected Hoses are connected with 4 bolt split flange kits 1 1 2 on suction side amp 1 on pressure side Description Pump Assembly Tandem Pump Split Flance Kit 1 Flange O Ring for 1 Flange Qty Each Kit Bolt Hex Head Qty Each Kit Lockwasher Qty Each Kit Split Flance Kit 1 1 2 Flange O Ring for
164. that the hex nuts that were left on the tie rod is loose Insert the tie rods qty 4 and the hex nuts qty 8 onto the tie rods The hex nuts must be screwed on at the same rate and on each end try to keep the same amountof threads sticking out the nuts on both ends of the tie rods Snug the nuts down an all 4 tie rod evenly and alternating as to keep the same amount of pressure evenly Torque the tie Rod nuts to 80 ft lbs based on a 1 2 tie rod Install the vent plug into the cylinder head port figure 9 item 9 at the Rod End of cylinder Install the hydraulic elbow adapter to the base end of cylinder figure 9 item 8 Note plug the open end of the hydraulic adapter until time to connect the hose to it Hydraulic Elbow Vent Plug Adapter cyl head clevis cyl Wood or other soft rod amp piston asy material Bench Vise Figure 9 Work Bench 12 Install the cylinder onto mower Mount the cylinder with the base end figure 9 item 8 to the deck lug Mount the cylinder head rod end figure 9 item 9 of the cylinder to the axle lug When first using the rebuilt and or new cylinder it is not unusual for a light amount of oil to be pushed out of the vent The amount is the amount that was used to oil components during assembly If excessive amount leaks through the vent cylinder is not functioning properly Recheck the assembly steps for possible assembly error HYDRO 15 Service Manual 10 06 2006 Ala
165. the bearing cup from the inside of the bearing housing FIGURE 9 until it is seated against the bearing spacer in the open cover end The other bearing cup is seated against the pump mounting flange figure 9 DO not drive bearing in so far the open cover is damaged NOTE the bearing cups for the pump mount flange and the open cover side are the same size Cover Gasket Install the bearing Cones figure 4 items 14 amp 20 the bearing cone item 14 is smaller than the other 3 and will only fit the PTO side of the small gear shaft Bearing cones will be seated against shoulder at gear figure 10 Make certain seal ID is coated with light coat of grease Insert the shafts into the housing and through the seals figure 10 Install the housing gasket onto the housing half PraSpinedside Small Bearing Cone ltem 14 Large Gear amp Shaft Install Housing Gasket Here Small Gear amp Shaft Sitting on Block to Make it Siton Table Level HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 7 11 Speed Increaser Service amp Repair Install the PTO side of housing half figure 4 item 15 Male certain old gasket has been removed and gasket face of housing is clean Aligning the dowel pins figure 4 item 17 between the two housing halves the PTO side Housing half down over the pump side housing half It make require a soft hammer to tap the two halves together When two halves are together check to make certain gasket has
166. the bores one ata time Use the special installation tool figure 5 Tools recco mmended list and an arbor pres Be sure that the groove orseam are positioned as stated instep 5 previously Be sure to support casting so they are square and level to the arbor press andthe bushings are straightbefore attempting to press them in The bushing must be pressed into the bores flush with the casting face figure 30 F Figure 28 san e Figure 29 MS HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 3 18 MOTOR SERVICE amp REPAIR Just as earlier if the stone is used parts it is used on MUST be washed and dried Make certain bushings are flush with castings and there are NO burrs on the top ID of bushings figure 31 Bushing must not be higher than face of casting Motor will not bolt together correctly if it does Check to make certain that the dowel pins are in place in any new castings and that the location corresponds with the mating casting Before inserting any dowel pins check to make certain holes are clean the top of the holes do nothave burrs To insert dowels hold the dowel in alignment with the hole Gently startthe pininto the hole straight tap lightly with a soft hammer until dowel is seated into hole figure 32 Note as shown dowel pins have holes in the center this is for the retaining bolts to go through Remove the shaft end cover from the vice and turn it over 180 and re insert it into the vis
