Alamo HYDRO 15 User Manual

HYDRO 15

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4

1

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FLEX WING

MOWER

Published 09/06 Part No. 00756179S

PRODUCT SERVICE MANUAL

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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 Seguin, T exas 78155 830-379-1480

TO THE OWNER/OPERA T OR/DEALER

All implements with moving parts are potentially hazardous. There is no substitute for a cautious, safe-minded operator who recognizes the potential hazards and follows reasonable safety practices. The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents.

BEFORE YOU START!! Read the safety messages on the implement and shown in your manual.

Observe the rules of safety and common sense!

WARRANTY INFORMATION: Read and understand the complete Warranty Statement found in this Manual. Fill out the 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. This 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 with the Manufacturer is necessary.

CONTACTING MANUFACTURER: (Please help us Help You! Before You Call! )

Alamo Industrial Service Staff Members are dedicated to helping you solve yours or your customer’s service problem as quickly and efficiently as possible. Unfortunately, we receive entirely to many calls with only a minimum amount of information. In some cases, the correspondent has never gone out to look at the equipment and merely calls inquiring of the problems described to him by the operator or customer.

PART NUMBERS: Part numbers listed in this manual are subject to change without notice as

designs are made to adapter to the tractor or for a design improvement. Before ordering parts ALWAYS Measure old part to make certain that is the one you will need. This manual is designed to be used along with the Parts and Operators Manual.

Most calls received by Alamo Industrial Service can be classified into approx. 6 general categories.

1. Hydraulic or Mechanical Trouble Shooting.

2. Request for Technical Information or Specifications.

3. Mounting or Fitting Problem.

4. Special Service Problem.

5. Equipment Application Problems.

6. Tractor Problem 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. If the 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. Seguin TX. 78155, Technical Service Dept. PH: 830-379-1480

HYDRO 15 (Service Manual) 09/06

Index -1

INDEX

Section Page

Section 1 - Specifications...........................................................................1-1 to 1-7

Do Not Do or Allow Items (Read First Thing).......................... 1-2

Mower Specifications...........................................................1-3 to 1-5

Bolt Torque Specifications Chart........................................... 1-5

Pump & Motor Hydraulic Schematic - 15 Foot Model..............1-6

Pump & Motor Hydraulic Schematic - 10 Foot Model..............1-7

Section 2 - Pump Service & Repair.......................................................... 2-1 to 2- 22

Pump Repair Preparation Procedures................................... 2-2

Pump Test Procedure..........................................................2-3 to 2-4

Pump & Motor Hydraulic Schematic - 15 Foot Model..............2-5

Pump & Motor Hydraulic Schematic - 10 Foot Model..............2-6

Recommended & Required Tools.......................................... 2-7

Pump Cleaning & Removal................................................... 2-8

Pump Component Identification............................................ 2-9

Pump Dis-Assembly Preparations........................................ 2-10

Pump Dis-Assembly Procedures.......................................... 2-11 to 2-13

Pump Component Wear Inspection Guide............................. 2-14

Pump Assembly Preparation................................................2-15

Pump Assembly Procedures................................................2-16 to 2-21

Pump Recommended Start Up Procedure............................. 2-22

Section 3 - Motor Service & Repair..........................................................3-1 to 3-25

Motor Repair Preparation Procedures...................................3-2

Motor Test Procedure.......................................................... 3-3 to 3-4

Motor & Pump Hydraulic Schematic - 15 Foot Model..............3-5

Motor & Pump Hydraulic Schematic - 10 Foot Model..............3-6

Recommended & Required Tools.......................................... 3-7

Motor Cleaning & Removal................................................... 3-8

Motor Identification Center & Wings...................................... 3-8 to 3-9

Motor Dis-Assembly Preparation (Center)..............................3-10

Motor Dis-Assembly Preparation (Wings).............................. 3-11

Motor Component Identification.............................................3-12

Motor Dis-Assembly Procedures.......................................... 3-12 to 3-15

Motor Component Wear Inspection Guide.............................. 3-16

Motor Assembly Preparation................................................ 3-17

Motor Assembly Procedures................................................ 3-17 to 3-23

Motor Recommended Start Up Procedure.............................. 3-24

Motor Electrical System (wing Motors).................................. 3-24 to 3-25

Section 4 - Spindle Repair......................................................................... 4-1 to 4-10

Spindle Component Identification.......................................... 4-2

Blade Carrier Removal..........................................................4-9 TO 4-10

Spindle Removal Preparation................................................ 4-2

Spindle Housing Removal.....................................................4-2 to 4-3

Spindle Housing Dis-Assembly.............................................4-3 to 4-5

Spindle Component Inspection Part Condition........................4-5

Spindle Assembly Procedure............................................... 4-5 to 4-9

Blade Carrier Installation...................................................... 4-9 to 4-10

HYDRO 15 (Service Manual) 09/06

Index -2

INDEX

Section Page

Section 4 - Spindle Repair......................................................................... 4-1 to 4-10

Spindle Component Identification........................................................ 4-2

Blade Carrier Removal........................................................................4-9 TO 4-10

Spindle Removal Preparation.............................................................. 4-2

Spindle Housing Removal...................................................................4-2 to 4-3

Spindle Housing Dis-Assembly...........................................................4-3 to 4-5

Spindle Component Inspection Part Condition...................................... 4-5

Spindle Assembly Procedure..............................................................4-5 to 4-9

Blade Carrier Installation.................................................................... 4-9 to 4-10

Section 5 - Hydraulic Cylinder Repair & Service.................................... 5-1 to 5-30

