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Alamo DSEB-D16 User's Manual

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1. 2 Welding Mounting Tubes all the way around The Mounting Tubes must be welded to the High Frame all the way around Turn High frame as required to weld allthe way around See Figure 49 amp 50 These must be strong Welds 1 Left Side of High Frame amp Mounting Tube Weld Solid all the way around A PV E a ae _ Weld Solid all Figure 47 the way around i 5 i 1 v D Turning High frame to weld I fe w 3 mening High frame to weldhall the way around Mounting Tubes aC P around sa Pa gt p Tann Va S X Ne KN A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 4 21 Frame Rail Installation Remove High Frame for Welding 1 Remove Frame Rails Itis best to remove the Frame Rails to weld them Frame Rails will need to be welded in five places Note The RH Frame Rail and the LH Frame Rail will have the same Welding done For Illustration we are showing the RH Frame Rail but the LH will have to be done also 1 Do Not Weld next to Bolt Holes iit will interfere Hex Heads of Bolts q 2 Weld Front Mount Plate Weld down each side between Bolt Holes Do not Weld to where the Weld will interfere with the Hex Head of Bolts when they are installed Also weld across the Front of the Mounting Pad See Figure 51 55 amp 56 3 Weld Front Angle Mount Weld the Front Angle Mount to the Frame Rail on the Sides r
2. 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Index 4 INDEX ASSEMBLY INSTRUCTION Page Section 7 Cutter NTN NE 7 2 Boom Installation BOOM HoS6S eira 7 2 to 7 3 Pump Tank Hose Installation 7 4 to 7 5 Section 8 Control Handle Asy Installation Mechanical Valve 8 2 ON OFF Switch Schematic Standard Mechanical 8 3 ON OFF Switch Installation Standard Mechanical 8 4 Control Valve Operation Standard Mechanical 8 5 Hydraulic Hose Schematic Standard Mechanical 8 6 Hydraulic Hose Control Circuit Standard Mechanical 8 7 to 8 8 Remote Control Cable Installation Standard Mechanical 8 8 to 8 11 Section 9 Joystick Mount sla 0 9 2 Install Joystick Mount to Seat 9 3 Install Joystick Controler to Seat Bracket 9 4 Tractor Floor MARTEL oa eres dino Ene patri 9 4 Wire Harness to Tractor Connections 9 5 to 9 6 Tractor Ignition Wire Connection 9 6 Connect Wire Harness to JoystiCk nn 9 6 Tractor Floor EN ge a gesto PE O EO de cac 9 6 Tractor Cab De calINS Ned 9 7 Connect Wire Harness to Control Valve 9 8 to 9 13 Section 10 Attaching Flail Axe TODO ra asso nana cms mens 10 2 to 10 3 Attaching DIICNSTH AD aie annee 10 4 AUaching IIMDEercat Headline 10 5 Attaching X Frame Square Head 10 6
3. See Figure 3 The Boom will have to be lifted again when Head is installed Do not lift Boom with Hoist if the Cylinder hoses are open the Cylinders are built with the inter nal components covered with Oil If boom is raised by hoist while these hoses are discon nected oil may be forced out of collapsing end of cylinder High Frame Attach Swing Swing Cylinder Mount Cylinder to King Post and High Swing Cylinder Butt End A Boom JD6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 7 3 Hose Installation Pump Tank Hose Installation 1 Suction Hose Tank to Pump The Suction hose connects to the front RH side of Tank See Figure 8 and runs through a Hose Ring that is welded to the frame Rail See Figure 9 The Suction Hose connects to the front Pump on the Left Hand Side of Pump See Figure 10 2 Connect Pressure Hoses There are two pressure hoses that connect to the Pump The Larger Hose See Figure 10 amp 11 runs through a weld on Hose Ring and to the Cutter Motor Control Valve See Figure 12 The Small Hose runs to the Cyl Control Valve Connect the smaller hose to the pump and route with the larger hose ml _ pref 3 z F u 2 SUCTION HOSE Hose Ring M Sn Pump Pressure Hose to Cutter Motor Control Valve Tank Return Hose Side Pump Pressure Hose to Cutter Motor Control Valve Pump Pressur s Hose Side to Cyl Contro
4. Wire Harness Valve Mounting 2 WD amp 4 WD Installing Wire Harness To Valve 1 Wire Harness From Cab to Front The wire harness runs out the bottom of the Cab on the right hand side Run Harness along RH Frame rail of Tractor to the front of the Tractor See Figure 19 Note the wire i harness runs along with the hydraulic Hose Wire Harness runs along from the Tractor Stack Valve to the front of Tractor Frame Rails the tractor Do Not tie the Harness or Hoses Fn to the Tractor frame rail at this time 2 Wire Harness amp Front Rail Support The wire harness runs behind the front rail support on the RH side along side the hoses from the rear Tractor Stack valve See Fig ure 20 Do not tie any hoses or wire harness at this time Run Wire Harness along the front RH side untill it reaches the front of the Tank See Figure 21 a Pry them Run Wire Harness 4 Gaskets on Valve Terminals There are 5 wire terminals on Valve A Gasket will have to installed on each one These gas kets will only fit one way there are 4 slots in gasket 1 Slot is wider than the other 3 align these slots with correct terminal on Valve See Figure 22 amp 23 These Gaskets must be used Wire Plug Harness 2 Gaskets vi fi A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 9 8 Wire Harness Valve Mounting 2 WD amp 4 WD nstalling Wire Harness To Valve Cont
5. bench gt r 7 s f 1 ll a KW cg A i i i es Lie s ta LI J D Va installing Pump Driveshaft Spline 1 Install Pump into Splined Clamp Yoke Slide Clamp Yoke End the Pump Splined Shaft into the Spline Clamp Yoke See Figure 11 Leave the Bar stuck in through the Yoke as shown this helps to stabilize the Yoke as you slide Shaft into the Yoke Once Pump is slid into the Splined Yoke keep the Pump supported DO NOT let the Pump hang on the Yoke unsupported Barto Hold Driveshaft 2 Pump Driveshaft Yoke Gap Adjustment After sliding Pump Shaft into Splined Clamp Yoke the Pump and Yoke must be slid apart far enough to allow for a 1 16 to 1 8 Gap between them The Yoke edge cannottouch the Pump Housing it will damage the Housing and the Yoke if it does This is a very critical adjustment See Figure 12 Clamp 3 Tighten Clamp Yoke After Gap between M Ugo Boj Yoke and Pump has been adjusted tighten the Bolts amp Nuts on the Clamp Yoke See Figure 12 amp 13 Check Pump to Yoke Gap once more Keep Pump Supported do not let it hang on Yoke Splined Clamp Yoke 1 16 to 1 8 G Align Splines of A between Pump amp a Pump Shaft w Yoke must e ta PR a W y Barto Holo A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 3 5 Pump Drive Assembly Instructions
6. 1 The tractor won t start The mower on off switch if left in the on position will not allow the tractor to restart Be sure to push the switch into the off position and account for allthe tractor safety interlocks to enable the tractor to start Failure of the tractor starter safety lock system is normally attributed to a failure of the mower on off switch Check continuity at the switch Check for loose connections 2 Cutter motor won t start Normal causes of this type of malfunction include failure of the push pull switch failure of the solenoid coil loose connections loss of ground or a blown fuse If the mower won t start check continuity of the system with a test light to find an electrical problem Problems may also exist in the cutter valve and other systems 3 The problem may not be in the electrical system but because there are so many connections that could be malfunctioning it is the best place to start checking If the electrical connections are ok go on to the Tractor connections and or the Tractor components to check for the malfunction Some times the service technician thinks the best way to eliminate the Mower electrical connection problem is to bypass them this should never be done eliminating the starter safety system is dangerous and hard on the Hydraulic System The Hydraulic System will be trying to start at a low RPM which is not good Standard Control Valve Operation 1 This Control valve is the St
7. 1458392 Red Reflector 1458392 Yellow Reflector mount in front of CWT Cover 00756059 Warning Oil Leak 02957827 Danger Multi Hazard Rotary or 002369 Danger Multi Hazard Flail 8 4 02965262 Warning Hose Burst 9 002508 Alamo Industrial Logo Small on front upper Tank 10 4 00769394 Alamo Industrial Logo Large 2 1 2 3 4 5 6 7 Most Decals should already be installed when Tank Asembly is shipped A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 6 3 Decal Installation Cab Decal Installation 1 Install Decals on Windows inside Cab There are 8 decals that need to be installed on Windows and inside Cab of Tractor Clean all surfaces before installing Decals Do Not Install any Decals that will interfer with the Operator line of sight See Figure 35 36 37 38 2 Decal Part Number 1 amp 02962107 Valve Operation 5 Spool or 02962024 Valve Operation 4 Spool Install in lower Right Hand corner of Tractor Windshield See Figure 35 2 H0296 82 Danger Multi Hazard install in upper right corner of Left side window See Figure 36 3 02965262 Warning Hose Burst Install in upper left corner of Left Side window See Figure 37 4 0296467 7 Warning Boom Rest install in upper right corner Right Side Window See Figure 38 5 02963524 Attention Boom Swing install in upper right
8. Frame R ji Mounting installing them The RH and the LH Rail will install to the Tractor the same except for the Boom rest that installs on the RH Rail Rear Mount It is best to do the Left Hand Frame Rail first then the RH Rail Use a Hoist to install Frame rails to Tractor See Figure 1 Zi Install the Bolts into the rear Axle Housing to support the rear of the frame rails This is the same for LH amp RH Snug the Bolts only Do not tighten them yet because the frame rails will have to be moved around to align all the Bolt Holes See Figure 56 The RH rear Frame Rail Mounting will need the Bolts removed to install the Axle Mounted Boom Rest See figure 5 6 amp 7 0 Mounting to 3 Install the Bolts into the front mounting i a Rear one n a iy VP 2 lates on the LH and RH Side Snug them only CR See Figure 3 4 Install the LH Axle Straps The LH Axle Strap can be installed now See Figure 4 The Left Hand Axle Strap uses two long Bolts with Nuts The Bolts go down through the Holes in the rear Axle Mounting Plate that is welded to the rear of the frame rail Once the Rear Axle Strap is installed the Bolts for the LH Frame Rail and Axle Strap snug the Bolts only do not tightened them down See Figure 1 2 3 amp 4 Front Mounting Peds A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 5 2 Frame Rail Installation Re Install Fra
9. Installing Pump continued 5 Mount Pump to Pump Plate Remove the Bar that is slid through the Driveshaft Yoke and push the Pump inward See Figure 14 This will make the two piece Driveshaft slide together al lowing the Pump to be pushed towards the tractor Do this untill the Pump is against the Pump Plate See Figure 15 6 Install Pump Mounting Bolts While holding in on the Pump See Figure 15 start the two Pump Retaining Bolts Make sure both Bolts are started well before you stop supporting pump The Bolts should be snugged untill pump sits level before you stop supporting it See Figure 16 Let go of the Pump it may slide back some and leave a slight gap between Pump and Mounting Plate See Figure 16 7 Tightening Pump Mounting Bolts Thereis a shoulder on Pump Flange that must line up through hole in Pump Mounting Plate See Figure 14 if the Pump is slid back as in figure 14 try to push it inward untill it is against Pump Mount Plate as shown See Figure 15 Slowly and alternating from Left to the Right side tighten the Pump mounting bolts untillthey are tight DO NOT FORCE Pump through Pump Mount Plate if it will not freely slide in check for a problem of some kind Excess force could damage Pump Housing See Figure 16 Do Not remove any Plastic caps from Pump inlet or outlet at this time keep all openings plugged and sealed to keep them clean Pump Retaining Bol
10. Section 11 Filling Hydraulic Tankw Oil eee eee nenene 11 2 to 11 3 Section 12 Penne 12 2 Post Assembly Check List 12 3 Section 13 Boom Rest Plate Installation 13 2 to 13 3 Boom Swing ke te ea Ede ATOM PO ici 13 4 A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Index 5 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Index 6 SAFETY SECTION SAFETY Read these assembly instructions through completely and understand them before proceeding with the assembly of the equipement A safe and careful operator is the best operator Safety is of primary importance to the manufac turer and should be to the owner operator Most accidents can be avoided by being aware of your equipment your surroundings and observing certain precautions The first section of this manual includes a list of Safety Messages that if followed will help protect the operator and bystanders from injury or death Read and understand these Safety Messages before assem bling operating or servicing this Implement This equipment should only be operated by those persons who have read the Manual who are responsible and trained and who know how to do so safely and responsibly The Safety Alert Symbol combined with a Signal Word as seen below is used throughout this manual and on decals which are attached to the equipment The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR
11. See Figures 1 through 27 Tighten LH Side 4 TE a p ve A 5 i 4 7 Bd sen u gt STA Col al M s e TA AIN v D dol Bi Km i Tighten LH 8 RH KS s E A n lc a o o 4 i v a o me lt e i i v Tighten LH amp RH Side A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 5 7 Frame Rail Installation 4 WD Re Install High Frame to Tractor continued 9 Frame Mount should look like Shown below is basically what the High Frame should look like when assembled See Figure 26 Mounting Angle Mounting Bar Mounting Strap Tube Bolts amp Nuts Wleded to Frame Mounting Tube Frame Rail Approx 1 2 from end of A frame rail Mount P ate p T Bolts 4 A pl Support Bar Mounting Straps Mount with Bolts amp Nuts INI MN 5 Machete High Frame jg Rail 10 Tie Hoses to Tractor Frame Rail Use Plastic Wire Ties to tie the Hoses and Cables from the rear of the Tractor down Frame Rails Note below it is shown with the Frame Rails not mounted to Tractor this is done for illustration only See Figure 27 Inspect all the Hoses Wire harness and Cables to make sure they are secured and will not be rubbed or chaffed on anything Hoses and Wire harness should not be hanging down where they will be caught on anything If there is excess length in h
12. the end NE 7 Mounting that has the Angle Mount bolted to it goes to sA SEAN ds the Front away from the Tractor Cab The mounting Tube should be slid back till the end of mounting tube is about 1 2 from the end of the Frame Rail See Figure 34 Do Not Tack Weld any components at this time Note in figure 32 note the location of High Frame Tube Height as compared to Mount ing Tube Height this is the way that it will appear as looking over the Hood of the Trac tor toward LH Side A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 15 Frame Rail Installation Pre Install Mounting Tubes for High Frame continued Washer 1 8 thich inserted 10 Install Front Angle Mount Loosely Raiden blate SOn Front Angle Mount end Only bolt the Front Angle Mount on the other end front of each Mounting Tube See Figure FE 33 Notice the washer that is installed be _ Angl tween the Angle Mount and Mount Tube This p m is there because about a 1 16 Gapis needed Dm between the Mount Tube Plate andthe Angle Mount Plate Putting this 1 8 thick washer on the front Angle Mount end only will allow for this Gap on both ends See Figure 33 amp 34 This should be done on right hand and left hand side Mounting Tube This Gap allows the High Frame with the Mounting Tubes welded onto it to be lowered down between the front and rear Angle Mount which will be welded to the Frame rails later Do not do
