Mechanical Gearbox Archive-Repair Manual - Alamo Industrial

1 Mechanical GearboxArchive- repair ManualAn Alamo Group CompanyBy Gearbox P/N & Mower Model2002 EditionArchive BookRepair ManualPart LISTINGALAMO INDUSTRIAL1502 E. WalnutSeguin, Texas 78155830-372-3551 2002 Alamo Group 2002 Alamo Group -1G/B repair Manual 07/02 MODELRPMPart NoDate UsedPage - Aug. 1991 to 6 - 7AF60 - Nov. 1990 to Mar. 194 - Apr. 1995 to Current ..112 - 113AG120 Divider G/B Centered Feb. 1996 to 108 - Feb. 1996 to 92 - 95 Outboard G/B Centered Model (LH or RH Blade Box)540 / Feb. 1996 to Mar. 52 - Apr 1996 to - 143 Divider G/B Offset Model (LH Blade Box) Feb. 1996 to 80 - 83 Outboard G/B Offset Model (RH Blade Box) Feb. 1996 to Mar. 120 - Apr. 1996 to 162 - 165AG15-IVDivider Mar. 1985 to Apr. 16 - May 1986 to Jan 18 - Feb. 1988 to Mar. 40 - Apr. 1990 to Mar. 64 - Apr, 1991 to Dec. 40 - Jan. 1995 to 124 - Feb. 1988 to Mar. 32 - Apr.

2 1990 to Mar. 68 - Apr. 1991 to Dec. 32 - Jan. 1995 to 128 - 131 Center 00752140(A)..Mar. 1985 to Apr. 12 - May 1986 to May 24 - Jun 1996 to 132 - May 1986 to May 44 - Jun. 1996 to 148 - 151RH 00752140(A).. Mar. 1985 to Apr. 12 - May 1986 to May 20 - Jun. 1996 to 136 - May 1986 to May 56 - Jun 1996 to 144 - 147LH 00752141(A).. Mar. 1985 to Apr. May 1986 to May 24 - Jun. 1996 to 132 - May 1986 to May 52 - Jun. 1996 to 140 - 143 Index By ModelG/B repair Manual 07/02 2002 Alamo Group -2 MODELRPMPart NoDate UsedPage / AG14 Divider Sep. 1989 to Jul. 40 - Aug. 1994 to Current .. 124 - Sep. 1989 to Jul. 32 - Aug. 1994 to 128 - 131 Center Sep. 1989 to Nov. 24 - Dec. 1996 to 132 - Sep. 1989 to Nov. 60 - Dec. 1996 to 156 - 159RH Sep. 1989 to Nov. 52 - Dec. 1996 to 140 - Sep. 1989 to Nov.

3 44 - Dec. 1996 to 148 - 151LH Sep. 1989 to Nov. 56 - Dec. 1996 to 144 - Sep. 1989 to Nov. 48 - Dec. 1996 to 152 - 155AG415 Divider Mar. 1991 to Nov. 64 - Dec. 1994 to May 124 - 1998 to 36 - Mar. 1991 to Nov. 68 - Dec. 1994 to May 128 - 1998 to 28 - 31 Center Mar. 1991 to 96 - Mar. 1991 to - 107RH Mar. 1991 to 96 - Mar. 1991 to 102 - 107 LH Mar. 1991 to 96 - Mar. 1991 to 102 - 1988 to Jan. 12 - to Dec. 72 - Jan. 1992 to Nov. 76 - Dec. 1998 to 132 - to Dec. 72 - Jan. 1992 to Feb. 76 - Mar. 2001 to 166 - 169 Index By Model 2002 Alamo Group -3G/B repair Manual 07/02 Index By ModelMODELRPMPart NoDate UsedPage 1988 to Jan. 12 - to Dec. 72 - Jan. 1992 to Nov. 76 - Dec. 1998 to 132 - to Dec. 72 - Jan. 1992 to Feb. 76 - Mar. 2001 to 166 - Jun. 1998 to 132 - Apr.