Wing Lift Cylinders

Wing Lift & Fold Cylinder Schematic 15 ft............................................ 5-2 & 5-4

Wing Lift & Fold Cylinder Schematic 10 ft............................................ 5-3 & 5-5

Wing Lift & Fold Cylinder Removal...................................................... 5-8

Wing Lift & Fold Cylinder Dis-Assembly.............................................. 5-8 to 5-10

Wing Lift & Fold Cylinder Re-Assembly............................................... 5-10 to 5-14

Standard Axle Lift Cylinder (Standard 1 Cylinder System)

Axle Lift Cylinder Schematic (Standard 1 Cylinder 15 ft)........................5-2

Axle Lift Cylinder Schematic (Standard 1 Cylinder 10 ft)........................5-3

Axle Lift Cylinder Removal (Standard 1 Cylinder).................................. 5-16

Axle Lift Cylinder Dis-Assembly (Standard 1 Cylinder).......................... 5-16 to 5-18

Axle Lift Cylinder Component Inspection (Standard 1 Cylinder)............. 5-19

Axle Lift Cylinder Re-Assembly (Standard 1 Cylinder)........................... 5-19 to 5-21

Optional Axle Lift Cylinder (Optional 3 Cylinder System)

Axle Lift Cylinder Schematic (Optional 3 Cylinder 15 ft).........................5-4

Axle Lift Cylinder Schematic (Optional 3 Cylinder 10 ft).........................5-5

Axle Lift Cylinder Removal (Optional 3 Cylinder Axle Level Lift).............. 5-24

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................................................................. 6-2

Hydraulic Tank Oil Return Filter.......................................................... 6-3

Hydraulic Tank Oil Fill Procedure........................................................ 6-4 to 6-5

Section 7 - Speed Increaser (Speed Changer) Repair & Service......... 7-1 to 7-13

Speed Increaser To Tractor PTO Mount............................................... 7-2 to 7-5

Speed Increaser Component Identification............................................ 7-6 to 7-7

Speed Increaser Dis-Assembly For Component Inspection....................7- 8

Speed Increaser Dis-Assembly For Component Re-Placement.............. 7-8 to 7-9

Speed Increaser Re-Assembly For Component Re-Placement...............7-10 to 7-13

Section 8 - Tire - Wheel - Hub Repair & Service..................................... 8-1 to 8-7

Wheel Information..............................................................................8-2 to 8-3

Wheel Hub Dis-Assembly.................................................................. 8-3 to 8-4

Wheel Hub Re-Assembly................................................................... 8-5 to 8-7

HYDRO 15 (Service Manual) 09/06

Index -3

INDEX

Section 9 - Blades & Blade Carriers Service & Repair.......................... 9-1 to 9-3

Blade Carrier Service & Repair............................................................ 9-2

Blade Bolt Service & Repair............................................................... 9-3

Section 10 - leveling Mower Service & Repair........................................10-1 to 10-6

Tongue Clevis Connection.................................................................. 10-2

Leveling Rod Component Identification................................................. 10-3

Assembling Control Rods...................................................... 10-4

Adjusting Control Rods..................................................................... 10-5

Adjusting Wing Axles........................................................................ 10-6

Leveling Mower..................................................................................10-1 to 10-6

Section 11 - Trouble Shooting Guide........................................................ 11-1 to 11-3

Probable Cause & Solutions...............................................................11-2 to 11-3

HYDRO 15 (Service Manual) 09/06

Index -4

Section 1

HYDRO 15

Model

HYDRO 15 (Service Manual) 09/06

Specifications

Section 1 - 1

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

1. 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 secured to prevent someone from starting it and parked in accordance with the tractor manufactures recommendation, See tractor operators manual and/or decals for parking tractor securely.

2.

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 the hydraulics always keep the hoses sealed by using temporary caps to plug them, do not just leave them open to the elements

3. 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.

4. DO NOT install higher rated fuses than are recommended by manufacturer for any components.

5. DO NOT do any welding on unit unless the electrical components are unplugged first, this is to prevent a 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 recommended that mower be disconnected from tractor when being repaired.

6. DO NOT attempt to repair or adjust a component that is not intended to be repaired, example sealed components as there are no serviceable components inside.

7. 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.

8. 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.

9. DO NOT re-use old oil if it is contaminated, re-install dirty components or not completely clean the system after a repair if there is a possibility of oil contamination. Example: If the right wing motor has metal in it from a 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.

10. 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.

11. 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

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 lbs. w/ Chain Guards (this can vary w/ wheel type)

Mower Tongue Weight................................................... Approx 2200 lbs w/ Wings lowered

Cutting Capacity........................................................... Grass & Up To 1-1/2" dia Brush (Max)

Mower Overall Length.................................................... 199" Front To Back

Mower Overall Width..................................................... 186.5" w/Wings Down & 96" w/ Wings Folded (this can

be affected by tire size, type, & wing axle adjustment)

Number Blade Carriers...................................................3 on 15 ft Model & 2 on 10 Ft Model

Cutting Width Options................................................... 15 Ft or 10 Ft Model

Over All Cutting Width... (15 Ft Model)................ 180" Center & Wings Overall Cutting Width

(10 Ft. Model)............... 124-1/2" Center & Wing Overall Cutting Width

Cutting Height...............................................................2" Down to 15" Up w/ 700:15 Pneumatic Tires (Cutting

Height will vary with tire & Wheel sizes)

2" Down to 12" Up w/ 12" Tires (Cutting Height will vary

with tire & Wheel sizes)

Blade Carrier Cutting Width............................................ Center & 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 & 4" Wing overlap)

Blade 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.