13. 3 2 Pump Drive Assembly Instructions Installing Pump Drive Front Cover Components u 2 Access to Crankshaft Pulley The Factory Crankshaft Pulley will notneedto be removed The Pulley Adapter will be bolted to the Factory Crank shaft Pulley 3 Install Pulley Adapter The Pulley adapter to be used is a round plate with 4 threaded holes and four non threaded holes init Notice this pulley adapter willnothave a center hole in it See Figure 4 The Non treaded holes are Retaining used to mount the Adapter to the Pulley using Doc zo bolts 02979791 10mm 1 5 P X 35mm Gr 10 9 amp Lockwasher 00755954 10 mm Do notuse longer bolts to mount Pulley Adapter to Pulley than is supplied with mounting kit 4 Driveshaft Assembly The drive shaft is a two piece Assembly an inner and outer shaft assembly See Figure 5 The Shaft End has a four bolt flange yokes on it that connect to the Crankshaft Pulley Adapter The Tube end has a splined clamp yoke on it that connects to the Pump This Drive Shaft connects to the Pulley a Adapter Note that the Universals of the Driveshaft Pump Plate Mountiag H are intime When installed in tractor they should be K mw in time as shown both Yokes the same 4 4 Threaded Non Threaded Hales Splined Clamp Yoke a Tube End Flange Yoke Shaft End Pulley Adapter i Si NY Drive Shaft Part 02979790 MEP Assembly JR EK A Boom JD 6615 7615 Asy Instru
14. Frame Rail Horizontal Tube High Frame Horizontal Tube MA Frame Rail leading to rear Machete High Frame Vertical Tube Frame Rail Tube 8 Frame Rail must be align parallel with each other up and down here Set High Frame in Line with Frame Rail Vertical Tube as shown Po Frame Rail Vertical Tube Axle Housing of Tractor 8 Re check all alignment points Re check the alignment of the Frame Rails and High Frame for level mounting position These components must be aligned now before any Tack welding begins A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 14 Frame Rail Installation Pre Install Mounting Tubes for High Frame continued Machete High RH Frame Rail Front Shown Frame Rail to Rear Axle Mounting Cut one end off Tube Width Item Part No Qty Description 1 Mounting Tubes Length may Vary with Mount Kit Bolt 3 4 X 2 Long Not Shown Locknut 3 4 Toplock Not Shown Bar Mounting Strap Bar Mounting Strap Cut one end off LH Rail only Locknut Toplock Bolt 3 4 X 10 1 2 Long Angle Mount Front only 02918600 00037200 02966639 02966639 00037200 02957039 02966641 ND D Oo R BR D 9 Install Mounting Tubes Loosely bolt ET the Front Angle Mount end of Mounting Tube High Frame JH See Figure 32 Slide 1 Mounting Tubeinon Mere Ty Oy top of the Frame Rail on each side
15. SAFETY IS INVOLVED The Symbol and Signal Word are intended to warn the owner operator of impending hazards and the degree of possible injury faced when operating this equipment Practice all usual and customary safe working precautions and above all remember safety is up to YOU Only YOU can prevent serious injury or death from unsafe practices CAUTION The lowest level of Safety Message warns of possible injury Decals located on the Equipment with this Signal Word are Black and Yellow WARNING Serious injury or possible death Decals are Black and Orange DANGER Imminent death critical injury Decals are Red and White sc A A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Safety Section 2 SAFETY PELIGRO Si no lee Ingles pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad sa 3 ILEA EL INSTRUCTIVO READ UNDERSTAND and FOLLOW the following Safety Messages Serious injury or death may occur unless care is E taken to follow the warnings and instructions stated in the Safety Messages Always use good common sense to avoid hazards SG 2 p PELIGRO Sino lee Ingles pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad sa 3 i LEA EL INSTRUCTIVO Perform service repairs and lubrication according to the maintenance section Ensure the unit is properly lubricated as specified in the l
16. Tire Limit This should be Z addressed when ordering the Mount Kit designed E to fit with the specified Tire Size If larger than Tires specified for Mount Kit are installed mount ing kit may not fit RCS GAAR Tm r7 UT A T The Pig Tail Brackets will be welded to the underside of the Rails so it will be necessary to scrape the paint off from this area before attaching and welding them See Figure 57 These Pigtails are to hold the Hoses up Be sure to run the hoses for the Boom through these Pigtail rings NOTE All parts are painted When welding is required scrape away the paint in the area to l PTT be welded to help assure the integrity of the Mn weld Repaint Touch up welded parts after tav u finished welding Weld here on Do not weld Pigtail Bracket both sides Across the Tube a p AM T TM i 7 CUT Il us hd a a Z t at Not Shown in Figure 57 Actual Location A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 23 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 4 24 section 5 A Boom Frame Rail amp High Frame Final Installation A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 5 1 Frame Rail Installation Re Install Frame Rails to Tractor 1 Re Install Frame Rails With the Welding done touch up or re paint frame rails before re
17. are torqued to 170 ft Ibs casse King Pin Retaining Nut is properly locked in place canos All Welds inspected toinsure proper welds and locations Hydraulic System emma Oil Level in Hydraulic Tank is within the sight gauge Item 5 page 1 5 Hose connections are tightented according to specifications Hoses do not have any kinks or twist in them ae Front Pump Shaft adapter bolts are tight Item 6 page 1 5 mm Front Pump Shaft Coupler Drive Shaft is lubricated and has an anti seize compound on the Splines of Pump and Shafts Item 7 page 1 5 acess The Pump Drive Shaft has correct alignment Suction Hose has no leaks or kinks Rotary Mower Head mme Skid Shoe Bolts are torqued to 120 ft lbs Item 8 page 1 5 cons Spindle Housing Bolts are torqued to 400 ft Ibs Item 9 page 1 5 cose The Spindle Housing is properly lubricated item 10 page 1 5 Motor Bolts are torqued to 120 ft Ibs Item 11 page 1 5 Blade Carrier Bar Bolts torque to 400 ft lbs Item 12 page 1 5 All Blade Bolts are torqued the retainings Pins are in place item 13 page 1 5 nose Blades Swing freely Item 14 page 1 5 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section1 3 A BOOM PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component lo
18. area is clean Material the size of a human hair can contaminate the Hydraulic System Required A place to keep all Components separate and clean untill ready for them Recommended Electrical Butt connectors and Electrical Pliers Required Paint Scraper to remove Paint before welding Recommended Floor Jack 2 1 2 Ton capacity Required An asortment of large C Clamps Required A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 1 2 A BOOM PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection After Assembly is complete Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component location Saftey Equipment conse Operators Manual is with Unit The Safety Decals are installed as listed in the Assembly Manual Valve operation plate is installed nonne Operators cage or Tractor Cab is in place Item 1 page 1 5 0022 Deflectors are installed on the Mower Head Item 2 page 1 5 Tractor Rops or Cab with seatbels installed properly Frame and Boom Axle Plate Bolts are torqued to 240 ft lbs Item 3 page 1 5 Boom Rest Axle Plate Bolts are torqued to 240 ft Ibs 20022 Front Rail Bolts are torqued to 170 ft Ibs Item 17 page 1 5 canos Front Support Bolts are torqued to 240 ft Ibs Item 4 page 1 5 esse Hydraulic Tank mounting Pins Bolts in place correctly caos Boom Main Pins
19. both directions It is important to plumb the motor so that it rotates to deposit the spoil properly The direction of rotation can be observed by standing behind the Ditcher Head beside the right rear tire If the Ditcher rotates clockwise it is plumbed for forward rotation and the spoil will be deposited away from the tractor If the Ditcher is the reverse design then the proper rotation is counter clockwise when observed from the rear Do Not try to reverse Ditcher from Rotation it was designed for it will not work The Forward and reverse Rotation Models do not use the same Blade Assembly 4 Note The two hoses P N 02961054 connecting the main boom to dipper arm are used to connect the Ditcher motor The 90 degree fittings attach to the fittings on the main boom and the straight fittings attach to the 90 degree fittings on the hydraulic motor See Figure 69 below WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connec tions before applying pressure Keep hands and body away from pinholes and mozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid under pressure is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result A Boom JD6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Se
20. bottom na gt Weld Gusset to Stabilizer on both sides A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 5 4 Frame Rail Installation 4 WD Re Install High Frame to Tractor 1 High Frame Paint Re Paintor Touch up Paint on High Frame now before lowering it on to Tractor Keep in mind there will be one more Place to Weld on High frame that will need touch up Paint later this will be the Counter Weight Lug that weld to High frame The Lug for the Counter Weight will be installed later 2 High Frame Mounting to Tractor This is a two Person Job to maintain control of High Frame and guide it down over frame rails See Figure 14 3 Align High Frame The High frame with the Mounting tubes welded to it will sit down over Frame Rails The welded on Mounting tubes will slide down into the Angle mounts that are weldedto the Frame rails See Figure 15 amp 16 Both sides must go down evenly s between the front and rear s 4 Aligning Mounting Holes The Holesinthe Angle angle mount Mounts welded to the Frame Rail and the Mounting Tube Plates that are welded to the High Frame must be aligned This can be done with a Pry Bar inserted into one of the holes and moved around See Figure 17 In some cases the Frame Rails may have to be moved slightly this is the reason the Bolts were only snugged and not tightened Do not take Hoist off of High Frame untill all Bolts are tightened T
21. connected to the frame below the cab If grounding to the Cab Tractor floor connect ground now Ignition Switch 9 Install Wiring Harness to Joystick Pull the Wiring Har Cut Tractor Starter ness up till it touches the bottom Wire to Starter Sole of the Joystick connection See noid and reroute Figure 14 Align the Plug Guides through Joystick there are 1 wide and 2 narrow Harness Brown lugs that prevent the plug from wires being installed wrong Screw the plug retainer onto the Joystick Plug this will be hand tightened Joystick Wiring FIG U RE 1 3 Harness 10 Reinstall Floor Mat DO NOT cut Floor Mat Make sure you have remounted the wire harness protector over wire harness under floor mat See figure 8 Push the wire harness over against the side panel See Figure 15 Putthe floor mat down as it was originally When finished floor mat should be as smooth as it was before installation A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 9 6 Joystick Mounting 2 WD amp 4 WD Installing Warning and Instruction Decals 1 Alwaysclean windows before installing decals Windows must be dry and free of any oil after cleaning do not touch windows before decals are installed Take precaution to make sure decals are right side up and straight when installing them they cannot be taken off and redone di Identify Decals Lay all the Decals out and ID each one so you will know which is in
22. it See Figure 2 amp 3 Itis 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 cleaned first 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 See Figure 4 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 11 2 Fill Hydraulic Tank Fill Hydraulic Tank with Oil 5 Fill Tank Fill the Hydraulic Tank See Figure 4 Fill tank till the Oil is visable in the sight Gauge See Figure 5 amp 8 This will fill tank for the start but it will have to filled again later 6 Fill Suction Hose with Oil Remove the Suction Hose at the Tank See Figure 6 and fill the hose with clean oil THIS IS A MUST DO The Suction Hose must be filled 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 See Figure 7 A k k dp Filler Cap gt P 4 N a 1 gt ut m CE A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 11 3 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Se
23. raised if passersby bystanders or traffic are in the area to reduce possibility of injury or death from objects thrown by Blades under Guards or mower structure 8 Before dismounting secure implement in transport position or lower to ground Puttractorin park or set brake disengage PTO stop engine remove key and wait until noise of rotation has ceased to prevent crushing by entanglement in rotating parts which could cause injury or death Never mount or dismount a moving vehicle Crushing from runover may cause serious injury or death 5 TRANSPORT SAFELY 6 USE SMV LIGHTS 8 7 DO NOT OPERATE WITH 8 DO NOT MOUNT OR REFLECTORS CUTTER OR WING RAISED DISMOUNT WHILE NNN 02967827 WARRANTY INFORMATION Read and understand the complete Warranty Statement found in this Manual Fill out the Warranty Registration Form in full and return it 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 The use of will fit parts will void your warranty and can cause catastrophic failure with possible injury or death INTRODUCTION ABOUT THIS MANUAL The intent of this publication to provide the competent technician with the information necessary to perform the CORRECT Assembly 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 provid
24. to assist you in tracing wires through harness if needed Do not change or modify the harness plugs in any way Servo Control MEtaltiel e hete Jalel e A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 9 10 Joystick Plug Bottom of Joystick Console Joystick w Push Pull Motor Switch amp Rocker Master Switch Dbl Trigger Switches FIGURE 30 Danfoss Command Circuit Joystick B J D C K Rocker Switch Positive Z Output B D LB J Wht BIk E i 5 Wht Bik mn E Motor Push Pull Switch With Momentary Start Grnd Master Switch E Te _ Grey Blk E Org Blk M M Brn Bik m Actual Pin Location IS SHOWN in this Illustration Narrow Notch 2 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 9 11 Wire Harness Joystick Console Plug to Valve Actual Pin Location is Shown for Plug in Wire Harness Plug New Style this Illustration Narrow Notch 2 Start Solenoid Loop Piston Pump M Soleniod Lock Valve DIPPER TILT DOOR EXTEND A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 9 12 Control Valve Electric Hydraulic CONTROL VALVES See Figure 32 The Alamo A Boom Optional Hydraulic Control Valve is an Electro Hydraulic Electric over Hydraulic Valve The Valve is designed to utilize Oil from the Tractors Hydraulic System This is b
25. to find which hose is hooked to which end of a Cylinder Listed below is a list of which end of Hydraulic Cylinder should be connected to which Port on valve See Figure 2 amp 3 MECHANICAL VALVE MODELS Cylinder Rod End Port Base End Port Tilt B A Standard Extend Door B A Only used with 28 Model or Optional Cutter Door Dipper B A Standard Lift A B Standard Swing A B Standard You must consult the Parts Manual to determine correct Hoses used on the Model you have Also the tyoe Head used will make the Hose vary There is a Electrical control valve Option this will make a difference of which hose is connected where If the hoses are connected to the wrong side of valve it should not damage any thing it will mean that the control lever function will be reversed or may not work at all because the Relief Valve is in the wrong direction of Oil Flow to operate Changing the Hoses on the hose ports of the valve will change this REMOTE CABLE OPERATION AND INSTALLATION 1 Remote operation of the boom movement control valve can be achieved with the use of cables and remote actuator handles The remote operation system is standard equipment on cab tractor units and can be installed on ROPS tractors as well See Figure 4 Four cable lengths are available and should be ordered based on the length required to reach from the valve to the Operator s location with out binding or kinking Cable lengths are l
26. tractor and implement to prevent misuse abuse and accidents Practice before operating in a confined area or near passersby Learn how to stop engine suddenly in an emergency Be alert for passersby and especially children 2 Allow no children on or near folding mower or tractor Allow no riders on tractor or implement Falling off may cause serious injury or death from being run over by tractor or mower or contact with rotating blades 3 Operate SAM with tractor having Roll Over Protective Structure ROPS and with seat beit securely fastened to prevent injury and possible death from falling off or tractor overturn Personal Protective Equipment such as Hard Hat Safety Glasses Safety Shoes amp Ear Plugs are recommended 4 Block up or support raised machine and all lifted components den before putting hands or feet under or working underneath any lifted component to prevent crushing injury or death from sudden dropping or inadvertent operation of controls Make certain area is clear before lowering or folding 5 Before transporting put Lift Lever in detent or full lift position Install Transport Safety Devices securely on folding mowers Put Booms securely in Transport Rest Folding and Boom Mowers have raised center of gravity Slow down when turning and on hillsides 6 Make certain that SMV sign waming lights and reflectors are clearly visible Follow local traffic codes 7 Never operate with Cutting Head or Folding Section