167. the dust cap onto hub until it is seated into the recess of the hub figure 12 amp 13 Caution dust cap must be installed squarely and driven on until they are fully seated When Assembled look at figure 12 amp 13 this is what it should look like FIGURE 11 FIGURE 12 Whi Hub Asy 1 piece Seal FIGURE 13 whi Hub Asy 3 piece Seal HYDRO 15 Service Manual 09 06 O 2006 Alamo Industrial Section 8 7 NOTES HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 8 Section 9 HYDRO 15 Blades amp Blade Carrier Service amp Repair Section 9 1 Blade amp Blade Carrier Service amp Repair Blade amp Blade Carriers Service amp Repair ale Make certain the mower and tractor are secured in a safe and proper parked position hydraulic axle and wings lowered or secured by the transport bars Make certain that tractor is safely parked according to tractor manufacturers recommendations Tractor should be secured or dis abled in a way that it cannot be started unless the serviceing technician is ready for it to be started Never get under any equipment unless itis secured and supported by sufficent jackstands DO NOT depend on hydraulics or brackets to support equipment if you are going to be under it this is important See the Operators Manual for recommended Maintance schedules and recommendations There are blade carriers option of bar carrier or pan carrier figure 1
168. tion Example If the right wing motor has metal init froma failure the left wing motor is most likely also contaminated The center motor and possibly the pump the hoses the tank the filter housings as well as the filters will most likely need cleaning and or replacing DO NOT start or engage system if the oil level is not at the proper level or condition Never start or run unit low or out of oil 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 It is recommended that any oil installed be done using a commercial oil buggy with a filtered system a buggy system can also be used to clean the oil HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 1 2 SPECIFICATIONS HYDRO 15 FLEX WING General Specifications for Mower Tractor Horse Power Required 70 90 HP Tractor PTO RPM 540 RPM required Mower Paint Colors Alamo Yellow Std Other Colors Optional Mower Gross Weight 4200 Ibs w Chain Guards this can vary w wheel type Mower Tongue Weight Approx 2200 lbs w Wings lowered Cutting Capacity Grass amp Up To 1 1 2 dia Brush Max Mower Overall Length 199 Front To Back Mower Overall Width 186 5 w Wings Down amp 96 w Wings Folded this can be affected by tire size type amp wing axle adjustment Number Blade Carriers 3 on 15 ft Model amp 2 on 10 Ft Model Cutting Width Options 15 Ft or 10 Ft Model
169. tion 3 13 MOTOR SERVICE amp REPAIR Inspect the thrust plate for damage or wear at this time see wear tolerance chart for pump and motors in this section this will help in looking for other wear or damage to other components and also enable you to start making a list of components that need replacing figure 25 Carefully remove drive gear and driven gear figure 21 Avoid tapping the gear teeth together or against other hardened surfaces figure 21 Keepthese gears together as they are a matched set Examine the gears for wear and damage Note the dowels figure 21 amp 22 that are in gear housing sometimes these will come out and be in the end cover orthey may stay inthe gear housing It will be OK as long as the same components are to be reassembled butifsome components are to be replaced and some are not then these dowel pins will have to be re moved and re inserted IMPORTANT Ifworking on center LH 8 RH motor at same time itis important not to mix the components of the motors Keepthe Gears separated between the motors as gears are matched sets DO NOT mix used gears and new gears a motor Remove the second thrust plate figure 21 the 2nd thrust plate is at the bottom of gear housing and is visible after gears have been removed Make a note howthis was removed there is a smooth side and there is a grooved side The smooth side will always face the gears the grooved sideis for channel seals Inspect the thrust p