Blade Carrier Mounting.................................................. Bolts Direct to Blade Spindle f/ Under Side

Bolts........................................Qty 4

Type........................................ Allen Head Bolts

Torque..................................... 400 ft lbs

Installation............................... Use Thread L ock Compound

Lockwasher.............................. Qty 4

Blade Options.............................................................. Fan

Blade Size....................................................................1/2" thick X 3.5" wide X 22-1/4" long (measure blade

length from center of bolt hole to end of blade)

Blade Rotation.............................................................. CCW rotation Center & LH Wing, CW RH Wing

Blade 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 & Nut...........................1" Structural Steel Flat Washer & Toplock Locknut

Torque......................................300 ft lbs

Blade Tip Speed............................................................Blade Tip Speed Based on Max Pressure & RPM

Center Section Blade Tip Speed......................... 18,262 FPM (Operating Speed)

Wing Section Blade Tip Speed........................... 13,194 FPM (Operating Speed)

Blade Spindle.............................................................. 1 On Center Section & 1 On Each Wing

Spindle Bearing Type........................................ Adjustable Roller Bearing Cup & Cone)

Spindle Seal..................................................... Replaceble Round Seal Bottom & 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

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 & 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.

Pump HP......................................................... 145 HP Dual Stage Gear Type

Speed Changer Gear Ratio.................................1 RPM Input X 4 RPM Output (Increase)

Tractor PTO Speed............................................540 RPM Required

Pump RPM.......................................................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 & Wing..................................... 1 & 2 on 15 ft Model / 1 & 1 on 10 ft Model

Motor Type...................................................... Gear Type

Motor HP Rating........... Center..........................75 HP @ 3000 PSI

Wing........................... 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. lbs

Hydraulic Oil Type........................................................ 100AW or Equivalent SAE 30 Weight Hyd Oil

Hydraulic Oil Capacity.................................................. Tank & 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 & Center)

Hydraulic Reservoir Pressure......................................... 11 PSI (Return Pressure)

Mower Deck Leveling Adjustment................................... Mechanical f/ Front to Rear (at Assembly Setup &

Self Leveling While Operating)

Mower Center Deck Control Rods................................... Dual Control Rods.

Mower Hitch................................................................. Self Leveling

Axle Lifting............................... Standard...................... Hydraulic Cylinder Center Axle & 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................. Center..........................Rubber Bump Pads (Standard)

Wing............................Coil Springs each Wing Axle (Standard)

Mower Wing Leveling.................Standard...................... Wing Axle mechanical Screw Lift Adjustment

Optional....................... Wing Axle & Center Axle Hydraulic Lift Adjustment

Mower Wing Lift and Fold...........Standard..................... Hydraulic Cylinder, 1 each Wing

Optional...................... Cable Winch a nd Stand

Wing Lift & Fold........................................................... Hydraulic Standard

Wing Lift Range........................................................... 22° Down & 90° Up

Wing Winch Stand.................... Standard...................... Bolt on Weldment

Wing Winch............................. Optional....................... Manual Operated Cable Lift Winch

Mower Wing Transport...............Standard.................... Welded Bracket and Pin Assembly

Hydraulic Control Valve..............Option..........................Remote 3 Spool (15 ft) or 2 spool (10 ft) w/ Detent

Hydraulic Control Valve Type......Option......................... Open or Closed Center

Wing Deck Side Skirts.............. Standard...................... 10-3/8" High - 1/4" thick

HYDRO 15 (Service Manual) 09/06

Section 1 - 4

SPECIFICATIONS - HYDRO 15 FLEX WING

Skid Shoes...............................Standard...................... Standard Cen ter & Wings, Replaceable Bolt on.

Deck Material Thickness............................................... 10 ga. Steel with formed channel reinforcement

Deck Reinforcement.................. Standard.................... Hydraulic Oil Cooling Tubes welded to deck

Wheels........................................................................ 6 Standard or 4 Optional

Wheel Type Standard.................................................... 6:00 X 9 Std (Qty 6)

Wheel Type Option........................................................15" Wheel less tire

15" Wheel & Pneumatic Tire Asy Used or Recapped Airplane Tire & 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 & 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 lbs & (Nm) IMPORTANT ! Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE, Component

Application Torque will vary dependimg on what is bolted down and the type material (Metal) that is being bolted together. Thread condition and lubrication will vary Torque settings.

Bolt Dia.

inch

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4

Inche Sizes

2 (B)

Plain Head

Not Used Not Used Not Used 35 (47) 55 (75) 75 (102) 105 (142) 185 (251) 160 (217) 250 (339) 330 (447) 480 (651)

3 Dashes

85 (115) 130 (176) 170 (230) 300 (407) 445 (603) 670 (908)

910 (1234)

1250 (1695)

5 (D)

10 (14) 20 (27) 35 (47) 55 (75)

8 (F)

6 Dashes

14 (19) 30 (41) 50 (68) 80 (108) 120 (163) 175 (230) 240 (325) 425 (576) 685 (929) 1030 (1396) 1460 (1979) 2060 (2793)

ALWAYS

CHECK

MARKINGS

ON

TOP

OF BOLT HEAD

OR

OTHER

BOLT

DESCRIP-

TIONS

Bolt Dia. mm

6 8 10 12 14 16 18 20 22 24 27 30 33 36

Metric Sizes

4.8

5 11 20 37 60 92 118 160 215 285 450 600 800 900

8.8

7 20 40 70

100 155 216 270 330 500

875 1200 1600

2100

10.8

12 25 58 105 140 200 280 355 430 700 1000 1700 2300 3000

HYDRO 15 (Service Manual) 09/06

Section 1 - 5

SPECIFICATIONS - HYDRO 15 FLEX WING

8

1

15 FT - PUMP & MOTOR HYDRAULIC SCHEMATIC

CAUTION !