27. www Alamo Industrial Com Attempt to diagnose or repair problem before calling 2 If a callto 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 and Information provided by customer CONTACT ALAMO INDUSTRIAL Alamo Industrial 1502 E Walnut St Seguin TX 78155 Technical Service Dept PH 830 372 2708 A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Index 3 INDEX ASSEMBLY INSTRUCTION Page Safety Section Operation Salely ziss a osiruu kudaz sn uu du inu i aj 1 Section 1 Tools and Supplies Needed f AssemblY 1 2 Pre Dilivery Check List 1 3 to 1 5 Sectio
28. 7 Assembly Tools Supplies and Equipment Needed Tools that are recommended to complete this assembly There are number of different ways to do things some items are recommended to make assembly easier but may not be required An over Head Hoist the hoist or Lift should be a 2 1 2 ton capacity minimum Hoist should be able to move and stop within fractions of an inch Hoist should also have a 12 foot lift Required Compressed Air Air must be filtered and dry A Safety air nozzle for blowing out Hoses and Fitting prior to assembly Required Complete Air Impact Sockets 1 2 Drive and 3 4 drive Recommended Torque Wrench 400 ft Ib rating can use a Torque Amplifier Wrench Required Complete Set of Hand Wrenches from 7 16 to 2 Recommended Assortment of Screwdrivers Short ones and Long ones Required Electric Grinder or Air Grinder Size according to needs Required Burr Grinder Electric or Air optional for resizing Holes and removing Burrs from stamped metal or stamped holes Required Welder capable of welding up to 3 8 material Use experienced Welder Personel Required Flame Proof or flame retardant Material to Cover and protect Tractor finish and components during assembly Required A good fire Extinguisher on hand before any welding or grinding begins Required Clean dust free work area clean Lint Free towels or wipes Do not do any welding use compressed Air or lay out any component unless
29. 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 3 Frame Rail Installation Frame Rail Pre Assembly continued Frame Rail Stiffener Kit Crossmember Shown below is the Frame Rail Stiffener Kit This mounts under the Tractor and will be added to the Frame Rails during Assembly Item 5 Rail Support Gussets are shipped loose and are not part of the Assembly they will be bolted to the tractor and when instructed you will need to weld the Frame Rail Support to them See Figure 2 Frame Stiiffener Kit Frame Rail RH Shown Frame Rail Stiffener Kit Crossmember Part No Description 02970118 Frame Rail Stiffener Kit Item 1 thru 4 02970115 Rail Stiffener Weldment 02970086 Tube Rail Stiffiner 02712500 Bolt 1 NC X 4 GR8 5JRC1680 Locknut 1 NC Toplock 02978499 Gusset Rail Support A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 4 Frame Rail Installation Frame Rail Pre Assembly continued High Frame Mounting Tube Components See Figure 3 amp 4 These Components are to be laid out and will be tack welded to frame Rails and High frame during Pre Assembly Process Locate and ID these Parts for later installation Remember DO NOT Weld any components untill instructed to do SO High Frame Mounting Tube Componnets Machete High RH Frame Rail Front Shown Frame Rail to Rear Axle Cut Off Width of Frame Rail Tube Part No Descr
30. Also the ON and OFF Switch will bolt to the Handles See Figure 15 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 8 11 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 8 12 section 9 A BOOM Optional Joystick Wire Harness amp Valve Installation Section 9 1 Optional Joystick Mounting 00 Aa QT w Cushion Removed Three Existing Holes F 4 FIGURE 1 Item Part No Qty Description 1 00011100 2 Flatwasher 3 8 2 00012101 2 Lockwasher 3 8 3 00011400 2 Bolt 3 8 NC X 1 4 00750940 3 Locknut 5 16 Toplock 5 00023500 3 Flatwasher 5 16 6 10119000 3 Bolt 5 16 NC X 1 7 02978806 1 Bracket Seat Mounted Joystick Bo 1 Joystick Shown as Illustration Only Q Tractor Seat A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 9 2 Option Joystick Mounting nstalling Joystick Mount to Irac tor Seat 1 Remove Tractor Seat Cushion Remove Lower Seat Cushion from Tractor Seat The Seat Cushion should have three phillips head screws across the front edge See Figure 2 Once these screws are removed lift up on the front of the Seat Cushion which should slide forward and out 2 Joystick Bracket mounting holes The three mounting holes are already in the Standard Seat Mounting Plate If a custom Seat or for some reason these thr
31. End Installation Procedure 1 Each controller assembly comes fully as sembled All required hardware etc is included The control cables are not included with the control handles and should be ordered separately The Controller must face forward as shown or controls will be backward See Figure 12 2 Toattach the cable manipulate the controller handle so that the attachment nut is exposed as shown Remove the lower most nut and screw from the controller housing Thread the cable nut into the controller attachment nut and tighten See Figure 13 3 Allowthe controller handle to return to neutral Slide the cable guide tube into the control housing and reinstall and tighten the housing screw 4 Check the operation of the spool cable and controller Some adjustment atthe valve end may be required too ensure that the spool returns to neutral when the controller is in the neutral position See Figure 14 5 The control lever assemblies utilizes a small spring to make up for free play in the cable to valve connection The control valve spool spring pro vides the centering capabilities of the controller and the valve spool Lack of centering at the controller is normally attributed to poor ad justment at the valve to cable connection or binding of the cables due to poor routing 6 The control lever assemblies will bolt to gether to form a group of handles there will be 4 for thr 4 spool valve and 5 for the 5 spool valve
32. Figure 27 Find the two wires in harness that has eye terminals on them Connect them to the Solenoid Lock Valve See Figure 27 s SJ N Solengjd A Lock Valve 9 Servo Control Manifold Solenoid Lo E cate the last Plug in the harness This Plug is a NU two wire self sealing push connector the Con M trol manifolds Solenoid is located on the top of ha the Pump and activates the Pump when en gaged See Figure 28 and 29 NOT USED ON A BOOM Disregard this Section 10 Wire Harness Completed Pull the Wire harness back toward Cab to remove any ex cess slack only enough to remove slack not to make Wire Harness tight Do Not tie wire har ness or hoses to Tractor Frame Rails Yet Tying Wire Harness and Hose up outof way will be done later The Wiring Schematic is shown in this book as a reference only the wire har 1 DE we ness will come to you assembled and ready to PRP Servo Control M Manifold Solenoid mount The only wires that will have to be altered dui are the wires inside that connect to the existing Tractor Wires These inside wires are intention FIGURE 28 ally leftlong so they can be cut as needed None of the wires with the factory plugs will have to be Cut Pl g a M 11 Seethenexttwo pages for Wiring Sche matic this is listed as reference only Pin loca tions in schematic are actual pin locations in Plugs Plugs are marked with the letters as shown This schematic is listed
33. Front Frame rails on the mount pad so that there is room for the Bolt heads to clear the Frame Rail Here we have wedged a Screwdriver with a 1 4 shank between the Bolt Head and the Frame Rail Anything about that size can be used to keep enough distance so bolt can be removed and reinstalled without interference Use a C Clamp to hold it in place when aligned Do this on Both the RH and LH side See Figure 20 2 rame Rail C Clamp TT Front p PE ts E Mi a Shanked Front Rail Screwdriver Mounting pa A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 11 Frame Rail Installation Pre Installing High Frame 1 High Frame Shipping Pallet The High frame is shipped bolted to a Pallet Do not unbolt this from the Pallet untill the Hoist has been connected to the High frame The Hoist must be supporting the weight of the High Frame before any of the bolts holding High frame to pallet are removed 2 Prepare High Frame for Lifting There are two lift lugs welded to the top of the High frame for lifting it See Figure 21 These Lugs will lift the bare High Frame straight without the King Post Sub Assembly bolted to it With the King Post Sub Assembly bolted to the High Frame it will require you to adjust the length of the lifting chain and lifting point to balance the load See Figure 22 and lift High frame level High frame must be lev
34. Group Inc Section 10 2 Optional Mower Head Installation Attaching Flail Head 1 With a Forklift or Hoist lower the boom Weldment on the Flail Head Align the boom Weldment with the Mower Head Hitch Post Insert special bolts item 1 p n 02956972 and item 2 p n 00752405 into Boom Weldment and Hitch Post Attach nuts item 3 p n 02030300 and item 4 p n 00037200 to bolt and tighten securely Note Additional support may be needed at the end of the Boom to aid in installation 2 Install Hoses Female JX in position as shown hand tighten DO NOT start Tractor untill after filling Hyd Tank with Oil See Filling Hyd Tank Section Fully extend and retract tilt cylinder and insure hoses do not bind or kink then secure fittings Tighten any leaking Hydraulic Fittings If fluid still leaks loosen the fitting apply a pipe thread compound to the end threads and tighten Do not allow Thread compond to get into Hydraulic system Care must be taken when tightening over tightening can cause the fittings to crack and require replacement fittings Use recommened hose end and torque values found in chart in operators manual 3 Warning Escaping fluid under pressure can penetrate the skin causing serious injury Re lieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and mozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks
35. If any fluid under pressure is injected into the skin it must be surgically removed withing a few hours by a doctor familiar with this type injury or gangrene may result 4 Hoses should not interfere with mower operation such as being pinched kinked or entering the cutter housing The hoses may be twisted slightly To hold them up and or inward tighten the fitting once the proper location is found Note the position of hoses and fittings It is important that they are installed as shown 02961074 View A 02961074 Female JX amp Male JX90 deg Elbow 02960407 View A A Boom JD6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 10 3 Optional Mower Head Installation Attaching Ditcher Head 1 With a forklift or hoist lower the Boom Weldment down in the Ditcher Head Align the Boom Weldment with the Ditcher Head Hitch Post together Insert special pins p n 02958929 into Boom Weldment and Hitch Post Attach with washer P N 00749185 and roll pin P N 00610600 NOTE Additional support may be needed at the end of the Boom to aid in installation See Figure 5 2 Attach Hydraulic Hoses as illustrated See Figure 69 Tighten all Hydraulic Fittings Care must be taken when tightening Hydraulic Fittings Over tightening can cause the fittings to crack and require replacement Use recommended hose end torque values found in chart in operators manual 3 The motor for the Ditcher will operate in
36. Line on the Boom parrelel with the Bolt on Boom Rest across the Boom See Figure 5 amp 6 This line will be used to align the the Boom Plate Rest Hook for welding to Boom 6 Clamp Boom Rest Hook to Boom Align Boom Rest Hook with the line on Boom and clamp with large C Clamp See Figure 7 Remove Paint if possible See Figure 8 Weld both sides of the Boom Rest Hook to Boom See Figure 9 Move Boom back into Boom rest and check for fit Marked Clean off Paint before Welding both sides amp as shown A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 13 3 Boom Swing Stop Installation Boom Swing Stop installation 1 Position Boom Swing Stop Lug BoomSwing Stop Log is used to prevent Boom from swinging back to far and hitting Cab With Boom folded and restin on Boom Hook in Boom Rest Plate Position the BoomSwing Stop on King Post Mount behond the Lift Cylinder Lug See Figure 10 This can be difficult to hold heare while you tack it it is important that it be square and touch the Cylinder lug as shown See Figure 10 2 Tack Weld Boom Swing Stop Lug Tack Weld the Boom Swing Stop Lug to the King Post Mount DO Not Weld to the King Post See Figure 11 Tack Wled the Lug secure enough that the Boom can be swung out to the side this gives you more rome to weld on the Boom Swing Stop Lug completly See Figure 12 3 Weld Boom Swing Stop Lug Solid After the Boom is
37. M A BOOM Assembly Instruction Manual ALAMO John Deere 6615 and 7615 Tractors equipped with additional options special equipment tractor manufacturer modifications new tractor models or Customer alterations may prevent this Mount Kit from being properly mounted to the tractor Alamo Group is not responsible for modifications to the MountKit to accommodate these differences ALAMO INDUSTRIAL Part No 02980169 1502 E Walnut Seguin Texas 78155 MEMBER OF THE Va ALAMO GROUP 210 372 3551 O 2003 Alamo Group Inc ALWAYS ON THE CUTTING EDGE TO THE OWNER OPERATOR DEALER All implements with moving paris 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 A DANGER FAILING TO FOLLOW SAFETY MESSAGES AND OPERATING INSTRUCTIONS CAN CAUSE SERIOUS BODILY INJURY OR EVEN DEATH TO OPERATOR AND OTHERS IN THE AREA 2 NO RIDERS NO 3 USE SAFETY SHOES 4 BLOCK UP SECURELY TORS HARD HAT SAFETY BEFORE WORKING ey OPERA GLASSES SEAT BELTS ROPS amp 1 Study and understand Operator s Manuals Safety Decals and Instructional Decals for
38. Prepare Tractor Axle Housing First look up under Tractor at the rear axle where the frame Rails mount you will see holes in the Axle castings on both LH and RH side that has plastic plugs in them The Plastic Plugs will have to be removed now as they cannot be removed once the Frame Rails are in place See Figure 12 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 9 Frame Rail Installation Pre Installing Frame Rails continued T Installing Frame Rails Using a Hoist lift the frame rail and slide it into place under the right rear Axle Hold the frame rails as shown to prevent it from moving See Figure 13 Using a Floor Jack See Figure 14 support the Frame Rail up under the Axle Note the RH and LH Frame rail will install the same so you can work either side first 8 Install first Frame Rail to Tractor amp pomo 2 Use Extreme caution so Rear Axle The Frame Rails Mount to the rear asse e that Frame Rail will not hit Axle of Tractor The RH Side has Longer Bolts Cab or Hood amp cause than the LH Side does This is because the Axle damage Mounted Boom Restwill also mount here using some of the same Bolts For now use shorter Bolts to hold Frame Rail up to Axle while you finish the Pre Installation The Bolts that were removed from the Tractor when you mounted the Front Frame Rail Supports will work well for this See Figure 15 9 Installthe other Frame Rail The other fr
39. Rail Installation Pre Installing Frame Rails 1 Lay Out Components in Display It is helpful to lay out the component in as neat a display as possible Lay out the Bolts accord ing to size and length Lay out the Nuts and washer by size This will allow you to see how many of each part as you use them and help to identify any missing parts See figure 6 2 Front Frame Rail Supports These Frame Rail Support Mounts part 02979765 LH amp 02979766 RH These should already be mounted from previous Assembly of Front Pump and Drive Shaft Components It is easier to mount the Pump Drive Shaft before these Frame Supports are installed If you are mounting the Frame rail supports now there are important things to remem ber There are 4 bolts that go through Tractor Frame that will have to be removed before this can be mounted DO NOT remove these 4 bolts from both sides LH amp RH of the Tractor atthe same time Remove the 4 from one side or the other install the 4 retaining New Bolts that hold the Rail Support Weldment on and tighten them Then go to a the other side and remove the 4 Bolts from A sus Tractor Frame Rail and install Machete Frame trame Rail rail Supports using the 4 new Support Retain ing Bolts The Tank Support brackets con Support Brackets nect to the Tractor These will be mounted when the Frame Rail Supports are installed See Figure 7 3 Rail Support Gusset Mount There are two Bolts in the Tr