170. tion if lifting them Most Airplane tires are a different size This will make it difficult to replace some of these wheels and tires as they may not be the same dia around C Pneumatic Tires that are mounted on two piece Wheels Two piece wheels bolt together two halves to make the wheel The air MUST be removed form these wheels before they are unbolted completely remove the stem valve from the wheel and wait until all air has evacuated tire and wheel before attempting to work on this wheel Air pressure must not exceed the rating listed on the decal on used air craft tires and wheel On standard Phnuematic tires do not exceed tire manufacturers pressure rating The wheels should be checked to see if wheel bearings are out of adjustment or damaged The tires wheels and hubs need to be inspected for broken or lost components Best way to check the wheel bearing adjustment is to Jack the wheel off the ground Grab the wheel and try to move it in or out figure 1 If any movement exists remove the wheel and inspect the bearings and repair and or readjust the wheel If the wheel is operated for only a few hours with it out of adjustment the bearings and hub could be worn to the point that they would need to be replaced Readjustment and repacking of the wheel bearings is considered a maintenance requirement check the operators manual for the unit for recommended intervals Most common problems with wheel hubs is the loss of the dust cap If run withou
171. tor with the Bolt Nut and Washers provided with the tongue see Step 2 and figure 1 2 amp 3 Make certain to tighten the locknut onto the Bolt 150 ft lbs so that it holds the Clevis Locknut parallel with the draw bar figure 2 Figure 1 Tongue Hitch Bolt Tractor Draw Bar Hitch Pin Spring Washers Tongue Clevis Tongue Clevis Tractor Draw Bar Forez CorrectWay Fgues HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 10 2 Leveling Control Rods Service amp Repair Description ep 3 2 Level Rod Weldment 112 Long Single Control Rod Level Rod Weldment 110 Long Dual Control Rod Swivel Bar Bushing Weldment A Dim 2 1 2 Long See Figure 5 Bushing Weldment A Dim 1 2 Long See Figure 5 Hex Adjusting Nut Bolt Hex Head Locknut Top Lock Tongue Weldment Center Section Weldment Axle Wedment 1 Jam Nut The single control rod is shown or the RH side control rod the LH control rod Figure 4 when dual control rods are used will be the same components as the RH Under stand the Control Rod s from rear axle to E 4 2 tongue quantity of parts will depend on single or 6 7 8 _ double control rods The control rod connects to the rear axle weldment item 9 with a bolt and locknut E ML item 6 connects to the tongue with swivel bar item 2 and bushing weldment item 3 There have been 7 7 3 two bushing
172. treme damage to the hydraulic system and or to the mower deck cooling tubes The pressure side of the pump hydraulic flow MUST NEVER be sent directly to the deck cooling tubes as the excess pressure will damage them The hydraulic oil flow can only be sent through the deck cooling tubes when it is being returned to the tank with little or no resistance Some components of hydraulic system are not meantthe be repaired only replaced Do Not dis assemble acomponent if it is a part intended for replacement only When storing a pump or its components for any reason it is recommended they be stored in a clean area and covered to protect from any dust components that have been washed be coated which oil if they are made of material that may rust HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 2 PUMP SERVICE amp REPAIR Recommended To Test Old Hydraulic Pump before it is Removed 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 until Pump failed from excessive pressure 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 Check Oil level in reservoir fill to fu
173. usted and bearings have no end play Bearing Grease Fitting Dust Adjusting Outer Bearing Cup Y a Cap Nut e Piece Outer Bearing Seal Axle Spindle Inner Bearing Cotter Spindle Lug Nut Cone amp Cup Pin Washer Coned fe WhI Hub Asy FIGURE 10 1 piece Seal HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 8 6 Tire Wheel Hub Service amp Repair Grease Fitting J 4 Three Piece Seal Protector Outer Bearing Seal Axle Spindle Cone Inner Bearing Cotter Spindle Cone amp Cup Pin Washer Whl Hub Asy FIGURE 10A i Wheel Stud 3 piece Seal Install cotter pin item 3 Push Cotter Pin into hole until the head loop in cotter pin is no higher that the washer figure 11 Bend the cotter pin outward figure 11 it may require the ends of the cotter pin to be cut if so use a pair of diagonal cutters DO NOT Cut cotter pin so short the ends can not be bent over figure 11 Make certain the cotter pin doesn t stick outward so far that it rubs the dust cap that is to be installed Bearing Dust Adjusting Cap Nut Outer Bearing Cup Cotter Pin Cotter Pin Installed amp Bent Install dust cap item 2 The Hub can be Installed greased now if wanted Pump grease in through fitting until grease comes out the front between rollers of outer bearing cone Carefully drive dust cap item 2 onto up aligning the dust cap rim with the edge of hub Carefully drive