NEVER Connect Pump Pressure

Line direct to cooling tubes, as it will damage the tubes.

15

L-Wing Cooling Tube

19

1

4

3

20

5

2

2345678901234567

9

21

11

R-Wing Cooling Tube

6

8

12

7

18

14

21

Center (LH & RH) Cooling Tubes

10

20

Item Description

1 Tandem Pump Asy 2 Suction (Tank to Wing Pump) 3 Suction (Tank to Center Pump) 4 Pressure (Pump to Bulk Head Fitting) 5 Pressure (Pump to Bulk Head Fitting) 6 Pressure (Bulk Head Fititng to Center Motor) 7 Pressure (Bulk Head Fitting to Wing Motors) 8 Motor Asy (Center Sction Motor) 9 Return (Center Motor to Wing CoolingTube) 1 0 Return (Wing Tube to Center Cooling Tube) 1 1 Return (Center Coolingg Tube to Fiter / Tank)

HYDRO 15 (Service Manual) 09/06

Item Description

1 2 Case Drain (R- Wing Motor to Cooling Tube) 1 3 Wing Motor Asy (R- Wing) 1 4 Return / Pressure (f/ R-Wing to L-Wing Motor) 1 5 Return (Center Cooling Tube to Filter / Tank) 1 6 Return Filter & Gauge (Wing Motors Return) 1 7 Return Filter & Gauge (Center Motor Return) 1 8 Return (L-Wing Motor to Cooling Tube) 1 9 Case Drain (L-Wing Motor to Cooling Tube) 2 0 Wing Motor Asy (L-Wing) 21 Return (L-Wing Tube to Center Cooling Tube)

Section 1 - 6

13

SPECIFICATIONS - HYDRO 15 FLEX WING

8

1234567890123456789012345

1

12

10 FT - PUMP & MOTOR HYDRAULIC SCHEMATIC

CAUTION !

NEVER Connect Pump Pressure

Line direct to cooling tubes, as it will damage the tubes.

15

1

4

3

16

5

2

2345678901234567

17

11

R-Wing Cooling Tube

9

6

8

12

Item Description

1 Tandem Pump Asy 2 Suction (Tank to Wing Pump) 3 Suction (Tank to Center Pump) 4 Pressure (Wing Pump to Bulk Head Fitting) 5 Pressure (Center Pump to Bulk Head Fitting) 6 Pressure (Bulk Head Fititng to Center Motor) 7 Pressure (Bulk Head Fitting to Wing Motor) 8 Motor Asy (Center Sction Motor) 9 Return (Center Motor to Wing CoolingTube) 1 0 Return (Wing Tube to Center Cooling Tube) 1 1 Return (Center Coolingg Tube to Fiter / Tank)

HYDRO 15 (Service Manual) 09/06

7

14

Center (LH & RH) Cooling Tubes

Item Description

1 2 Case Drain (R- Wing Motor to Cooling Tube) 1 3 Wing Motor Asy (R- Wing) 1 4 Return (R-Wing Motor to Cooling Tube) 1 5 Return (Center Cooling Tube to Filter / Tank) 1 6 Return Filter & Gauge (Wing Motor Return) 1 7 Return Filter & Gauge (Center Motor Return)

Section 1 - 7

10

13

NOTES

HYDRO 15 (Service Manual) 09/06

Section 1 - 8

Section 2

HYDRO 15

Service & Repair

HYDRO 15 (Service Manual) 09/06

Pump

Section 2 - 1

PUMP SERVICE & REPAIR

Recommended Reading Before any Service Work Begins:

1. Read this section completely before starting inspection or repair to the mower hydraulic system to become familiar with its components.

2. 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.

3. 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.

4. 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.

5. 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 on a very hot day the temperature of the metal and oil can be hot, test the temperature.

6. The drawing and illustrations in this section are to help understand the components of the pump. This section is not intended to be a parts manual or operators manual although it is intended to be used with the other manuals.

7. 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 render the component un-serviceable

8. 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 component in the wrong place and then turned in the wrong direction the pressure will usually blow the input seal out and may damage other components.

9. When making repairs always make certain that the cause of the failure is identified and repaired. Sometimes the cause of the failure is not corrected and another failure occurs rapidly because the cause of the failure is still there.

10. 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.

11. 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 extreme damage to the hydraulic system and/or to the mower deck cooling tubes.

12. 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.

13. Some components of hydraulic system are not meant the be repaired, only replaced. Do Not dis-assemble a component if it is a part intended for replacement only.

14. 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

Section 2 - 2

PUMP SERVICE & 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.

B. Before connecting any lines to Pump, fill all Ports with clean Oil to provide initial Lubrication. This is

especially important is Pump is located at a higher level than Oil Reservoir.

C. Check Oil level in reservoir, fill to full level if needed, Reservoir must have more Oil than the Pump GPM

capacity.

D. After connecting the Lines and mounting the replacement Pump, make sure that Oil is not warmer than

Pump temperature. If Oil is warmer than pump run Pump at short intervals till Pump and Oil temperature is equalized. Hot Oil must not be fed into cold Pump.