40. Shown below are example of Frame rails There is a Right and Left Frame Rail They will not interchange from side to side LH must be mounted on the Left and Right on the Right To ID which is which the easiest way is to look for the Counter Weight Mounting Tubes See Figure 1 Item 2 these are welded on to the LH Frame Rail Only The Rail Mounting Pad See Figure 1 Item 4 is loose and not welded to the front of the Frame Rail untill final assembly Item Part No Qty Description 1 02979767 1 4 WD Frame Rail Weldment LH Shown 02979768 1 4 WD Frame Rail Weldment RH Not Shown di 2 Rear Mounting Plate Welded on LH and RH Frame Rail 4 02725900 2 Front Rail Mounting Pad not welded to frame rail when recievedl 5 02974704 2 Stabilizer Strap Axle Straps Fit above Axle Note tem 3 is welded to both LH and RH Frame Rails from the factory Item 4 will be welded on during assembly procedures Do not weld on any components until instructed to do so then check instructions carefully because some components are only to be tack welded then removed to be welded later Actual Tube Design may vary from drawing above Shown above is a general Frame Rail Weldment While Frame Rails may be designed different the mounting process will be the same 3 Point Arm Stabilizers on tractor will have to be removed when mounting Frame rails and will have to be modified to be used again This modification will be customers responsibility A Boom JD 6615
41. Wheel drive Frame on 4 Wheel Drive Tractor or vice versa it will not work Hydraulic Tank The Hydraulic Tank is mounted on the LH side of High Frame It willbe mounted by the Mounting tubes that are welded to the High Frame and the Tubes that are welded on to the Hydraulic Tank There will be long bolts with Allen Heads that will be inserted down through these tubes Tank Mounted Counter Weight There is a tank mounted counter weight that will be mounted on to the Hydraulic Tank useing Allen Head Bolts There will be a cover that bolts on over counter weight A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 4 6 High Frame Installation High Frame amp King Post Asy NOTE 2 Wheel Drive High Frame and 4 Wheel Drive High Frame Frame looks the same ex cept King Post and Bracing is higher up The 2 Wheel Drive and the 4 Wheel Drive High Frames will not inter change King Post Suction Line Es Oil Return Filter Hydraulic Tank Mounting Tube Counter Weight Mounting Tube Oil Suction Filter Tank Counter Weight Weldment Counter Weight Cover NOTE Shown above is a general view of the High Frame Counter Weight and Cover and may not look the same as the one for your application The Assembly procedures will be the same even if the shape of Tank and Weight are different than shown A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 4 7 Frame
42. Wheel Weight Mntg start the other two Locknuts Do Lock Nut not tighten yet See Figure 2 5 Looking at the outside make sure the three special Wash Wheel Weight ers Figure 1 Item 2 are aligned with the Slots inthe Wheel Weight Special Washers IE 1400 lbs Tighten the three Bolts now You Part 02971569 will need an assistant to hold the other Side while you are tightening the Bolts While tightening Bolts check to make sure the three spe cial washers are seated correctly If these Bolts are tightened and washer are not seated into the recess on Wheel Weight dam age will occur See Figure 3 6 Remove forklift away from Wheel and Weight Re check tightness of Wheel Weight retain ing Bolts Bolts should torque to 500 ft Ibs A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 2 3 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 2 4 Section 3 A Boom Front Pump amp Drive Shaft Installation O 2003 Alamo Group Inc Section 3 1 Pump Drive Assembly Instructions DS Installing Pump Pump Drive Components and Hydraulic Tank This Section covers the installation of Pump Drive Components Pump Assembly and the Hydraulic Tank Some precautions must be followed during the Assembly Process and before unit is ever started for the first time 1 Tractor must be disabled to prevent accidental engine start and preve
43. actor frame rail that will need to be removed in order to mount this gusset support It is easier to do now with the frame rails off It will need to be installed now as the Frame Stiffener Assembly will line up with these Gussets Note the angle on the Gusset as it is being mounted See Figure 8 See Figure 2 for drawing of Frame Stiff ener Kit and Part numbers for components F l gt igure A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 8 Frame Rail Installation Pre Installing Frame Rails continued 4 Front Rail Mounting Pad There are two of these Pads one is used on the left and Front Rail fl one on the right These Pads are the same Mounting Pad so it will not matter which goes on which side PN 02725900 See Figure 9 Set the Pad down over the VETEEN Front rail Support aligning the four holes in yT pad with the four holes Support Insert the four Bolts into the mount pad and plates on front support mount See Figure 10 Install a nut on one or two of the Bolts but do not tighten them the Bolts are only installed to prevent the Pad from moving side to side 5 Locate RH and LH Frame Rail There are two different frame rails RH and LH Start with either one you want for illustration we started with the RH See Figure 11 Re member the LH is the one with the Counter Weight Mount Tubes welded onto it See Figure 1 Front Frame Rail Mount Pad 4 6
44. ame rail willinstallthe same as the first did DO NOT do any welding at this time 10 Frame Stabilizer Kit Locate the Frame Stabilizer Kit See Figure 16 This should be bolted together as shown for fitting under me EE Fleet Jack and tractor and to Frame rails it must be bolted together 1 Frame Rail A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 10 Frame Rail Installation Pre Installing Frame Rails continued 11 Raising Frame Stabilizer Kit Up Under Tractor Using a Floor Jack slide Stabilizer Kit under Tractor right behind the front wheels See Figure 17 Note the Floor Jack used here has had channel built for it that cradles the square shape this is also good for supporting the frame rails during assembly Using Jack helps to align Stabilizer to frame rails This is shown on a 2 WD Tractor for illustration and is the same for the 4 WD 12 Align Stabilizer Kit Raise Stabilizer Kit with the Floor Jack up untill it is flush up againstthe Stabilizer Gusset Support that should already be bolted to the frame from earlier installation steps See Figure 18 This should be this way on the RH and LH side DO NOT Weld Gusset to Stabilizer yet this will be done later Secure the Machete Stabilizer kit to the Frame Rails with C Clamps on RE West both LH and RH See Figure 19 You may leave the Floor Jack or remove it 13 Align Frame Rails on Front Mount Pads Locate the
45. an be removed now Remove the four mounting bolts and slide the Tube forward or back to get it out See Figure 39 3 Go back and check to make sure you have tack welded the Frame Rail to Mounting Plate and Stabilizer to Frame Rail See Fig ures 31 through 39 Tack Weld 2 places each side of Frame Rail 1 v S Ea O 2003 Alamo Group Inc M Figure 37 A Boom JD 6615 7615 Asy Instruction Manual 07 03 4 a x p LE k mm Gap Between a Frame Rail amp Bolt NA T 4 1 Tack Weld Here Stablizer Gusset DO N T WELD OW Section 4 17 Frame Rail Installation Tack Welding Frame Rails continued 4 Frame Stiffener Assembly The frame stiffener is an assembly designed to run under the Tractor to tie the two Frame Rails together and support each other The Gusset Rail Support is designed to stabilize the Frame Rails to the tractor frame Re check the left hand and right hand sides to make sure the alignment is still correct and the tack Welding has been performed Vertical Tube of RH Frame Rail Front Wheel End C Clamp Here x Rear Axle End Tack Weld here on both Hh Horizontal Tube sides Front and Back only gt after alignment Gusset Rail Support Tack Weld Here Align Flush with Bottom s after final of Vertical Tube AN assembly only RH Rail Stiffener Weldment RH Side Rail Stiffener Tube Crossmember LH Frame Rail is LH Rail Stiffener We
46. andard 4 Spool that is remote cable Controlled The 28 ft model used a 5 Spool valve with the 5 Th Spool operating the Boom Extension THIS SECTION WILL NOT apply to the OPTIONAL ELECTRONIC JOYSTICK CONTROLS This Section mostly shows the 4 Spool Valve The 5 Spool Valve is mainly the same with the 5 Spool operating the Hydraulic Door option on the Rotary headorthe Boom Extension Cylinderon the 28 ft Model See Figure 5 amp 6 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 8 4 Cylinder Control Valve Installation Standard Control Valve Operation continued 2 The Standard Tandem Dual Pump System is Shown there is a Single Pump System Option available The Single Pump only supplies the Hydraulics for the Cutter Head Motor and the Tractor Hydraulic System is used to supply the Boom Cylinder movements The Schematic is very much the same except the Cylinder Control Valve Hose connections are run to and from the tractor instead of the way they are shown in the Schematic on the next page See System Schematic drawings for Pump Repair Section Pressure One Way Restrictors B Side Handle 3 The Control valve will bolt on the top of the High Frame on the right hand side There is atab welded to the Frame that has two holes in it the Valve mount plate will bolt to this tab and the valve will bolt to mount plate See Figure 6 The Valve in Figure 6 shows the Hoses and Control Cables alread
47. any tack welding till instructed to Put a Spacer Mounting Angle Washer Here w Bolts amp Nuts Mounting Tube Frame Rail Approx 1 2 from end V oa ka brkk kb ba dd bekk bebe j ai TA lt Front Bar Mounting Straps Set High Support l Ay with Bolts amp Nuts Frame in Line with Frame Rail Machete High Frame 4 Frame Rail A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 4 16 Frame Rail Installation Tack Welding Frame Rails 1 Tack Weld Frame Rails to Front Mount ing Pads Check to make sure that the Frame rail is still aligned on front rail Mounting Pad Frame Rail should not interfere with the Mount ing Pad bolt heads Check the LH and RH Frame rail See Figure 35 If alignment is correct Tack Weld the Frame Rails to the Front Rail Mounting Pads See Figure 32 When tack Welding use 4 good tack welds per Frame rail 2 on each side of Tube See Figure 37 The C Clamp on The Frame Rail Tube at the mounting pad can be left on till later 2 Tack Weld Frame rails to Frame Rail Stiffener Tack Weld the frame Stiffener Brack ets to the Frame Rails but be sure you DO NOT tack Weld the Stabilizer Gusset at this time See Figure 38 The reason for not welding the stabilizer gusset at this time is because it would make it more difficult for you when you remove the High Frame and Frame rails for final welding The Tube Crossmember of the Frame Stabilizer c
48. asically considered a Selector Valve The Hydraulic Control Valve must be compatible with the type Tractor System being utilized There is only one type System used The Fixed Displacement Open Center Continuos Flow Hydraulic Supply is from front Aux Pump Pump Pressure Port Tank Return Port Pressure Gauge M A Z Inlet Section n BD OLI 5 Spool 19 TI me Handl 5 Shown as 0011 mi Dipper Illustration A Only a e LI Tilt 4 LoL ui Door Extend Starter ek FI B pa Junction Box Joystick Solenoid sm Valve Dp Clamp Voltage Supply TN 4 MT L Pump Solenoid Connector Me ml Red o fr Dipper Tilt Door Extend 2 3 4 5 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 9 13 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 9 14 Section 10 A BOOM Head Installation Optional Heads Optional Mower Head Installation Attaching Flail Axe Head 1 With a Forklift or Hoist lower the boom Weldment on the Flail Axe Head Align the boom Weldment with the Flail Axe Head Hitch Post In sert special bolts item 1 p n 02956972 and item 2 p n 00752405 into Boom Weldment and Hitch Post Attach nuts item 3 p n 02030300 and item 4 p n 00037200 to bolt and tighten securely Note Additional support may be needed at the end of the Boom to aid in installation 2 Ins
49. ay the Hose in a drain pan This will catch any Oil expelled when Cylinder is pulled out 3 With a hoist raise the Boom Arm 1 and lower onto the King Post 2 Align the Boom Arm and King Post with the Lift Hinge Point Insert Main Pin Bolt 3 into Boom Weldment and Turn ing Arm Attach Lockwasher 4 Washer 5 and Bolt 6 and tighten also see Parts Section on the Boom Assembly See Figure 3 4 amp 5 Note Additional support may Approximate Lift pont be need at the end of the Boom r Lifting Lugs weld on here to aid in installation A Boom JD6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 7 2 Boom Installation Boom Installation Boom Hoses Boom continued Retaining Pin 4 Attach the Rod end of the Lift Cylinder 7 to the Lift Section with Pin 8 Bolt 9 and Nut 10 also see Parts Section on the Boom Assembly See Figure 3 5 Attach the Swing Cylinder The Swing Cylinder attaches to the King Post on the Rod End and to the High frame on the Butt end of cylinder There are two holes on the High frame that cylinder can be connected to The outer Hole is the one that cylinder pin should be put in for a rear swing A Boom A Forward Swing A Boom is rare majority wil be rear Swing parks to the rear for Transport See Figure 6 amp 7 6 Leave Boom Supported by Hoist untill Boom is connected to King Post and all cylin ders attached
50. be connected at the Tractor Ignition Switch But they can be connected as ex plained below If connected as shown below S A Wires must be traced to find the correct za 2 m wires k 2 Preparing Tractor Floor Mat First thing to do is remove the Battery Cables from Battery Do Not perform any work on Tractor unless this has been done Raise the Floor Mat up on the RH Side by the RH Door You will need to fold it back approx 12 to 14 inches See Figure 8 DO NOT Tear or Cut any Holes in Floor Mat as it will NOT be required You will also find a large oblong shaped rub ber plug this will be pulled up later but it is not necessary at this time 3 Tractor Wiring Harness Under the E Wire Cover Floor Mat on the right hand side you will find a su Tractor Wiring Loom Running across Floor gt iii remove the plastic cover that is over the wire 2 loom Using Tractor Manufacturers Service Manual Identify Which Wire is in this Loom A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 9 4 Joystick Mounting 2 WD amp 4 WD Installing Wiring Harness for Joystick Continued 4 Wires to be Connected You will need to find the wire from the switch that activates the Starter Solenoid for the Tractor This wire will need to be cutto form 2 ends You will need to locate the Ignition Switch Power Wire this wire will have current only when I
51. ber plug can be sealed using silicone sealer Floor mat will lay back down aroung cables and leave a small area of floor mat opening See Figure 3 5 Control Cables to Valve The control cables will connect to Valve as shown in figure 3 To ID which cable is which have one person move handle inside and mark which cable moves outside The cable connection procedure is shown See Figures 4 through 14 gt z A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 8 2 ESTO Cutter A NE Valve TE 10Amp Spade Fuse Yellow or Orange Wire Quick Line Splice Connecior Solenoid Tractor Starter Tractor Ignition Switch A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 8 3 ON OFF Switch Installation Wire Harness Standard Mechanical Valve 1 Starter Safety Switch Schematic Mechanical Cable Operated Valve Type NOT correct for Optional Joystick Electronic Controls 2 Figure 4 illustrates a common wire harness connection for A Boom mowers with mechanical cable controls If the Joystick Optional controls are used the Wiring will be different than shown 3 Individual installations may vary and are dependent on the electrical and safety system designs of the tractor to which the mower is mounted 4 Consult the specific mounting instructions to determine the correct wire routing for each specific unit Common Problems