174. ut from under the machine This is a good time to check the spindle to make sure it is properly tight To do this grab the blade bar and pull outward and push inward See Figure 6 There should be no noticeable movement If the spindle is loose refer to assembly and disassembly of Spindle in previous Service amp Repair section HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section9 3 NOTES HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 9 4 Section 10 HYDRO 15 Leveling Mower Service amp Repair Leveling Control Rods Service amp Repair Tongue Clevis amp Leveling Control Rods Components 1 Make certain the mower and tractor are secured in a safe and proper parked position hydraulic axle and wings lowered or secured by the transport bars Make certain that tractor is safely parked according to tractor manufacturers recommendations Tractor should be secured or dis abled in a way that it cannot be started unless the servicing technician is ready for it to be started Never get under any equipment unless itis secured and supported by sufficient jack stands DO NOT depend on hydraulics or brackets to support equipment if you are going to be under it this is important See the Operators Manual for recommended Maintenance schedules and recommendations Tractor Draw Bar connection the mower must be connected to the tractor draw bar before the mowing height can be adjusted This mower use
175. ut with the bearing cone Bearing Cups the bearing cups items 9 amp 10 can be inspected while still in the hub If bearing cups are serviceable and bearing cones are serviceable then there is no reason to remove the bearing cups from the hub Ifthe bearing cup or bearing cone is un serviceable and either needs replacing then both should be replaced at the same time do not use used bearing cups or bearing cones against new bearing cups or bearing cones Grease fitting itis not required to remove the grease fitting item 12 unless it is damaged or grease cannot be pumped through it Some grease fittings are the drive in type and some are the screw in type You will be able to ID these by looking at area where grease fittings enter wheel hub Drive in grease fittings will pull out by clamping them and pulling upward on them Clean all components bearings nut washer and hub itself Inspect all components including the wheel studs item 11 in hub If wheel studs need to be replace it is recommended that the old stud bepressed out and the new one pressed in Inspect the bearing cups item 9 amp 10 they should not have noticeable wear scratches pitting or any other damage that will make them un serviceable If the bearing cups need to be replace the old ones should be pressed out and new ones pressed in If the bearing cones are damaged and should be replaced the bearing cups should be replaced also or vice versa It is not recommended that
176. with the gears Carefully lift or pry the bearing carrier figure 10 item 13 off carefully to avoid damage to carrier figure 17 The dowel pins will remain in the bearing carrier housing or the gear housing it will not require that they be removed unless the housing is to be replaced and then only to arrange the dowel pins order so the components will fit together Remove the connecting shaft figure 10 item 14 as shown figure 18 by pulling it up out of the drive gear shaft splines Inspect the shaft for wear and or damage Inspect the end of the drive gear Remove the thrust plate note the thrust plate will have the channel seal in it figure 10 item 7 amp 8 Note the smooth side of thrust plate always goes toward the gear Care fully remove the drive gear and the driven gear figure 10 item9 Avoidtapping the gearteeth together or against other hardened surfaces figure 18 pull the drive gear straight up The drive gear has the splined shaft on the other end and care must be taken not to hit the splined shaft against sides and damaging them Keep these gears together because they are a matched set Examine the gears for wear and or damage HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 12 PUMP SERVICE amp REPAIR Lift or pry off the first section of gear housing figure 10 item 12 Be careful not to damage machined surfaces figure 19 Inspect the gear housing See wear tolerance chart for pump a