E. Operate the Pump for at least two minutes at no load and at low RPM (400 RPM min and 1400 RPM max.).

Watch Flow Meter Pressure (or Pressure Gauge). During this break-in period, the unit should run free and not develop an excessive amount of heat. Heat should not exceed 100 deg F. 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.

F. If normal Pressure and Heat readings are seen then the New or Rebuilt Pump installation should be done,

remove Flow Meter (Pressure Gauge) from line, reconnect Line and check all connections.

Test Equipment Needed:

1. Flow Meter, The Flow meter should have components to measure: A. Guage to Measure the Oil Temperature. B. Gauge to Measure Oil Pressure PSI (Load and No Load). C. Gauge to Measure Oil Flow in G.P.M. D. A Valve to load system to check operating Pressure (PSI). E. Assortment of Connections to connect to Hydraulic System.

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 must be 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.

3. 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.

4. Completely open the pressure valve on the flow meter.

HYDRO 15 (Service Manual) 09/06

Section 2 - 3

PUMP SERVICE & REPAIR

5. Record all the readings during the test. Start the system, run at 540 PTO speed (which will run pump at required speed) until the Oil temperature 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. and record the readings pressure, temperature and flow (GPM). Continues this at 500 psi increments until a maximum of 2000 psi.

6. If the flow rate is 85 % or greater of beginning flow rate at no load, the pump is 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

Figure 1

HYDRO 15 (Service Manual) 09/06

Section 2 - 4

15 FT - PUMP & MOTOR HYDRAULIC SCHEMATIC

7

12

Wing Supply (Front) Pump Half

Center Supply (Rear) Pump Half

15

PUMP SERVICE & REPAIR

1

CAUTION ! NEVER Connect

Pump Pressure Line direct to cooling

4

5

2

234567890123456

tubes, as it will damage the tubes.

3

20

21

11

L-Wing Cooling Tube

9

R-Wing Cooling Tube

6

8

12

19

7

18

14

21

Center (LH & RH) Cooling Tubes

10

20

13

Figure 2

Item Description

1 Tandem Pump Asy 2 Suction (Tank to Wing Pump) 3 Suction (Tank to Center Pump) 4 Pressure (Pump to Bulk Head Fitting) 5 Pressure (Pump to Bulk Head Fitting) 6 Pressure (Bulk Head Fititng to Center Motor) 7 Pressure (Bulk Head Fitting to Wing Motors) 8 Motor Asy (Center Sction Motor) 9 Return (Center Motor to Wing CoolingTube) 1 0 Return (Wing Tube to Center Cooling Tube) 1 1 Return (Center Coolingg Tube to Fiter / Tank)

HYDRO 15 (Service Manual) 09/06

Item Description

1 2 Case Drain (R- Wing Motor to Cooling Tube) 1 3 Wing Motor Asy (R- Wing) 1 4 Return / Pressure (f/ R-Wing to L-Wing Motor) 1 5 Return (Center Cooling Tube to Filter / Tank) 1 6 Return Filter & Gauge (Wing Motors Return) 1 7 Return Filter & Gauge (Center Motor Return) 1 8 Return (L-Wing Motor to Cooling Tube) 1 9 Case Drain (L-Wing Motor to Cooling Tube) 2 0 Wing Motor Asy (L-Wing) 21 Return (L-Wing Tube to Center Cooling Tube)

Section 2 - 5

PUMP SERVICE & REPAIR

7

12

10 FT - PUMP & MOTOR HYDRAULIC SCHEMATIC

Wing Supply (Front) Pump Half

Center Supply (Rear) Pump Half

15

1

CAUTION ! NEVER

4

5

3

16

2

234567890123456

Connect Pump Pressure Line direct to cooling tubes, as it will damage the tubes.

17

11

R-Wing Cooling Tube

9

6

8

12

7

14

Center (LH & RH) Cooling Tubes

Figure 3

Item Description

1 Tandem Pump Asy 2 Suction (Tank to Wing Pump) 3 Suction (Tank to Center Pump) 4 Pressure (Wing Pump to Bulk Head Fitting) 5 Pressure (Center Pump to Bulk Head Fitting) 6 Pressure (Bulk Head Fititng to Center Motor) 7 Pressure (Bulk Head Fitting to Wing Motor) 8 Motor Asy (Center Sction Motor) 9 Return (Center Motor to Wing CoolingTube) 1 0 Return (Wing Tube to Center Cooling Tube) 1 1 Return (Center Coolingg Tube to Fiter / Tank)

HYDRO 15 (Service Manual) 09/06

Item Description

1 2 Case Drain (R- Wing Motor to Cooling Tube) 1 3 Wing Motor Asy (R- Wing) 1 4 Return (R-Wing Motor to Cooling Tube) 1 5 Return (Center Cooling Tube to Filter / Tank) 1 6 Return Filter & Gauge (Wing Motor Return) 1 7 Return Filter & Gauge (Center Motor Return)

Section 2 - 6

10

13

PUMP SERVICE & REPAIR

Recommended Tools:

Listed below are some of the toolds that are recommended for the dis-assembly and reassembly of the pump for the HYDRO 15 Mower.