52. cation Flail Mower Head Skid Shoe Bolts are torqued to 120 ft lbs Item 15 page 5 Motor Bolts are torqued to 120 ft lbs Belt Alignment amp tension adjustment is correct Cutter shaft bearings are properly lubricated Roller bearings are properly lubricated Item 16 Page 5 Blades swing freely Tractor Mower Operation Inspection Using all Safety precautions operate the Tractor and Mower unit for 30 minutes and while the unit is running check the following items Note Only make adjustments after the mower has been turned off and all motion has stopped and all hydraulic pressure has been relieved No Hydraulic oil leaks at the hose connections Operate the boom and mower head throughout its full range of motion and check for hose s rubbing pinching or kinking Make sure the Return Filter Gauge is reading in the Green after Oil is warm Check the function of the Mower Head On Off Valve and switch for proper function Make sure that the tractor will not start with the mower on off switch in the on position Check the Blade Rotation for the Rotary Mower Head to make sure it is turning Clockwise looking from the top of the mower deck Make sure the control valve boom movements agree with the valve operation decal Make Sure Boom Movement operates as expected and is smooth and under control no air in the control system Look for any unusual or excessive noise or vibrations Make sure all Wheel Weights are installed Tires are Filled
53. ch tightening can cause the fittings to crack and require replacement Use recommended hose end torque valves found in the Maintenance section WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and mozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid under pressure is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Pressure Hose Flow Divider A Boom JD6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 10 5 Optional Mower Head Installation X Frame Square Head FIGURE 30 Attachment 1 With a forklift or hoist lower the Boom Weldment down on the X Frame Square Head Align the Boom Weldment with the X Frame Square Head Hitch Post Insert special bolts 1 x 9 item 1 and item 2 3 4 x 5 1 2 into Boom Weldment and Hitch Post Attach nuts 1 item 3 and item 4 3 4 to bolt and tighten securely Note Additional support may be needed at the end of the Boom to aid in installation Fig ure 7 2 Connect the Pivot Hitch toMower as shown in Paris and Assembvly Manuals See Figure 8 3 Connect Hoses to Mower Head Connect Hoses as shown See Figu
54. ckout device work correctly on machine Tractor should not start if mower switch is on 12 Is swing cylinder pinned in correct hole On rear swing type machine cylinder should be pinned to outside hole On front swing type machine cylinder should be pinned in inside hole 13 Is machine equipped with proper operator protection Must have cage or cage panels 14 L Does mower operate when on off switch is on Stop when switch is off 15 Is head rotation correct On rotary heads looking from the top of the deck rotation should be clockwise so that debris will be thrown away from the tractor On flails rotation can be forward or reverse but forward rotation is standard 16 E If furnishing a square head are spindle housing bolts tight Is spindle assembly tight Are bolts that hold blade bar to spindle tight 17 Does head operate smoothly at normal operating speed Head should not vibrate excessively A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 12 3 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 12 4 section 13 A BOOM Boom Rest Plate and Boom Swing Stop Installation Boom Rest Plate amp Hook Installation Boom Rest Plate installation 1 Boom rest Mounted Boom rest should already be mounted and tighten down to Tractor from y fy earlier assembly section At the top of the Boom rest Boom TL 1 t
55. corner Right Side Window See Figure 38 6 00763977 Noticeto Owner install in upper right corner Right Side Window See Figure 38 7 02965093 Proper Engine Operation install in upper right corner Right Side Window See Figure 38 8 02962748 Pull On to Start Push to Stop Install on ON SER 3 OFF Switch See Figure 35 Fe i EE These Decals will need to be installed by the person o 21 Vil Bi a mounting the A Boom Clean all windows and make sure they are dry before installing Decals DO NOT install any Decals in a position that will interfer with the operators view pr O MOT MOUN e i hh A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 6 4 Section A BOOM Boom Installation Section 7 1 Boom Installation Cutter Motor Control Valve Asy 1 Cutter Motor Control Valve Asy Install the Cutter Motor Control Valve Asy to the LH side of High Frame it will not have the Hoses attached as shown the Hoses will be connected later See Figure 1 Boom Installation Boom Hoses 1 Hoses on Booms are shipped folded back inside Boom Hoses must be pulled out and moved to clear then routed in the end of Boom before installing Boom on the King Post See Figure 2 2 Pull the Lift Cylinder out to its full stroke to aid in the installation of the Lift arm See Figure 3 When Pulling Cylinder Out attach a Hose to the Rod end and l
56. ction 10 4 Optional Mower Head Installation Attaching Timber Cat Head 1 Attach the Timber Cat Head to the boom using the pins included with the head Be careful not to damage the pivot bushings in the boom when inserting the pins Attach the 90 elbow Item 1 to the front port of the boom and position it so that it faces down Attach the 90 end of the return hose P N 02973125 to the fitting and attach the straight end to the 90 fitting Item 2 on the flow divider if it is not already connected Attach the pressure hose P N 02973124 to the rear port of the boom and attach the other end to the 90 elbow Item 3 on the flow divider if it is not already attached See Figure 6 2 Be sure the hoses are routed as shown in the figure and securly tighten all connections Stop here and go to Hydraulic Oil Tank fill setion DO NOT Start Tractor untill Hydraulic tank has been filled Start tractor and move the head tilt through its motions and check for excessive twisting and bending It may require many attempts to obtain the optimum hose connection position Once achieved start the tractor and position the head in a safe area for operation if necessary baracade the head to prevent any contact while it is being operated This unit is dangerous STAY AWAY anytime the tractor is in operation Turn on the head and bring the tractor engine up to normal operating speed 540 PTO RPM Tighten any leaking hydraulic fittings Caution too mu
57. ction 11 4 section 12 A BOOM Hydraulic Start Up Procedures Start up Instructions 1 Read all safety instructions Decals on the A Boom warn you of particular and multiple Hazards Many decals are attached close to part of the A Boom where there is a possible hazard Read and make sure you understand the safety messages before you operate the A Boom Keep all decals clean and readable Replace lost or damaged decals 2 Before operating read all the safety and operating instructions in the Operator s Manuals for both the tractor and mower 3 When the hydraulic tank has been filled The Pump Suction Hose filled with Hydraulic Oil and the mower unit Head properly assembled the unit should be started up NOTE Make sure that no materials tools or jacks have been left under the mower head Make sure the front and rear of the mower are properly guarded to prevent any foreign objects from being thrown by the mower All other workers should be kept a safe distance from the unit before the mower is started 4 Startthe tractor and idle at a slow engine speed until oil is being pumped Check for any leaks this is easiest with an assistant watching for leaks Do not run if Oil is leaking 5 Bleed the air out of all hydraulic cylinders one at a time by extending them to their full length DO NOT SWING THE BOOM till last and you have gone to the Rest Stop and Support Section for instructions 6 Engage the Cutter Control Valve at low e
58. ction Manual 07 03 O 2003 Alamo Group Inc Section 3 3 Pump Drive Assembly Instructions Installing Pump Drive Components continued 6 Install Shaft End of Driveline Engine end Install the Shaft 1 2 Assembly w Flanged Yoke into the Engine compartment of Tractor install it from the LH front Side down and under radiator See Figure 6 This needs to be installed this way because the Flange Yoke will not go through the Crankshaft access hole in the front of the Tractor See Figure 3 Bolt the Flange Yoke to the Pulley Adapter using the four 7 16 X 1 1 4 Bolts Part 02976344 use the four Lock Washers Part 00022200 put Locktite on the threads of the Bolts and install them into Pulley Adapter To Tighten these four Bolts use a long extension and go through the front Crankshaft Pulley access hole in front of Tractor Do Not use bolts longer than 1 1 4 long longer bolts will damage Crankshaft Pulley Installing Pump Mount Plate amp Tube End of Driveshaft 1 Install Pump Mount Plate Install Front Pump Plate 02976087 standard mount plate See Figure 7 or 02979080 optional Pump Mount Plate w Pump Guard built on Not Shown use the 2 Spacers on the JD 6615 Series Do not install Pump Mount Plate without using these Spacers The Spacers are for Tractor Hood Clearance Insert the 4 bolts and lock washers into Pump Mount Plate and spacers See Figure 7 tighten them to re quired Torque See Bolt Torque Cha
59. e See Figure 29 5 Check High Frame for Level Check the two Magnetic Levels that you installed earlier The Top Level should be from side to side ofthe Tractor See Figure 27 The level A A Frame Rail on the King Post Pivot Pin should be level M making High Frame Level straight up and Down See Figure 28 Leave the Magnets on the High frame as you will have to check then one more time later DO NOT do any welding atthis time 6 Secure High Frame to Frame Rails Secure the High Frame to the Frame rails with C Clamps on both sides See Figure 29 Do not weld anything at this time F A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 4 13 Frame Rail Installation Pre Installing High Frame continued r Align High frame to Frame Rails The High Frame Vertical Tube should be as directly above the Vertical tube of the frame rails as possible See Figure 30 The illustrations in figure 30 shows the High Frame not directly over the Frame Rail Vertical Tube try to get it as directly over it as you can The height of the High frame should be no higher than the Cab of the Tractor The horizontal tube of the High Frame should be just above the height of the horizontal Tube of the Frame Rail See Figure 29 amp 30 Clamp the High frame to the Frame Rail when aligned and leveled See Figure 29 Leave the Hoist connected to the High frame for safety and additional support
60. e 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 where correspondence with the Manufacturer is neces sary CONTACTING MANUFACTURER Please help us Help You Before You Call Alamo Industrial Service Staff Members are dedicated to helping you solve your problem or your customers 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 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 Inquiries P 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 Assembly Manual or Service Manual many of these are available via the Alamo Industrial Internet site
61. ee holes have to be drilled use caution not to drill them in to where the bolts will interfere with the Tractor Seat Slide Adjustment Rail 3 Bolt Mounting Bracket to Seat Insert the three 5 16 Bolts with Flatwashers on them through the holes in the Seat Plate See Figure 4 The Mounting Bracket is under the Seat Plate as shown in the drawing Install the three 5 16 Lock nuts on the Bolts from the Bottom Tighten the three Bolts and nuts 4 Re install Tractor Seat Cushion Re install Tractor Seat Cushion in reverse of step 1 Test Seat to make Sure that it does not bind when slid forward or back as adjustment If there is a Bind check and correct problem A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 9 3 Joystick Mounting 2 WD amp 4 WD InstallingJoystick to Bracket 1 Bolt Joystick to Mounting Bracket Set Joystick Assembly on Mounting Bracket Make sure Joystick is mounted as shown the Push Pull Switch in rear and Toggle Switch to the front See Figure 6 2 Installing Joystick Mounting Bolts Find the two 3 8 bolt put Lockwasher and Flatwasher on them Start these bolts from the bottom up through Bracket and into Joy stick Console The Joystick Console holes are threaded so no Nuts are needed Tight ened the two retaining Bolts See Figure 1 Item 3 and Figure 2 Installing Wiring Harness for Joystick 1 It is recommended that the Wires for Joystick
62. el when lifted over Frame rails 3 Level High Frame Use two magnetic Levels as shown These magnets should be installed before lifting High frame The First Magnetic level is put on the Top of the High Frame on the Bottom Side See Figure 23 This level will allow you to level the frame from left to right without having to climb up later to use a Level that you hold The Second Magnetic Level is put on the Kin Post Pivot toward the front of the tractor so that it will level the High Frame from front to rear as shown See Figure 24 Top of High Frame King Post Vii Front of Pivot Pin Ti N Tractor Magnetic Level a i 1 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 4 12 Frame Rail Installation Pre Installing High Frame continued 4 Lower High frame down over Tractor TT This is a two man job in order to keep control of M High Frame on both sides of tractor See Figure 25 Lower the High Frame down over gt hk U the Frame rails See Figure 26 slowly as it Min gt must straddle the Frame Rails See Figure I _ height 26 Lower High Frame untill the top of the High ve Ed frame Frame is no higher than the cab of The Tractor max and no lower than 24 1 2 from frame to hood as the min distance See Figure 25 Another mark to look at is the Horizontal tube of the High frame should be parallel up and down with the Frame Rail Tube as shown on next pag
63. ent use the Tractor flashing warning lights and follow alllocaltraffic regulations sc 6 tractor in gear can result in injury or death Read the Tractor operators manual for proper starting instructions sa 13 DANGER Start tractor only when properly seated in the Tractor seat Starting a DANGER 4 Start only from seat in park or neutral Starting in gear kills DANGER Do not operate this Equipment with hydraulic oil leaking Oil is expensive and its presence could present a hazard Do not check for leaks with your hand Use apiece of heavy paper or cardboard High pressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene If oildoes penetrate the skin have the injury treated immediately by a physician knowledge able and skilled in this procedure 56 15 WARNING Always read carefully and comply fully with the manufacturers instruc tions when handling oil solvents cleansers and any other chemical agent sa 22 DANGER All Safety Shields Guards and Safety devices including Tractor PT but not limited to the Deflectors Chain Guards Steel Shield Guards Gearbox Shields PTO integral shields and O Retractable Door Shields should be used and main tained in good working condition All safety devices should be inspected carefully at least daily for missing or broken components Missing broken or worn items must be replaced at once to reduce the possib
64. from the Angle Mount ing to the Mounting Bar that you have welded to the mounting Tube See Figure 43 Transfer that measurement to the bottom of the Frame Rail and Tack Weld a cut off Bar Mounting Strap there See Figure 44 Fig ure 44 shows a top Un Cut Mounting Bar being held down with a C Clamp this is done to make it easier to transfer measurement to lower Bar Mounting Strap Do not weld a strap to the top of the Frame Rail here See Figure 44 9 Recheck that all components are Tack Welded See Figures 31 through 45 Weld Here u Y E y N A X a ho Here Figure 44 RM Lower Bar Mounting Strap Cutt Off Weld Rear of LH Mount ing Tube toward Cab Measure Distance Here Upper Bar Mounting Strap Cut Off y Lower Bar Mounting Strap Cut Off A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 20 Frame Rail Installation Remove High Frame for Final Welding 1 Remove and Weld High Frame Lift the High frame back up off of frame rails See Figure 46 Finish Weld Mount Tubes The Mounting Tubes are to be welded completely all the way around This is why itis best to take High frame off so that the Weld can done as strong as possible and in places that you can t get to with High frame mounted on Frame rails This is also recommended so Assemblies can be turned while welding to get maximum quality welds