4 1991 to Apr. 102 - May 1996 to 102 - Apr. 1991 to Apr. 84 - May 1996 to 84 - 89AG96 Divider G/B Centered Jun. 1992 to 108 - Jun. 1992 to 92 - 95 Outboard G/B Centered Model (LH or RH Blade Box)540 / Jun. 1992 to Apr. 96 - May 1996 to 96 - 101 Divider G/B Offset Model (LH Blade Box) Jun. 1992 to 80 - 83 Outboard G/B Offset Model (RH Blade Box) Jun. 1992 to Jun. 120 - Jul. 1997 to 162 - 165AT60 - May 1991 to 198 - May 1990 to Apr. 90 - May 1995 to 160 - 161 Grass Flex, ', ', ', ' & 'Divider Jan. 1993 to 116 - 119 Rear Jan. 1993 to 114 - 115 Wing Jan. 1990 to 114 - 115G/B repair Manual 07/02 2002 Alamo Group -4 Index By Gearbox NoDate UsedPage Gater Jun. 1996 to 198 - 199 SHD - 50" - 60" - 74" - 88" - 96" Mar. 1972 to Aug. 196 - Sep. 1990 to - 199 Stingray 10 & 15 Divider Mar. 2002 174 - Mar. 2002 to 186 - 189 Center Mar.

5 2002 to 170 - Mar. 2002 to 190 - 193RH Wing540 / Mar. 2002 to 178 - 181LH Wing540 / Mar. 2002 to 182 - 185 Index By ModelGearbox 12 - 60-63 Gearbox 2002 Alamo Group -5G/B repair Manual 07/02 Gearbox By Gearbox repair MANUALTo Use this Model Type in Index or Find Gearbox Assembly Number in list. Use PartsBreakdown for Gearbox as reference to part assembly Book is intended to be a Quick reference Information, See Operator Manualfor Model if more information is Listed in this Manual show the steps to assemble the Gearbox aswell as the Parts Break Down. The Procedure to Dis-Assemble Gearbox is inmost cases the reverse of the Assembly Index is Listed By Model Name and Date Gearbox Used. It is also Listed ByGearbox Assembly than one Gearbox Assembly may be refered to on same Page, so read allPart Numbers & Parts Descriptions.

6 The Drawing May Not be exact to Scale forSize, Same drawing may be for different Gearboxes, This refers to Gear Sizesand in some case's Gear Location, Read all directions before Gearboxes look very similar, it does not mean parts will interchange,Check all Part Numbers if changing repair Manual 07/02 2002 Alamo Group 001544 ItemPart Asy, (540 RPM)148291 Casing248321 Key30017263 Bearing448341 Oil Seal548351 Input Shaft648361 Crown Gear (30 teeth)748371 Spacer80017211 Internal Clip948391 External Clip1048471 Shoulder Ring1148481 Seal, Dust Shield120017152 Shim1348501 Output Shaft (12 teeth)140017132 Plug1548521 Bearing1648531 Cover1748551 Shoulder Ring1848571O-Ring138,9,10,11,12731431215 16,17,181142,63457G/B repair Manual 07/02 2002 Alamo Group Input Shaft and Gear, Install Front Bearing (item 3) into Main Housing(item 1) Bearing will install from back side of Key (item 2) into Input Shaft, Slide input Gear (item 6) on to Shaft from front Input Seal into Main Housing from the Out Side or Seal can be installed later ifwanted, If Seal is installed coat ID of Seal with light coat of Grease and also coat areaon Shaft where Seal contacts Input Shaft with Gear on it through Seal and Main Housing from the Back of MainHousing.

7 Use caution not to damage Input Seal if it has been Rear Cover O-Ring (item 18) into Housing and coat it with a light coat of Rear Cover (item 16) into Housing, Cover is held in place by Shoulder Ring (item17) which is installed Output Shaft (item 13) , with Bearings and componts as shown in Drawinginto Main Housing (Item 1), install Input shaft before installing Output components onto Output Shaft (item 13), First slide the Shims (item 12) at topof Output Shaft under Gear on use the same quanity as was removed, Install TopBearing (item 3) on till it seats against Lower Bearing Spacer (item 7) on Output Shaft, This Spacer has the OD sameas the Bearings so it will be loose on Shaft. Put Lower Bearing (item 3) on Shaft til itseats against Bearing more Shims (item 12) on output shaft, Use same Quanity as was taken the External Snap ring (item 9) onto Output Out out Shaft, Bearings, Shims, Bearing Spacer and Snap Ring should be all oneassembly now. Slide this assembly up into Main Housing from the Bottom, It may berquired to move Bearing spacer side to side to keep it lined up.