1. Arbor Press

2. Awl

3. 1-1/2" Dia steel ball

4. Bearing Puller (Owaonna Tool Co.

MD-956 or equivalent)

5. Bushing Remover Tool (figure 4)

6. Clean lintless Cloth

7. Deburing Tool (an old file with cutting

teeth ground off)

8. Machinest Hammer

9. Soft Hammer

10. Permatex Aviation Form-A-Gasket.™

(No. 3 non hardening sealant or equal)

11. Medium Grit Carborundurn Stone.

12. Seal removal Tool (figure 6)

13. Oil and Grease

14. Snap Ring Pliers

15. Prick Punch

16. Bushing Installation Tool (figure 5).

17. Scale (1/32" or 1/64" graduations)

18. Small Screw Driver

19. Torque Wrench (in. lbs & ft lbs)

20. Vise with 6" minimum opening

21. Bar for Lip Seal Installation

For Front (Wing Supply) Pump use 1-3/4" dia X 2" Bar For Rear (Center Supply) Pump use 2-1/2" dia X 2" Bar

22. Special Steel Sleeve (figure 7)

Seal Removal Tool: Easily made from old screw driver. Heat the tip and bend as shown. Grind the tip to fit the notch behind the shaft seal.

Bushing Puller: The bushings in the pump may be removed from tier bores, using blind hole collet-type bushing pullers similar to those manufactured by Owatonna Tool Co. The Table below illustrates the modification necessary to adapt the OTC collets to this task. Equivalent pullers from other suppliers may be modified in a similar fashion.

Pump

Wing Supply

Pump

Center Supply

Pump

Figure 4

Bushing Installation

Tool A.I.S.I 8620

Bearing Qaulity

Steel Heat treated

AB C

.980 .970

1.382

1.372 C

AB

.06

.875

Ref

1.260

1.250

.100 .090

.100 .120

.015 R Maximum

A

B .06

Make

f/ OTC

Collet No.

33863

33865

Surface

Finish

32

C D

30°

Figure 5

Pump

Wing Supply

Pump

Center Supply

Pump

A

3.00

30°

B

1.47

1.73

Grind Relief Allowable

C dia.

1.492

+ .000

- .002 + .000

- .002

1.054

D dia.

1.250

1.750

Figure 6

C Rad

F°

HYDRO 15 (Service Manual) 09/06

1/4" Hole Drill through

Wing Supply

B

A

E

D

Center Supply

1/4"

Pump A

Pump

3-3/8"

Figure 7

Special Steel Sleeve: The special steel sleeve is used to insert the 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. The drawing and cgart give details for making this special tool.

B C Rad

4-1/2" 1.065 .015" X 45°

4-1/2"

All external surfaces MUST be free of scratches and burrs

9/16"

D Rad E dia.

+ .000

- .002 + .000

1.377

- .002

1.002

1.250

+ .002

- .000 + .002

- .000

F° Chamfer

.015" X 60°

Section 2 - 7

PUMP SERVICE & REPAIR

Pump Cleaning & Removal:

1. Clean Pump, Hoses and all connections before disconnecting any components from the pump. This will keep contamination 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, if the 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 out when hoses are dis-connected. The hoses will need to be capped (plugged) after removal being disconnected. If cap is not leak proof then hoses must remain 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 &1" on pressure side)

7

Figure 8

Tandem Mounted Pump

3

Figure 9

6

5

1

4

2

Item Qty Description 1 1 Pump Assembly (Tandem Pump) 2 2 Split Flance Kit, (1" Flange)

1 O-Ring (for 1" Flange) (Qty Each Kit) 4 Bolt, Hex Head, (Qty Each Kit) 4 Lockwasher (Qty Each Kit)

3 2 Split Flance Kit, (1-1/2" Flange)

1 O-Ring (for 1" Flange) (Qty Each Kit) 4 Bolt, Hex Head, (Qty Each Kit)

4 Lockwasher (Qty Each Kit) 4 1 Hose Asy, 1" Hose & Flange (Pressure to Wing Motors) 5 1 Hose Asy, 1" Hose & Flange (Pressure to Center Motor) 6 1 Hose Asy, 1-1/2" Hose & Flange. (Suction Hose for Center Motor 7 1 Hose Asy, 1-1/2" Hose & Flange. (Suction Hose for Wing Motor)

HYDRO 15 (Service Manual) 09/06

Section 2 - 8

PUMP SERVICE & REPAIR

Pump Component Schematic

4

2

3

1

12

11

10

8

7

6

15

11

8

7

6

5

9

Item 5 install this side (outlet side)

6

7

8

10

16

11

10

11

10

20

19

18

13

14

5

6

7

8

Item Qty Description 1 1 Snap Ring 2 1 Bearing, Outboard 3 1 Seal, Input 4 1 Shaft End Cover 5 1 Plug 6 8 Bushings 7 4 Channel Seal 8 4 Thrust Plate 9 1 Integral Drive Shaft and Gear Set 1 0 4 Gasket Seal

Figure 10

22

21

17

Item 5 install this side (outlet side)

Item Qty Description 11 8 Dowel Pins 12 1 Gear Housing 13 1 Bearing Carrier 14 1 Connecting Shaft 1 5 1 Gear Set (Matched) 16 1 Gear Housing 17 1 Port End Cover 18 4 Studs 19 4 Lockwasher 20 4 Nuts 21 4 Lockwasher 22 4 Bolt

HYDRO 15 (Service Manual) 09/06

Section 2 - 9

PUMP SERVICE & 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 & 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

1" Split Flange Pressure (outlet) Side

5

Port End Cover

Rear Gear Housing

4

1" Split Flange Pressure (outlet) Side

3

Port Bearing Housing

2

Front Gear Housing

Service Technician Makes Alignment Marks Here

Figure 10A

HYDRO 15 (Service Manual) 09/06

1

Speed Changer

&

Tractor PTO

Section 2 - 10

Shaft End Cover

See Figure 10

for Compo-

nent Item

Number

PUMP SERVICE & REPAIR

Pump Dis-Assembly CAUTION! :

Important information - read before dis-assembly:

1. 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.