65. ghten up See Figure 28 amp 29 Install both bolts as shown See Figure 28 Snug the Bolts don t tighten them yet 2 Counter Weight Cover CWT The Counter Weight Cover will bolt to counter weight See Figure 28 amp 30 3 Parts Operators Manual Cannister The Parts Operators Manual Cannister Bolts to the top of the Hydraulic tank See Figure 30 The Parts Operators Manual should be put into cannister prior to delivery of Unit to the operator Hydraulic Mounting O Mounting Frame Bol Counter Weight Bolt on Cover Counter Rail Weight CWT Hyd Tank Mounting Tubes w Bolts A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 6 2 Decal Installation Tank Oil Level Sight Gauge 1 Oil Level Sight Gauge is mounted on the side of the tank facing the rear of the tractor The Tank may have to have the Paint touched up or repainted completly Use caution not to paint over this or damage it See Figure 31 amp 32 Tank Decal Installation dir OilLevel 1 Install Decals on Hydrailic Tank and CWT Cover There are 10 decals that need to be installed on the Hydraulic Tank and CWT Cover See Figure 32 33 34 Counter Weight must be Installed befor Boom is mounted to King Post Decal Part Number See Figure 32 33 34 02966305 attention Universal Tractor Hydraulic Oil 4 02958241 Operators Safety Decal 02977417 Operators Manual Inside
66. gnition Switch is on This Wire will have a wire Tee d into it See Figure 9 5 Wire Harness Through Cab Thereisa large rubber plug in floor this is where the Joystick wiring harness will be put through the cab floor This plug can be pulled up through the floor See Figure 10 it will be required to cut a hole in this plug for the Wire harness to run through 6 Insert it Wire harness through Floor Plug till the 4 wires that are notin the wire Harness are even with the Floor The wires that are sticking out of harness will be run under Floor mat and under dash panel to switch or connected to the tractor harness These wires are made long be cause of the different places they can be con nected on various models 7 Connecting Harness Wires There are 4 wires that must be connected inside Tractor 1 Red Wire power supply 1 Black Wire Ground and 2 Brown Wires Neutral Safety Switch These will have to be spliced into Tractor circuits See Figure 13 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 9 5 Joystick Mounting 2 WD amp 4 WD Installing Wiring Battery Shown here is typical Ignition Harness to Joystick cc wire connection Your Ignition may Continued vary but the function will not 8 Ground Wire The Black gamer wire at the harness See Figure 11 and 13 can be connected inside the cab floor or it can be run down through the floor and
67. here are 8 bolts and Nuts that must be installed into the holes of the Angle Mounts Snug these between the froht and rear Aligning on the RH side angle mgunt A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 5 5 Frame Rail Installation 4 WD Re Install High Frame to Tractor continued 5 Install Mounting Tube Bolts The High frame must still be hung on the Hoist for safety and support but sitting down on the frame rails There are 8 Bolts and Nuts that go through the Angle Mounts and the Plates on the end of the Mounting Tubes There are 2 on each end and 4 on each side Install these 8 Bolts now but snug them only do nottighten them down yet See Figure 18 You may need to insert a bar into one of the holes to align them See Figure 19 6 Install Bar Mounting Straps The rear Bar Mount ing Straps are the ones that were cut and welded to the tubes just put the Bolt through these See F Figure 20 Snug the Bolt in using the Lock Nuts The Front Bar Mounting Strap will have a strap on the Bottom and another one on the top with a bolt on each side Install these bolts and nuts Snug them only for now See Figure 21 Install the Bar mounting Straps with Bolts and Nuts on the LH and RH Side 7 Tighten High frame Mounting Bolts Tighten the 8 Bolts and Nuts for the Mounting Tubes See Figure 18 amp 19 Tighten the Bolts for the Bar Mounting Straps These bolts must be tighten s
68. here will be a Boom rest Plate bolted to Boom rest Plate this should be mounted out to the Far right side See Figure 1 2 Boom Rest Weld on Transport Plate There is a Boom Rest Hook plate tied to the Top Boom Hoses for shippment and cannot be mounted till the a Assembly of this Unit is finished Remove this plate Axle Mounted Ad BoomiRest now it is tied to Boom hoses with th 2 plastic ties Do Not Weld on yet wait tillinstructed to do so See Figure 2 3 Swinging Boom Extreme caution must be used when swinging Boom There is NO BOOM STOP INSTALLED and can not be installed till later Slowly swing boom Up and back watching the Cab so as not to hit it with the Boom Do nor raise Boom higher than the inner stop om Boom rest plate bolted to the top of the Boom rest Swing Boom till it is aligned in Boom Rest The Head should be in the folded position as you lower Boom See Figure 3 4 Slowly lower the Boom down into Boom Rest You will need to take measurement on the Boom See Figure 4 here and Mark the Boom so you can weld on the stop plate to Boom The Height of the Boom when in the Boom Rest should not exceed 12 ft 9 in max See Figure 4 A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 13 2 Boom Rest Plate amp Hook Installation Boom Rest Plate installation 5 Marking Boom Use a Black or color de sired to mark the Boom Make a
69. his trial if when another component makes the previous one interferes The Tractor should be covered and protected from Spark from the Welder and Grinder at all times It will be your responsibility to protect the Tractor and its components DO NOT WELD or GRIND near any Glass or Painted Surface unless it is protected from sparks these Sparks will damage any surface The purpose for Setting Frame up tack welding it then removing it is because with the amount of Welding that will have to be done these frame components will need to be repainted The repainting is easier with frames off The Frame components are shipped already painted but this is to protect the metal plan on repainting them after welding DO NOT weld any frame or component untill instructed to do so in the instructions Read through this entire instruction book to be familiar with which part goes where and when DO NOT try to man handle large components alone one slip can break a window damage a hood or worse Note the order of assembly of other Assemblies example the Pump Drive Shaft Front Rail Supports Rear Stack Valve Modifications and Joystick Assembly are assembled to Tractor before the frame rails This is because some components will be in the way of others after they are assembled A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 4 2 Frame Rail Installation Frame Rail Pre Assembly continued RH amp LH Frame Rails
70. ility of injury or death from thrown objects entanglement or blade contact scm 3 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Safety Section 5 PTO Integral hield Chain S Defiector SAFETY DANGER DANGER gt WARNING gt WARNING gt WARNING gt WARNING gt WARNING gt NEVER use drugs or alcohol immediately before or while operating the Tractor and Implement Drugs and alcohol will affect an operator s alertness and coordination and therefore affect the operator s ability to operate the equipment safely Before operating the Tractor or Imple ment an operator on prescription or over the counter medication must consult a medical professional regarding any side effects of the medi cation that would hinder their ability to operate the Equipment safely NEVER knowingly allow anyone to operate this equipment when their alertness or coordination is impaired Serious injury or death to the operator or others could result if the operator is under the influence of drugs or alcohol sa 27 Operate the Tractor and or Implement controls only while properly seated in the Tractor seat with the seat belt securely fastened around you Inadvertent movement of the Tractor or Implement may cause serious injury or death 56 29 Engine Exhaust some of its constituents and certain vehicle components contain or emit chemical
71. imited to 48 60 72 and 102 inches 2 Toinstallthe cables to the valve each valve section will require a cable installation kit 4 kits for a 4 spool valve 5 kits for a 5 spool valve etc Each individual valve connection kit can be ordered using part number 02971274 Figure 4 displays the contents of each kit Cables are not included in Cable Connection Kit A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 8 8 Cylinder Control Valve Installation Flange Flat Washers Flange Bolts Lock Washers Flange Sleeve Connecting Pin pe OP FEN a La a e Retaining Pin P fi ni Nn a IN ta Spacer Rings Cable Eye Fitting Cable Eye Jam Nut Cable Valve End Shown Not Figure 4 included with Connection Kit di Turn the Jam Nut and the Flange Sleeve Assembly onto the threaded cable end to the entire length of the threads Cables are not included in Valve connec tion Kit See Figure 5 Figure 5 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 8 9 Cylinder Control Valve Installation REMOTE CABLE OPERATION AND INSTALLATION continued 4 Turnthe cable eye Jam nut onthe threaded cable end until it bottoms Thread the Cable Eye onto the cable end until it bottoms on the cable Turn the eye to align with the spool end and secure the jam nut against the cable eye See Figure 6 5 Slide the cable eye into the slot
72. in the spool and align the holes Insert the connection pin and install the retaining pin into the hole in the connecting pin and secure by bending both ears of the retaining pin back and around the con necting pin See Figure 7 6 With the cable attached to the valve turn the Flange Sleeve Assembly back onto the threaded cable end until it is flush with the valve face When turning on the assembly make sure that the valve spool remains in the neutral position See Figure 8 f Tightenthe Jam Nutonto the Flange Sleeve Assembly to lock it into position See Figure 9 8 Tighten the Flange into position using the two allen head screws Use a flat washer to support a lock washer on each bolt See Figure 10 9 Interference will occur between the Flange Sleeve Assembly and the casting of the Inlet Section on the Valve Section next to the Inlet Section To compensate the provided shims should be placed on the Flange Sleeve Assem bly under the flange See Figure 11 A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 8 10 Cylinder Control Valve Installation REMOTE CABLE OPERATION AND INSTALLATION continued 10 Each cable is controlled by the operator with the use of single axis control handle assemblies A single control handle assembly is required to oper ate each individual valve section The control handle assemblies are ordered as PN 02971243 Control Assembly Controller
73. inued di Wire Harness Terminal Identification The Wire Harness Terminal Plugs are marked in writ ing on the plug Swing Lift Dipper Tilt and Door terminal plugs 5 Total The Valve terminals are in this same order starting at the bottom and coming up on the valve You will need to have a short handle Phillips screwdriver for this See Figure 26 6 Wire Harness Terminal Installation You will need to feed wire harness under the fitting across tank See Figure 24 lay the Plugs outin the Orderthey are to be installed starting atthe bottom terminal 7 Terminal Connections Make surethateach terminal Plug on Valve has had the Gasket in Stalled on it then Install Swing Terminal and tighten Plug Retaining Screw Continue this with all 5 plugs starting at the bottom and coming up See Figure25 PLUG FUNCTION 1 Bottom Plug Swing Terminal 2 2nd Plug Up Lift Terminal S gt M 3 3 rd Plug Up Dipper Terminal SG Terminale A 4 4th Plug Up Tilt Terminal na Plugs 5 Top Plug Door Terminal Connect and tighten all 5 terminal plugs one at a time till all 5 are connected See Figure 26 Short Handle Phillips Screwdriver A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 9 9 Wire Harness Valve Mounting 2 WD amp 4 WD Installing Wire Harness To Valve Continued 8 Solenoid Lock Valve Connection Sole noid Lock valve is mounted onthe Valve Tilt Port on the RH Side See
74. iption Mounting Tubes Length will Vary with Mount Kit Bolt 3 4 X 2 Long Not Shown Locknut 3 4 Toplock Not Shown Bar Mounting Strap Bar Mounting Strap Cut In Half Locknut Toplock Bolt 3 4 X 10 1 2 Long Angle Mount 02918600 00037200 02966639 02966639 00037200 02957039 02966641 MO 0 NE AN A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 5 High Frame Installation Frame Rail Pre Assembly continued High Frame Mounting Tube Componenis See Figure 4 These Componenis are Sitting in approx position of assembly to illustrate where they are to be when tack welding them Space is left between them for Illustration only they will be closer together when assembled Also See Figure 3 on previous Page Bolts 3 each side Angle Mount 2 each side Mounting Tube 1 each side HETT a 9 Mounting Bolt Holes 2 each end Rear of Frame Rail Angle Mount 3 2 each side gt Bar Mounting V Front Strap Cut Off of 2 each side F rame Locknuts 3 each side Rail Bar Mounting High Frame and King Post Frame Sub Assembly See Figure 5 The High frame will come with the King Post Sub Assembly built to it The 2 Wheel drive and 4 Wheel Drive High frames are different and will not interchange between 2 WD and 4 WD Tractors the 4 Wheel drive High Frame has the King Post Mounting welded higher up on frame than 2 WD Frame DO NOT try to use a 2
75. it See Figure 2 amp 3 1 Hydraulic power for the cylinder control circuit is taken from the second smaller stage of the hydraulic pump Oil is supplied through hose 2 to the four or five spool control valve where it is directed to the appropriate cylinder through the cylinder hoses All of the cylinders are double acting The system is protected from excessive pressure by an adjustable pressure relief valve located on the inlet section of the valve The pressure relief valve is factory set at 2000 PSI for the 17 20 8 23 foot booms and to 2500 PSI on the 28 foot booms In addition at least 3 individual cylinder circuits are protected by a non adjustable work port relief valve See Specifications in the Service repair Manual 2 One way restrictors are added to the valve sections such that the return flow from the cylinders when performing gravity aided function will slow the flow of return oil and allow for a more controllable movement of the boom See the specifications for size of restriction and location in the Service repair Manual 3 Oil is returned from the valve through Return hose to the Cutter Motor Control valve where it then passes through Return hose into the return filter and into the tank 4 The valve utilized on the A Boom mowers to facilitate the control of the boom movement functions is either a 4 Spool or 5 Spool open center sectional manually operated valve The manual operation is performed with the use of nor
76. l Valve ee NL Pump pressure to Cutter Motor A Boom JD6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 7 4 Hose Installation Pump Tank Hose Installation continued 3 Connect hose from Pump to Cylinder Control Valve This willbe the smallhose connec tion on thr RH side of the pump See Figure 10 for this hose this hose cannot be connected to Cyl Control valve untill later 4 Connect Hose from Cutter Valve to Motor The Hose from the Cutter Motor Control Valve runs down the Boom using Steel lines and Hoses See Figure 12 5 Connect Return Hose from Motor to Cutter Motor Control Valve Connect the hose from the Motor return to the Cutter Motor Control Valve See Figure 12 6 Return Hose from Cutter Valve to Tank Connect the return hose from the Cutter Motor Control valve to the Tank See Figure 12 This hose will run down under tractor to the left side See Figure 13 anfd then back up the LH side to the Tank See Figure 14 The return hose connects to the return Filter Housing See Figure 15 T Return Pressure Gauge The Return Pres sure Gauge is a low Pressure Guage that displays uses in Green and Red Fields Return should stay in the Green when Oil is warm and Tractor is running See Figure 15 ii Return Hose A from Cutter Valve to Tank A Boom JD6615 7615 Asy Instruction Manual 07 03 Section 7 5 O 2003 Alamo Group Inc Pressure f