8 Slide assembly in tillupper Bearing bottoms out in Lower Internal Snap Ring (item 8) into lower end of Main Housing, This retainsOutput Shaft and components. DO NOT install lower Seal at this Shaft for end Play and Gear Back-Lash, there should be no end play, If thereis install more Shims (item 12) on Shaft, If Shaft is to tight use less Shims. Gear Back-Lash should be .016" to .019" if it is not then move Shims (item 12) from Top to Bottomor Bottom to Top, Where ever they are moved from they will have to go to the other endto keep End Play Lower Seal ( Item 11 Dust Shield), Coat Seal ID with light coat of grease, InstallShoulder Ring (item 10) Gearbox with oil. DO NOT Fill with Oil above Oil Level Plug. Wait a while letGearbox sit and have time for Oil to run down into lower Bearings and recheck OilLevel. ALWAYS recheck Oil Level after running Mower 1/2 to 1 hour. Inspect Sealsfor leaking after filling with Oil and after running 1/2 to 1 001544 Assembly InstructionsG/B repair Manual 07/02 2002 Alamo Group Section -8 GearboxP/N 0074900361334,3512,15940,41,424419,36,45 102616,174,3927,281112443383,29,30318331 4,1519,36,451122,23520,2125729,3029,3072 520,21522,231119,36,454,39 Top ViewRight SideViewFrontBack 2002 Alamo Group Section -9G/B repair Manual 07/02 ItemPart Asy(540 RPM)

9 1007494771 Main Housing2007494781 Cover300749479-Locking Compound4007494801 Cap5007494812 Housing Divider6007494821 Shaft, Blade7007494832 Shaft, Side Output8007494841 Shaft, Input9007494851 Retaining Ring10007494861 Retaining Ring11007494873 Gear, 17 Tooth12007494881 Bearing Cup13007494891 Seal14007575331 Bearing Cup15007494911 Bearing Cone16007494921 Bearing Cup17007494931 Bearing Cone18007494941 Bearing Cone19007494953 Cotter Pin20007494962 Bearing Cup21007494972 Bearing Cone22007494982 Bearing Cup23007494992 Bearing Cone24007495001 Retaining Ring25007495012 Seal26007495021 Plug27007495034 Bolt, Hex Head28007495044 Lockwasher290074950514 Bolt, Hex Head300002220014 Lockwasher31007495071 Plug, VentTorque Item 43 to 100 ft. 00749003 ItemPart Cup35007495111 Bearing Cone36007495123 Nut, Slotted37007495133 Shim, Fiber .005"007495143 Shim, Alum .007"007495151 Shim, Alum .020"38007495161 Shim, Alum .005"007495172 Shim, Alum .007"007495181 Shim, Alum .020"39007495192 Shim.

10 005"007495202 Shim, .007"40007485394 Nut41007485384 Bolt42000039014 Lockwasher43007495241 Gear, 25 Tooth44007495251 Gear, 17 Tooth45007495263 WasherG/B repair Manual 07/02 2002 Alamo Group Section -10 Installation Part Numbers are for Gearbox #00749003 (540 RPM) Output Shaft (Blade Shaft) First, Install Bearings, Gears, Shafts and Componentsin Main Housing (item 1) Main Housing (item 1), Front Bearing Cap (item 2), Rear Bearing Cap (item 4) and thetwo Side Drive Housings (item 5) for condition, this will include checking where Retaining Ring(item 9 & 10) are inserted in lower end (output Shaft area), All seal areas for Burrs or scratchesthat will cause Seals to Leak., Inspect all Bolt Holes and threads, Inspect all areas whereBearing Cups must Internal Snap Ring (item 10) into bottom and Internal Snap Ring (item 9) into MainHousing (item 1) lower opening for Output Shaft. Make sure they are seated in Lower Bearing Cup (item 34) thick end first into housing from the bottom, Cup shouldgo in till it is seated against lower Retaining Ring (item 10).