2. If parts are difficult to come apart during dis-assembly, tap gently with a soft hammer (never use an iron hammer).

3. 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.

4. Never hammer bushing into bores: always use an arbor press.

Pump Dis-Assembly:

1. 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. It is recommended that marks be done with metal stamps that will mark components for correct assembly order for & 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).

Figure 11

Figure 12

2. 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 & 20) , This will allow for the 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

HYDRO 15 (Service Manual) 09/06

Figure 13

Figure 15

Section 2 - 11

PUMP SERVICE & REPAIR

3. Lift the 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).

4. Remove the thrust plate (figure 10 item 8). 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 10 item 7). 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.

5. 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 in the end cover or they may stay in the gear housing. It will be 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.

Figure 16

6. Remove the outer gear housing (figure 10 item 16). Lift the 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 & 8) that was under the gears, sometimes this thrust

plate will come out with the gears.

7. 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.

8. 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 & 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 item 9). Avoid tapping the gear teeth 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

Figure 17

Figure 18

HYDRO 15 (Service Manual) 09/06

Section 2 - 12

PUMP SERVICE & REPAIR

9. 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

and motors in this section). for wear and / or damage.

10. Inspect all of the 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). Remove the bushings with care not to damage housings (figure

20).

11. 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).

12. Remove the shaft bearing (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.

Figure 19

13. Remove shaft end cover it 180° over and re-insert it into vice. Remove the double lip seal by inserting the special seal removal tool (see figure 6 recom-

mended tools). Make note of which way seal is removed. Inspect

the shaft end cover seal seat area (figure 23).

14. 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 all the components, DO NOT use any material that will leave lint on components, it 's best to air dry the components. Useextreme caution when cleaning gear sets, DO NOT use any abrasive materials at all and DO

NOT bang the gears together. Keep the gears in the 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).

(figure 10 item 4) from vice and turn

Figure 20

Figure 21

Figure 22

HYDRO 15 (Service Manual) 09/06

Figure 23

Section 2 - 13

PUMP SERVICE & REPAIR

Wear Tolerance for Pump & 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

Gear Housing

Cut-Out Area

Gear Wear Area

Wear in excess of .007" cut-out necessitates replacement of the Gear 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 dirt. Where cut-out is moderate, 0.007" or less, gear housing is in good enough 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).

Gear Teeth

Gear Hubs

Seal Area

Gear Teeth

Splines

Thrust Plate

Gears:

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)

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.

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.

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

Section 2 - 14

PUMP SERVICE & 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 & 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 Retaining Nuts & studs (Torque to 3000 in lbs.

1" Split Flange Pressure (outlet) Side

5

Port End Cover

Rear Gear Housing

4

1" Split Flange Pressure (outlet) Side

3

Port Bearing Housing

2

Front Gear Housing

Service Technician Makes Alignment Marks Here

Figure 23A

HYDRO 15 (Service Manual) 09/06

1

Speed Changer

&

Tractor PTO

Section 2 - 15

Shaft End Cover

See Figure 10 for

Component Item

Number

KEEP THESE MARKS ALIGNED During Assembly

PUMP SERVICE & REPAIR

Pump Assembly CAUTION! :

Important information - read before assembly:

1. 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.

2. Make certain any replacement parts have been compared to the old parts to make certain they are correct.

3. 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.

4. Never hammer bushing into bores: always use an arbor press, Hammering will damage bushings and possibly the bores in the housing.

5. (NOTE illustrations shown here are for a single pump, the tandem sections, the disassembly will be basically the same with the exception tandem pump has two pump section instead of one. See figure 9 & 10 for reference to components).

pump is longer with more

Thrust Plate

Relief Groove (High

Pressure)

Gear Side

(Smooth Side)

Figure 24

Gear Housing

Inlet

(Suction)

Core

Opening

Channel

Seal Side

(Grooved Side)

Gear Bore

Thrust Plate

Installed in Gear

Housing

Relief Groove (High

Pressure)

Outlet

(pressure)

Core

Opening

Gasket Seal

Thrust Plate CAUTION! : (Figure 24)

Important information - read before assembly:

1. 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 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.

4. 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.

5. 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.

HYDRO 15 (Service Manual) 09/06

Section 2 - 16

PUMP SERVICE & REPAIR

Pump Assembly:

1. Check all the machined surfaces on all pump 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. This must be done equal all the way across the face of the machine surface to keep it level (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. Replace the parts with machined surfaces if required. Check components for wear or damage now before continuing.

2. If the 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 at the 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 26). Do this to each hole for the bushing that are to be replaced. IMPORTANT ! Bushing must be pressed inwith an arbor press DO NOT drive them in with a hammer.

3. Insert the shaft end cover in the vise with the machined surface up (figure 27). Examine the plug in the surfaced area.

It is NOT required to remove this plug un-less the shaft end

housing is being replaced. This pump (PGP/PGM 365 Series) has one plug and it is installed on determines the direction of travel of the 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

engaged, it will most likely blow the shaft seal out of it and it may damage other components in the mowers hydraulic system. This plugged is change by using a screw driver if need be.

4. If new plugs are to be installed, coat the threads of the plug with locktite™ thread sealant. If new plugs have been installed, they need to be screwed in 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 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 it to prevent chips from flying off of hammer . DO NOT use hammer direct to hit plugs

Figure 25

Figure 26

5. Note: Steps 5, 6, 7 & 8 apply to Shaft End Cover (figure

10 item 4), Bearing Carrier (figure 10 item 13) and Port End

Cover (figure 10 item 17) Any bushing removed from the shaft end cover, port end 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).