77. ldment Mounted Here 5 Locate Mounting Tubes and Hardware See Figure 31 for breakdown of these components A There will be one Mounting Tube for each side these tubes are the same so it will not matter which is on which side The Mounting Tubes are the same on either end See Figure 31 Item 1 B There will be 8 Bar Mounting Straps Part 02966639 these straps are the same but later in the assembly process 2 will have to be cut See Figure 31 Item 2 amp 2A C There are 2 Angle Mounts Part 02966641 these have two holes in them and when mounted the hole will be up See Figure 31 Item 5 D There are 8 bolts Part 02957039 amp Locknuts Part 00037200 the bolts are 3 4 X 10 1 2 Long See Figure 31 Item 4 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 18 Frame Rail Installation Tack Welding Frame Rails continued 6 Tack Weld Front and Rear Angle Mounts The Angle Mounts should be tack Welded to the Frame Rails in 4 places each Tack Weld in 4 This works best by weld a tack Weld in each Corners of Angle corner of Angle Mount See Figure 40 amp Mounts 41 All 4 of the Angle Mounts must be Tack FRE Welded to frame rail now T Tack Weld Mounting Tubes to High Frame The Mounting tubes will be Tack Welded to the High Frame in 3 places on top and 3 places on the bottom on both LH amp RH Side See Figure 42 amp 43 These Tack Welds need to be d
78. mal directly attached valve handles or through the use of cables and remote mechanical levers The 5 Spool has one more Spool than shown below it is to operate the Boom Extension on the 28 ft Boom or to operate a hydraulic activated Door on some heads The 5th spool will be located between the Dipper and Tilt Spool shown in figure 3 See Figure 15 later in this book D Although similar in appearance each valve section is specifically designed to perform the specified function for which it is assigned The Valve is shipped assembled and should not be disassembled during unit assembly B Port Side A Port Side Spool Detent Assembly ate M Control Cable Attachment Swing Pressure from Pump A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 8 7 Cylinder Control Valve Installation Cylinder Hydraulic Control Circuit continued 6 Hydraulic Cylinder Hoses The Hoses for the Hydraulic Cylinders will be marked with bands that have the Part Numbers on them These part numbers will vary with the size of the Boom Model The 28 ft model willhave more hoses for the Boom Extend Function the model with the Hydraulic Door on cutter head willhave more hoses To find which Hose you have you will need to consult the Parts Operators manual When connecting the Hoses to The Valve use these numbers to connect the correct hoses to the correct ports It may be required that you do some tracing of hoses
79. me Rails to Tractor continued 5 Install Axle Mounted Boom Rest This will a n require two people one to align the Boom rest with N EEE q the Hoist and one to align the Bolt holes on the m m m U bottom to start them into the Axle Housing See W Figure 5 6 amp 7 li When the Bolts are installed into the Frame Rail amp Boom Rest Plates and snugged up to Axle housing install the RH Axle Mounting Strap See Figure 8 9 amp 10 Do not tighten Bolts snug them only for now ba Ta Boom Rest ho A Plate T Boom Rest Weldment I id gt A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 5 3 Frame Rail Installation 4 WD Re Install Frame Rails to Tractor continued 6 Install Stabilizer Crossmember This will con sist of a Tube cross member and four Bolts and Nuts See Figure 11 Install the Bolts with the Nuts on Top and bolts coming in from the Bottom See Figure 12 this way only the Head of the Bolt is lower than the Crossmember Snug the Bolts do not tighten them yet 7 Weld Stabilizer Gusset to Rail Stiffener Weldment Weld the Gusset to the Stabilizer Weldment now Weld on both sides of the Gusset The LH Gusset and RH Gusset must be welded See Figure 13 Check that all Bolts and Nuts are installed Boom Rest Fr s E 74 Axle Strap Bolts Install with Nuts om x top and Bolt Heads on the
80. n 2 Fill Left rear Wheel w calcium Cloride nenen 2 2 Wheel Counter Weight Parts 2 2 Wheel Counter Weight InstallatiOn eee 2 3 Section 3 Front Pump Drive ae SEE 3 2 Crankshaft Pulley Preparation 3 3 Pump Driveshaft Assembly eee een nn 3 3 Pump Driveshaft Half SNatEnd ria 3 4 PUMP VOM ad reran E NE 3 4 to 3 5 Pump Drive hat UDE ETO nei 3 5 PUNT IS NNO ae o ae 3 5 to 3 6 Frame Rail Support Installation 3 7 Section 4 Frame Rail Pre Assembly 4 2 to 4 6 High Frame FF EEE O ici 4 7 Frame Rail Pre InstallatioN i 4 8 to 4 11 High Frame Pre InstallatioN ii 4 12 to 4 16 Tack Welding Frame ASSEMDlY a icsiuinacinuntaiesesininedntantadossaishesdncuado 4 17 to 4 21 Remove Frame for Final VVElONO isotsocias skuvusbavnsos ad ko vho vk vodna ao 4 21 to 4 23 Section 5 FramefrallsFnalInstallalion acilia 5 2 Boom o SUS AOP ae es n co do oo 9 3 Axle Sirap Installato une 5 4 Stabilizer RUINS AC O cisne nai saa P bin ne 5 4 PAG gg Page Ste MOM EE 9 9 to 5 8 Tie Up Hoses to Tractor Frame Stack valve Hoses 5 8 Section 6 Hydraulic Tank INS ANA LOTA ai ires resida 6 2 Hydraulic Tank Counter Weight Installation 6 2 Hydraulic Tank Oil Level Sight Gauge ss 6 3 Hydraulic Tank Decal Installation 6 3 CFA WSC al INS AMANO p MO R naanin RD O slohu 6 4 A Boom JD 6615
81. ng protection at all times for protection from injury including injury from items thrown by LA the equipment sa 16 WARNING Always wear safety shoes with steel toes when working on this equipment It is recommended that the safety shoes have metatarsal guards WARNING When welding use Welding hood with the appropriate OSHA required protective lens welding apron and welding gloves DANGER Always disconnect the wire leads from the mower valve solenoid before KR performing service on the Tractor or Mower Use caution when working on the Tractor or Mower Tractor engine must be stopped before we working on Mower or Tractor The Mower Blades could inadvertently be ai A turned on without warning and cause immediate dismemberment injury KG or death sBm 12 E DANGER Never run the tractor engine in a closed building or without adequate ventilation The exhaust fumes can be hazardous to your health SG 23 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Safety Section 4 SAFETY DANGER Before starting the mower make sure the area is clear and the floor has been swept The mower blade can throw objecis several hundred feet Thrown objects could damge property or cause severe bodily injuries even death WARNING Make certain that the Slow Moving Vehicle SMV sign is installed in such a way as to be clearly visible and legible When transporting the Equipm
82. ngine rom and run the mower slowly for a short period until all air is removed from the hoses Keep all persons WELL CLEAR of mower since Blades can THROW OBJECTS with great velocity for a considerable distance KEEP CLEAR 7 Run the mower at a low tractor engine speed until the mower Hydraulic Sytstem gets the Air out offit Operate at an engine speed that keeps the filter restriction gauge reading in the Green Zone With the hydraulic warm bring the tractor speed up to normal operating speed If the filter gauge reads in the red zone stop the unit release all hydraulic oil pressure and Check the filter element in the tank mounted filter or any Hose that may be kinked Restart the tractor and mower unit and again check the filter gauge oil must still be hot 8 If the filter gauge reads in the red when first started and does not drop as oil warmss then something is wrong contaminanis have been introduced into the hydraulic system or some thing connected wrong You may need to repeat previous steps again until the gauge reads in the green 9 Check the fluid level in the Hydraulic Tank and add oil if required As the air has been forced out of the Cylinders and Hoses it goes into the Hydraulic Tank and reduces the oil level The Hydraulic Oil must be at least at the level of the Sight Gauge on the side of the Tank 10 Basic trouble shooting guide for first start up A Electrical solenoid valve does not work check wiring possible fault
83. nt daamge to components 2 Al Fittings Hose Cylinders Tank must be kept plugged at all times No part of the Hydraulic System can be left open at any time 3 All Tools Work Area Components and Workers Hands must remain Clean when working on any part of the Hydraulic System 4 All components should be rechecked for tightness at least twice Hose routing also double checked Existing JD Bolts amp Washers JD Tractor Crankshaft Pulley K Q Q DVS I HLAVU D CDI gt lt ESDS SANTE p P JD Tractor Front Casting Part No Description 02976087 Front Pump Plate Standard Shown 02979080 Front Pump Plate Optional w Pump Guard 02979790 Pulley Adapter 02973712A Driveline Assembly 02975669 Bolt 20 mm 2 5P X 60 mm GR 10 9 02971158 Lockwasher 20 mm 02976344 Bolt 7 16 NC X 1 1 4 GR 8 00022200 Lockwasher 7 16 02892000 Bolt 1 2 NC X 1 1 2 GR8 00001300 Lockwasher 1 2 02978480 Spacer Pump Plate JD 6615 Series I O O1 R D DDR R RK V Installing Pump Drive Components 1 Remove Front Cover See Figure 2 Remove the 4 plastic plugs shown in figure 1 and discard them they will not be needed Remove the 2 Allen Head Cover Retaining Bolts After removal this front cover will not be used The front Casting will have a Driveline Hole in it See Figure 3 This will be the same on 2 WD or 4 WD A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section
84. o the straps stay even on both sides so Bars will stay even The rear bar strap mounting bolt uses the Bars that are welded to tube and only have one bolt See figure 20 amp 21 on Bar Mounting Strap Vi D Motnting sn om Tube Bolts 1 Mounting Tbe A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 5 6 Frame Rail Installation 4 WD Re Install High Frame to Tractor continued D Tighten All Frame Mounting Bolts Tighten all the Frame Mounting bolts that have only be snugged till now Go through and make sure none are missed Front Mounting Pad Bolts There are 4 Bolts on each Pad the LH and RH 8 Total See Figure 22 Frame Stiffener Crossmember There are 2 bolts on each side or 4 total Make sure these bolts have been installed with the nuts on top See Figure 23 Frame Rails to Rear Axles The Rear of the frame rails bolt up to the Bottom of the Tractor Axle Housing There is also an Axle Strap on each side which has long bolts through them from Axle Strap on top down and through the Frame rail Mount Plate The RH side also has the Boom rest bolted on with it and the Axle Strap bolts go through it Tighten all of these bolts at the rear axle of tractor See Figure 24 amp 25 Check all Bolts for Tightness Check to make sure all Frame Mounting bolts and nuts have been tightened Also inspect to make sure they are installed correctly
85. olts Install the Front Frame Rail Support Tighten the 4 bolts through Tractor Frame Rail See Figure 19 Tr ctor Frame Rail Bolts 5 I y NS BA A pp i S x No MS i Right Hand Frame rail i Support Shown CT 5 WE vi JM A td EN 3 an N M p ta L al SAN aa i Mounting Plates on Front Frame Rail Support the longer part toward front on RH and LH side A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 3 7 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 3 8 section 4 A Boom Frame Rail High Frame Setup Pre Assembly Installation A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 4 1 Frame Rail Set Up Frame Rail Pre Assembly The Frame Rail Set UP The Frame Rails for the Machete will be set up on the tractor positioned measured but not welded The Machete High frame is set on to Frame Rails positioned and leveled After all is set up and positioned it will be Tack Welded in Place on Tractor Thenit will be dis assembled and welded up on the Shop floor This is done to ensure better welds and to enable the parts to be turned so the components can be Flat Welded It has been found that this will make the components stronger This also gives a chance for all frame components to be test fitted and broken loose during t
86. one in an alternating pattern so Mounting Tubes do not Lift or move There should not be any gaps be tween Frame Rails High Frame or Mounting Tubes Do this on LH and RH Frames Tack Weld Mounting Tube Here Mounting Angle in 6 places 3 top amp 3 bottom w Bolts amp Nuts Machete High Frame Tack Weld Here ee to Frame Rail Approx 1 2 A from end vi LN MOLL A l A Bar Mounting Straps Set High with Bolts amp Nuts Frame in Line with Frame Rail Machete High Frame A Frame Rail A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 19 Frame Rail Installation Tack Welding Frame Rails continued 8 Weld Bar Mounting Straps The RH Front bar Mounting Straps will have to be cut See Figure 31 and welded to the top of the Mounting Tube See Figure 43 Another one cut off and welded to the Bottom of the Frame Rail See Figure 45 The length of these Bar mounting straps should be cut so it will not be sticking over past frame rail These can be Tack Welded while still mounted on Tractor Illustrations are shown with frame rails off of Tractor because it IS easierto see anditcan be done after they are removed from tractor if you want These must be Tack welded in align ment when installed so the holes are in line Ny Tack Weld BES in3 placesontop lt T Ne and 3 places on bottom i If not in line the Bolt cannot be installed Measure the distance
87. oses or wire harness gather this ex cess up under cab and secure it out of the way There will most likely be excess length in these Figure 27 hoses and wire harness A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 5 8 section 6 A Boom Hyd Tank CWT amp Decal Final Installation Section 6 1 Hyd Tank CWT Installation Hydraulic Tank Installation 1 Caution Care must be taken to keep Hydrau lic System clean Do not leave any openings in Tank while installing it they must remain sealed untill ready to install acomponent and then sealed back up 2 Hydraulic Tank Installation The Hydraulic Tank is shipped with the return Filter Assembly the Suction Filter assembly is already installed in the Tank The Hydraulic Tank is mounted on the LH side of LH Frame Rail The Mounting Tubes are welded to the Frame rail and to the Hydraulic Tank See Figure 28 amp 29 Do not fill Hydraulic Tank with Oil untill all the Hoses have been installed and tightened Counter Weight Installation 1 Counter Weight CWT Installation The Counter weight See Figure 28 mounts on the LH side and is mounted to the Hydraulic tank which mounts to the LH Frame Rail with a mounting bolts running up through tubes that have been welded to the frame rail and Tank The Bolts must be installed as shown with the Lock nuts to the inside Installing the Bolts this way will make them easier to ti
88. re 8 amp 9 Boom to Mowers Do Not Start tractor untill the hydraulic Tank has been filled Go to Hydraulic Tank Fill Section now After Oil has been fill Start Tractor and run the Hy draulic System through its funtions as out ra AN I lined in the Oil Fill Section NEVER Start gt k Tractor without Oil in system Oil level to csi Sight Glass it will damage the Hydraulic System if you do A Boom JD6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 10 6 Section 11 A BOOM Fill Hydraulic Tank Fill Hydraulic Tank Fill Hydraulic Tank with Oil 1 DO NOT START TRACTOR untill you have filled Hydraulic Oil Tank to a level as shown in Sight Glass gauge and fill the Suc tion Hose to Pump with Oil 2 Remove Filler Cap Remove Filler cap only when ready to fill hydraulic Tank with Oil Do Not leave the Cap off and the system Open always keep sytem closed when possible Avoid any oil contamiantion See Figure 1 3 Avoid Hydraulic Contamination by filtering the Hydraulic Oil while filling the Hydraulic Tank Filter buggies or carts are commercially available for Hy draulic system clean up and Oil transfer These con sist 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