177. with variable settings and Ohm Meter 3 Electrical Test Light 4 Wrenches Socket Wrenches Open and Boxed End Wrenches Flow Testing the Pump figure 1 1 Use a Flow Meter that is rated to 6000 PSI and 60 GPM Minimum This applies to the gear type pump and motor type only 2 the area around the hoses motor flow meter mustbe clean of all debris and dirt NO contamination can be allowed to enter the system or its components Make certain there is nothing in flow meter from previous use that will contaminate the hydraulic system dirty and contamination in test equipment hoses and valves can cause a failure to occur Disconnect the hydraulic return hose from the motor Connect the hoses to the flow meter as shown above recheck all connections to make certain they are connected correctly and fittings have been check for tightness Completely open the pressure valve on the flow meter HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 3 PUMP SERVICE amp REPAIR Record all the readings during the test Start the system run at 540 PTO speed which will run pump at required speed until the Oiltemperature reaches at least 110 F before starting test Check the flow GPM at 0 psi or no load Slowly close the pressure control valve valve on flow meter until the gauge pressure reaches 500 psi andrecord the readings pressure temperature and flow GPM Continues this at 500 psi increments until a maximum of 2
178. would be just below the center line of the bearings figure 3 Dis assemble for Replacement of Components 1 Check to make certain the splined adapter figure 2 has been removed so it does not fall out during moving the speed increaser if the new style without the snap ring is used make certain to get the tube spacer that goes with the splined adapter Ifthe old style with snap ring the snap ring will stay on the splined adapter Move the speed increaser to a wash area and clean the exterior of unit Set speed increaser above a drain pan remove the lower drain plug the upper vent breather and allow the speed increasers oil to drain out into catch pan Lay the speed increaser on bench with the tractor PTO side down againstthe bench figure 3 Remove Pump flange figure 4 item 6 by removing the 6 bolts and lockwashers figure 4 item 29 amp 30 Remove the pump flange by pulling straight up and away from speed increaser if need be use a screw driver to pry pump flange up being careful not to scratch the machined surfaces After remove inspect the pump flange and remove the seal figure 4 item 10 from pump flange There will be fibre gasket figure 4 item 24 be tween pump flange and speed increaser housing half figure 4 item 16 check to see if it stayed with pump flange or housing half Remove open cover figure 4 item 9 on the pump flange side by removing the 6 bolts amp lockwashers figure 4 item 29 amp 30 Pull the open cover up
179. ximum operating engine motor speed for the PTO rating See Specification Section HYDRO 15 Service Manual 09 06 2006 Alamo Industrial Section 2 22 Section 3 HYDRO 15 Motor Service amp Repair Section 3 1 MOTOR SERVICE amp REPAIR Recommended Reading Before any Service Work Begins Le Read this section completely before starting inspection or repair to the mower hydraulic system to become familiar with its components Identify the model of the mower model number serial number and other information that may be needed to identify which components or options that may be on the mower Make certain the mower and tractor are secured in a safe and proper parked position hydraulic axle and wings lowered Tractor safely parked according to tractor manufacturers recommendations Clean the complete hydraulic system in the area of the repairs Dirt is the enemy of all hydraulic systems and all steps must be taken to keep hydraulic system from being contaminated Make certain the hydraulic oil is not hot from being operated or tested All hydraulic components including hydraulic oil temperature should not exceed ambient temperatures If temperature is high it must be allowed top cool before attempting any repairs of the hydraulic system Caution should be taken if mower is sitting in hot sun ona very hot day the temperature of the metal and oil can be hot test the temperature The drawing andillustrations in this

Hydro 10 & 15 (00756179S)

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Hydro 10 &amp; 15 (00756179S)

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Hydro 10 & 15 (00756179S)