HYDRO 15 (Service Manual) 09/06

Section 2 - 17

Figure 27

PUMP SERVICE & REPAIR

6. 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 that the 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 must be pressed into the bores flush with the casting face (figure 30).

7. Repeat steps 1 and 2 after busings are installed (See

steps 1 & 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 and there are NO burrs on the top ID of bushings. (figure 31).

8. Check to make certain that the dowel pins are in place in

anynew 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 not have burrs. To insert dowels hold the dowel in alignment with the hole. Gently start the 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.

Figure 28

9. Remove the shaft end cover from the vice and turn it over

180° and re-insert it into 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 of the seal up, press it into the mounting flange side of the 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.

10. 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, if it will not go with light (continued next page)

Figure 29

Figure 30

HYDRO 15 (Service Manual) 09/06

Figure 31

Section 2 - 18

PUMP SERVICE & 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).

11. 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 of the shaft end cover.

1 2 Remove the shaft end cover (figure 10 item 4) from the vice and

turn it over 180° and re-insert it into the vise with the splined side down and re-insert it into the vise.

Grease the new Gasket Seals (figure 10 item 10) and insert it in 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 not to pinch the seal gasket, also be sure that the large rounded core is on the inlet side (figure 36).

13. Assemble the channel seals (figure 10 item 7) into the grooves in the thrust plates (figure 10 item 8) with the flat side of the seal facing away from the thrust plates as shown (figure

37 & 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.

Figure 32

Figure 33

14. Gently slip the thrust plate (figure 10 item 7 & 8) through 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 groove in the thrust plate should face the outlet side of the pump (see figure

23A).

15. Coat the driven gear journal 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

special steel sleeve (figure 7 recommended tools list). Lightly coat the 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.

Figure 34

Figure 35

HYDRO 15 (Service Manual) 09/06

Figure 36

Section 2 - 19

PUMP SERVICE & REPAIR

6

4

16. Slip the next thrust plate with the channel seal installed (figure 10 item 7 & 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 outlet side. Check the gear housing gasket seal (figure 10 item 10) is still in place on gear housing (figure 24 & 41).

17. Lightly coat the gear journals with grease. When placing the Bearing housing (figure 10 item 13) over gears, use 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 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).

18 Insert the 4 studs, 4 Lockwashers & 4 Nuts (See figure 23A) that

connect the previous sections. Tighten the stud nuts in alternating pattern until Torque of the nuts to 3000 in. lbs. (250 ft. lbs.)

19. Coat the connecting shaft (figure 10 item 14) use light coat of grease, insert it into spline of drive gear. Make certain that gasket seals are coated with clean grease and installed 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 & 44). Housing should fit flush to bearing housing. MAKING CERTAIN the marks made to keep the components in the same orientation when re-assembled are aligned (figure 23A).

20 Place the thrust plate (figure 10 item 7 & 8) into the gear housing

as per step 14. Coat the journal of the drive gear and the driven gear insert with light coat of grease.

the drive gear aligning the splined shaft end over the 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

Figure 39

together (figure 44). Make certain the gears are seated completely down andagainst the thrust plate face.

Figure 37

Channel Seal Side Grooved

Smooth Side Channel Seal Outward

Figure 38

Figure 40

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Gear Side Smooth

Thrust Plate

HYDRO 15 (Service Manual) 09/06

Figure 41

Section 2 - 20

Figure 42

PUMP SERVICE & 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 & 4 in the assembly instructions on correct way to install plugs (figure 27, 28 & 45).

22. Gently slip the thrust plate (figure 10 item 7 & 8) into the gear housing and into place on the shaft end (figure 46). The channel seal from should face the port end cover. The relief groove in the thrust plate should face the outlet side of the pump (see figure 23A & 24). The correct installation of the thrust plate and channel seal are very important, DO NOT install them wrong.

23. Make certain the bushings are OK or have been replaced correctly (see step 5, 6 & 7). Place the port end cover over the gear housing making certain your alignment marks (figure

23A)

are aligned and the gear journals of the gear set have a light coat of grease on them Recheck the gasket seal

(figure 10 item 10) is still in place. Tap the port end cover

lightly in the center, make certain that the dowel pins are aligned, cover should fit flush on gear housing (figure 46).

24. Thread the bolts & lockwashers in through shaft end cover and 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 47). Torque the bolts in increments until the bolts (qty 4) are torqued to 200 ft. lbs.

Figure 43

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

Figure 44

Figure 46

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Section 2 - 21

PUMP SERVICE & REPAIR

123456

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123456

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

age to the replacement pump in the event the relief valve has been set to high.

27. Before connecting any lines (hoses) to the pump fill all the ports with clean oil to provide initial lubrication on start up, fill the suction hoses with oil. This is particularly important if the pump is located above the reservoir. Use thread

sealant on all fittings and hose threads. DO NOT USE TEFLON TAPE.

28. 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.

Figure 47

Torque to 200 ft. lbs.

Torque to 250 ft lbs.

29. 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 to normal operating settings (See Specification Section).

30. 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)

2345

Figure 48

HYDRO 15 (Service Manual) 09/06

Section 2 - 22

Section 3

HYDRO 15

Service & Repair

HYDRO 15 (Service Manual) 09/06

Motor

Section 3 - 1

MOTOR SERVICE & REPAIR