89. rom hu Less Cutter Motor Valveto Motor 1 Return Hose to Tank Return Hose from Motor Return Hose from Cutter Valve to Tank Tank Return Hose to Tank Return Filter Housing eturn Hage Pressure Gauge NOTES A Boom JD6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 7 6 Section 8 A BOOM Standard Cylinder Control Valve Installation Section 8 1 Cylinder Control Valve Installation Control Handle Assembly Installation 1 The controller assemblies willbe bolted together using a tie rod bolt The control handles are the same and the cables are the same it is where they are connected to the control valve that makes a difference See Figure 1 2 The ON OFF Switch is bolted to the Control Handles This is a good place but can be mounted somewhere else is desired If Mounted somewhere else keep in mind it must be accessible quickly by the operator in ET case of emergency needs See Figure 1 ON OFF Switch 3 The Arm Rest is bolted to the Control 5 W Handles This has some options as to where it is bolted and can be bent to adjust to individual preference See Figure 2 4 Control Handle Stand is bolted to the floor of the Cab under the Floor Mat on the right hand side There is a rubber plug in floor under floor mat here remove and or cut the rubber plug to run the cables and wire har ness through it The opening around cables through rub
90. rovides anti freeze to approx 50 deg F below 0 Rotate Washer to Match Bolt Circle dia and Washer fits into 4 Wheel Weight Slot A Bolt is shown extra long in drawing for illustration only Figure 1 Item Part No Qty Description 1 02979603 3 Hex Head Bolt 7 8 NC X 16 2 02971569 3 Wheel Weight Washer Special 3 02970758 1 Wheel Weight Casting 1400 Ibs 4 5JRC1490 3 Locknut Top Lock 7 8 NC Note some Older Units used a All Thread Rod with Hex Nuts Lock Nuts with Flat Washer and Lock washer This was replaced with the Bolt Type shown above These Bolt and Nut combinations will replace the old All Thread type A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 2 2 Rear Wheel Counter Weight Installing Wheel Weight 1 This Wheel Weightis 1400 los Always use caution when working with it 2 Locate the three Holes in LH Rear Wheel Make sure these holes are 15 16 dia if not they must be reamed out 3 Lift Left Rear Tractor Wheel till it just clears the ground This will allow the Wheel to be rotated when aligning mounting holes for Weight 4 Using a forklift lift Wheel Weight into Wheel When Wheel Weight is centered in Wheel Se cure Forkliftand Set Parking Brake on Forklift Insert one of the three bolts through Weight and Wheel Rotate Wheel to align holes if needed Installa Hex Lock Nut on inside Insert the other two Bolts through Weight and Wheel and
91. rt 2 Driveline timeing means the universal joints are both the same position when driveline half is slid together If they are not timed it will decrease the life of the universal joint and in some cases could cause a vibration See Figure 5 on previous page 3 Install Tube End of Driveline Pump End Slide the Tube half of driveshaft through Pump Mount Plate and Tractor Crankshaft Access Hole See Figure 8 You will have to align the Universals when doing this time the Driveshaft Slide the two together where the Universal are in time See Figure 5 on previous page this will help the driveshaft to operate smoothly Figure 8 E Shaft 1 2 Assembly w Flanged Yoke Tractor Radiator k 4 Left Hand front side of Tractor Standard Pump Mount Plate Shown Tube Ehd of Driveshaft Standard Pump Mount Plate Shown Splined gt Clamp Yoke A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 3 4 Pump Drive Assembly Instructions Installing Pump Mount Plate amp Tube End of Driveshaft continued 4 Loosen Splined Clamp Yoke Insert a bar through the Yoke to hold Driveshaft up and to help Bar to Hold loosen the Bolts in the clamp Yoke See Figure 10 Drive Shaft This can be loosened with a hand Wrench or a Socket whicheveris easier for you See Figure 10 Some times it is easier to test fit the Tube End of Driveshaft to the Pump while the Pump is on the
92. s known to the state of California to cause cancer and birth defects or other reproductive harm SG 30 Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the state of Califor nia to cause cancer and birth defects or other reproductive harm Wash Hands after handling SG 31 Use extreme caution when getting onto the Implement to perform repairs maintenance and when removing accumulated material Only stand on solid flat surfaces to ensure good footing Use a ladder or raised stand to access high spots which cannot be reached from gound level Slipping and falling can cause serious injury or death so 33 Avoid contact with hot surfaces including hydraulic oil tanks pumps motors valves and hose connections Relieve hydraulic pressure before performing maintenance or repairs Use gloves and eye protection when servicing hot components Contact with a hot surface or fluid can cause serious injury from burns or scalding sc 34 Avoid contact with hot surfaces of the engine or muffler Use gloves and eye protection when servicing hot components Contact with a hot surface or fluid can cause serious injury from burns or scalding sc 38 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Safety Section 6 Section 1 A BOOM TOOL REQUIREMENTS AND PRE DELIVERY INSPECTION CHECKLIST Section1 1 ey sg Aa 10 11 12 13 14 15 16 1
93. stalled where The Decals will have the Part Number on them in the lower corners Decal No Description 00763977 Notice to Owner 02964677 Important Boom Rest 02963524 Attention Boom Swing 02965093 Proper Engine Operating 02965262 Warning Hose Burst 02967827 Multi Hazard 3 Multi Hazard Danger Decal This is installed on the Left Side Window of Cab on the inside to Drivers Left See Figure 16 4 Warning Hose Burst Decal This installs on the Right Side Window of Cab on the Inside to Drivers Right See Figure 17 Di Notice To Owner Decal This installs on the inside top rear of Right Door Glass See Figure 18 6 Attention Boom Swing Decal This in stalls on the inside top rear of Right Door Glass See Figure 18 Ta Important Boom Rest Decal This in stalls on the inside top rear of Right Door Glass See Figure 18 8 Proper Engine Operating Decal This installs on the inside top rear of Right Door Glass See Figure 18 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 9 7 02965262 amp 02963524 00763977 g ATTENTION TO PREVENT DAMAGE BOOM AND OR TO THI pane 1 Compota og eni mal Sa Wart arty Naper stan Card m today POTKINTY IMPORTANT TO PREVENT BOOM REST FAILURE i NEVER TRANSPORT WITH THE BOOM LIFT LEVER IN FLOAT POSITION AFTER CAREFULLY PLACING BOOM IN BOOM REST LEAVE THE DOOM LIFT LEVER M THE Lie i THe BOOM 02964677 02965093
94. swung out 90 deg from tractor completly weld the Stop Lug to the King Post Mount on High frame See Figure 12 Slowly swing th Boom inward to the Boom rest and make sure tha Boom cannot be swung in so far that it will hit the cab of tractor This is a very critical step and must be done with extreme caution so as not to damage Cab of tractor Boom Swing ack Weld N pa 4 4 v o A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 13 4 NOTES A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 13 5 A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 13 6 INDUSTRIAL A Boom JD 6615 amp JD7615 Assembly Manual 2003 Edition P N 02980169 A Boom JD 6615 Asy Instruction Manual 05 03 O 2003 Alamo Group Inc
95. tall Hoses p n 02972573 1 and p n 02972573 2 in positions shown Fully extend and retract tilt cylinder and insure hoses do not bind or kink then secure fittings Tighten any leak ing Hydraulic Fittings If fluid still leaks loosen the 45 Elbow fitting apply a pipe thread compound to the end 02960411 E threads and tighten Care must be taken when tightening can cause the fittings to crack and re quire replacement fittings Use recommened hose end and torque values found in chart on page 22 3 Warning Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before apply ing pressure Keep hands and body away from pinholes and mozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If any fluid under pressure is injected into the skin it must be surgically removed withing a Hose a i few hours by a doctor familiar with this type injury 02972573 v or gangrene may result Hose 2 4 Hoses should not interfere with mower op 02972574 eration such as being pinched kinked or entering the cutter housing The hoses may be twisted slightly To hold them up and or inward tighten the fitting once the proper location is found Note the position of hoses and fittings It is important that they are installed as shown A Boom JD6615 7615 Asy Instruction Manual 07 03 2008 Alamo
96. ts 2 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 3 6 Pump Drive Assembly Instructions Install Front frame Rail Supports 1 Remove Bolts from Tractor Frame Rails Find the front most 4 Bolts in the Tractor Frame Rail There are 4 onthe RH side and 4 on the LH Side DO NOT REMOVE THE BOLTS FROM BOTH SIDES AT THE SAME TIME ONLY do one side at a time the RH or the LH For illustration start with the RH Side See Figure 17 The RH amp LH Frame Rail Supports have a Right and a Left They will not inter change and must be mounted on the correct side Notice the way they are built the Plate part that bolts to Tractor is longer in the front on both LH amp RH Make sure the longest part is to the front See Figure 18 2 Install Frame Rail Support RH Side This works best with a 2 man team The RH Frame Rail Support the is held on with the 5 bolts that Bolts that are supplied w mounting kit Start all 5 bolts with Lockwasher before any of the 4 are tightened See Figure 18 When tightened down it will look like the picture in Figure 18 Tighten the four retaining bolts for the RH Frame Rail Support before lossening or removeing the bolts on the LH side 3 Install Frame Rail Support LH Side Make sure that the bolts on the RH side have been tightened before removing the four bolts on the LH side The LH Frame Rail Support will install the same as the RH side did Remove the 4 b
97. ubrication schedule and all bolts and nuts are properly torqued Failure to properly service repair and maintain this Implement in good operating condition could cause component failure and possible serious injury or even death sc 35 WARNING Operate this Equipment only with a Tractor equipped with an approved roll over protective system ROPS Always wear seat belts Serious injury or even death could result from falling off the tractor particularly during a turnover when the operator could be pinned under the ROPS 6 7 DANGER Never work under the Implement the framework or any lifted compo nent unless the Implement is securely supported or blocked up to prevent sudden or inadvertent falling which could cause serious injury or even death 56 14 WARNING Use caution and wear protective gloves when handling sharp objects such as blades knives and other cutting edges Be alertto worn component surfaces which have sharp edges Sharp surfaces can inflict severe laceration injuries if proper hand protection is not worn se 37 A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Safety Section 3 SAFETY WARNING Many of the parts are heavy and require lifting assistance Do not try to lift the heavy parts by yourself Get help from another employee or from an overhead crane WARNING The operator and all support personnel should wear hard hats safety shoes safety glasses and proper heari
98. unning parallel to the Frame Rail Not across Frame Rail See Figure 52 amp 58 Weld the Rear Angle Mount to Frame rail the same as the front See Figure 53 _ o Weld along sides of Angle Mount and frame rail on both sides this 4 Bar Mounting Strap Weld these all the way applies to A amp B around first check your measurements for place ment The Bar Mounting Straps are cut and must be placed to where they will line up with the ones that you welded to the High frame mounting tubes earlier See Figure 53 5 Frame Rail Stiffener Weldment Weld the Frame stiffener to Frame rail on both sides See Figure 24 Touch up or re paint frame compo nents after welding is completed There are other components that need to be installed before you reinstall frame A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 4 22 Frame Rail Installation Remove High Frame for Welding Continued 6 The Side Rails These Frame rails will be welded to the Rail Support Plates so it will be necessary to scrape the paint off approxi mately 5 8 of the base before attaching Clamp Side Rails to Front Mount Supporis See Figure 55 Tack weld rails to Front Mount Brackets After thorough check for hori zontal and parallel location weld a solid 1 4 fillet weld bead 8 long on both sides See Figure 56 Note that any Step Type Counter Weight must clear the Left Rear Tire NOTE There is a
99. with liquid and Counter Weight is installed Make sure the left rear wheel of the tractor stays on the ground when the boom is fully extended horizontally with 200 lbs placed on the outside of the mower head Post Operation Inspection Check that the oil in the hydraulic tank has not turned milky in color or has foam on top Check that there are no loose fasteners or hardware A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 1 4 Tractor Mower Component Location For Check List A Boom JD 6615 7615 Asy Instruction Manual 07 03 Section1 5 2003 Alamo Group Inc Section 2 A BOOM Wheel Weight Installation Section 2 1 Rear Wheel Counter Weight Fill Left Rear Wheel with Liquid The Left Rear Wheel must be filled with liguid Alamo Industrial recommends a Calcium Cloride Water Mixture The recommended Ratio ofa 30 70 mix 30 Calcium Cloride and 70 Water this mixture will add weight at about 10 5 Ibs per gallon Follow the Mixture procedures furnished by the Manufactured of the Brand of Calcium Cloride that you are useing Itis also recommended that a trained person installs the calcium Cloride Calcium Cloride must be added in addition to the Steel Wheel Wieght and the Counter Weight that hangs on the Left Side It is Not recommended to use straight Water in the Wheel as this would not provide protection against freezing A 30 70 Calcium Cloride Water mixture p
100. y connected this is for illustration only The Control Cables and Hoses are connected after the Valve is bolted to the mount plate Most of the Hoses shown in figure 6 are running from the Boom These Hoses must be connected to the correct Port on the valve and to the correct side to operate correctly A Boom JD 6615 7615 Asy Instruction Manual 07 03 2003 Alamo Group Inc Section 8 5 Cylinder Control Valve Installation System Schematic Typical 17 through 23 with 4 Spool Valve Hyd Pump PT 7 Lift Gyl 1 PT TT L 7 J J Boom Entend 28 kne or Door Cyl Option DIS Motor Return Valve C 1 Hyd E M 1 A Tank Motor Pressure L J M 2 Filter Hydraulic Motor Cylinder Hydraulic Control Circuit See Figures 2 8 3 The Hydraulic Schematic above shows a 5 Spool System The 4 Spool System is the same with the exception the 5 th spool which is installedbetween the Dipper and Tilt Cylinder Spools When you assemble this you will not have to assemble the Valve it will come to you already assembled as a 4 Spool or 5 Spool depending on which model and which option you ordered Hoses must be connected to the correct Valve Port so the Control Funtions will operate in the correct direction A Boom JD 6615 7615 Asy Instruction Manual 07 03 2008 Alamo Group Inc Section 8 6 Cylinder Control Valve Installation Cylinder Hydraulic Control Circu
101. y switch possible faulty solenoid B Pump is making noise check for obstruction in suction hose and tank suction assembly check alignment of pump driveshaft C Cylinders will not raise hoses from cylinder incorrectly connected to valve bank pump not suppling oil D Cylinder rises slowly hoses from cylinder incorrectly connected to valve bank work port reliefs on valve bank set too low replace as required E Filter reads in red viscosity of oil too high wait until oil heats up before checking filter gauge If gauge reads in red even after unit is hot then the filter must be replaced A Boom JD 6615 7615 Asy Instruction Manual 07 03 O 2003 Alamo Group Inc Section 12 2 Post Assembly Check List 1 Is oil level in the tank even with the sight gauge on the tank 2 Has the proper oil been used in the system Proper oil is Universal Tractor Hydraulic 3 Does Boom machine movement match operation decal Swing Lift Dipper Tilt 4 Is control valve free and does it not stick 5 Are all hoses tight and do not leak 6 Are all decals in place See Safety Section in Manual for decal description and placement 7 Does tractor pass Alamo Group Mower Stability Test 8 Have all grease points been adequately greased 9 Are all bolts tight 10 Have all hoses been properly routed so that hoses do not kink or bend when boom is articulated through all motions 11 Does starter lo

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