A-BOOM Assembly Instruction Manual 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 1502 E. Walnut Seguin, Texas 78155 210-372-3551 Part No. 02980169 © 2003 Alamo Group Inc.
TO THE OWNER/OPERATOR/DEALER All implements with moving parts are potentially hazardous. There is no substitute for a cautious, safe-minded operator who recognizes the potential hazards and follows reasonable safety practices. The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents. BEFORE YOU START!! Read the safety messages on the implement and shown in your manual.
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 provide enough detail to eliminate the need for contact of the Alamo Industrial Technical Service Dept.
INDEX - ASSEMBLY INSTRUCTION Page Safety Section Operation Safety............................................................................. 1 Section 1 Tools and Supplies Needed f/ Assembly.................................. 1-2 Pre-Dilivery Check List...................................................................... 1-3 to 1-5 Section 2 Fill Left rear Wheel w/ calcium Cloride............................................. 2-2 Wheel Counter Weight Parts.................................................
INDEX - ASSEMBLY INSTRUCTION Page Section 7 Cutter Motor Control Valve................................................................ 7-2 Boom Installation / Boom Hoses....................................................... 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)....................
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
SAFETY SECTION © 2003 Alamo Group Inc.
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 manufacturer and should be to the owner/operator. Most accidents can be avoided by being aware of your equipment, your surroundings, and observing certain precautions.
SAFETY PELIGRO! Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. (SG-3) !LEA EL INSTRUCTIVO! READ, UNDERSTAND, and FOLLOW the following Safety Messages. Serious injury or death may occur unless care is taken to follow the warnings and instructions stated in the Safety Messages. Always use good common sense to avoid hazards. (SG-2) Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad.
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 hearing protection at all times for protection from injury including injury from items thrown by the equipment. (SG-16) WARNING! Always wear safety shoes with steel toes when working on this equipment.
SAFETY DANGER! Before starting the mower make sure the area is clear and the floor has been swept. The mower blade can throw objects 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 Equipment use the Tractor flashing warning lights and follow all local traffic regulations.
SAFETY DANGER! 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 Implement, an operator on prescription or over-the-counter medication must consult a medical professional regarding any side effects of the medication that would hinder their ability to operate the Equipment safely.
Section 1 A-BOOM TOOL REQUIREMENTS AND PRE-DELIVERY INSPECTION CHECKLIST A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
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. 1. 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). 2. Compressed Air, Air must be filtered and dry.
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: ------------------------- Operators Manual is with Unit. The Safety Decals are installed as listed in the Assembly Manual. Valve operation plate is installed. Operators cage or Tractor Cab is in place.
A-BOOM PRE-DELIVERY INSPECTION CHECKLIST Pre-Operation Inspection: Check the following items before operating the unit to assure that they are properly assembled.
Tractor - Mower Component Location For Check List 1 6 3 7 5 17 4 2 11 2 16 10 9 8 12 13 14 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 2 A-BOOM Wheel Weight Installation A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
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 of a 30 / 70 mix (30% Calcium Cloride and 70% Water), this mixture will add weight at about 10.5 lbs per gallon. Follow the Mixture procedures furnished by the Manufactured of the Brand of Calcium Cloride that you are useing. It is also recommended that a trained person installs the calcium Cloride.
Rear Wheel Counter Weight Installing Wheel Weight 1. This Wheel Weight is 1400 lbs. 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.
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 3 A-Boom Front Pump & Drive Shaft Installation A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Pump / Drive Assembly Instructions 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 prevent daamge to components. 2.
Pump / Drive Assembly Instructions Installing Pump Drive Components: Front Cover 2. Access to Crankshaft Pulley. The Factory Crankshaft Pulley will not need to be removed. The Pulley Adapter will be bolted to the Factory Crankshaft Pulley. 3. Install Pulley Adapter. The Pulley adapter to be used is a round plate with 4 threaded holes and four non-threaded holes in it. Notice this pulley adapter will not have a center hole in it (See Figure 4).
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).
Pump / Drive Assembly Instructions Installing Pump Mount Plate & Tube End of Driveshaft: (continued) 4. Loosen Splined Clamp Yoke. Insert a bar through the Yoke to hold Driveshaft up and to help loosen the Bolts in the clamp Yoke (See Figure 10). This can be loosened with a hand Wrench or a Socket whichever is 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 bench.
Pump / Drive Assembly Instructions 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 allowing 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.
Pump / Drive Assembly Instructions Install Front frame Rail Supports: Tractor Frame Rail Bolts(5) 1. Remove Bolts from Tractor Frame Rails. Find the front most 4 Bolts in the Tractor Frame Rail, There are 4 on the 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 & LH Frame Rail Supports have a Right and a Left.
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 4 A-Boom Frame Rail / High Frame Setup / Pre- Assembly Installation A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
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. Then it 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.
Frame Rail Installation Frame Rail Pre-Assembly: (continued) RH & LH Frame Rails. 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.
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 Rail Installation Frame Rail Pre-Assembly: (continued) High Frame Mounting Tube Components. (See Figure 3 & 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 Installation Frame Rail Pre-Assembly: (continued) High Frame Mounting Tube Components. (See Figure 4) These Components 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.
High Frame Installation High Frame & King Post Asy NOTE: 2 Wheel Drive High Frame and 4 Wheel Drive Frame looks the same except King Post and Bracing is higher up. The 2 Wheel Drive and the 4 Wheel Drive High Frames will not interchange.
Frame 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 according 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 & 02979766 RH).
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 one on the right. These Pads are the same so it will not matter which goes on which side. (See Figure 9). Set the Pad down over the Front rail Support aligning the four holes in pad with the four holes Support. Insert the four Bolts into the mount pad and plates on front support mount (See Figure 10).
Frame Rail Installation Pre-Installing Frame Rails: (continued) 7. 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 & Rear Axle.
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.
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).
Frame Rail Installation Pre-Installing High Frame: (continued) 4. Lower High frame down over Tractor. This is a two man job in order to keep control of High Frame on both sides of tractor (See Figure 25). Lower the High Frame down over the Frame rails (See Figure 26) slowly, as it must straddle the Frame Rails (See Figure 26). Lower High Frame untill the top of the High 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) .
Frame Rail Installation Pre-Installing High Frame: (continued) 7. 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.
Frame Rail Installation Pre-Install Mounting Tubes for High Frame: (continued) Machete High Frame 1 1 2 2A RH Frame Rail Front Shown 2 2A 2A 4 Frame Rail (to Rear Axle) 6-3/4" 5 Figure 31 Mounting Tube Width Cut one end off Item Part No. Qty Description 1 ---Ref----02918600 00037200 02966639 02966639 00037200 02957039 02966641 2 4 4 6 2 8 8 2 Mounting Tubes, (Length may Vary with Mount Kit).
Frame Rail Installation Pre-Install Mounting Tubes for High Frame: (continued) Washer 1/8" thich inserted between Plates on Front Angle Mount end Only 10. Install Front Angle Mount. Loosely bolt the Front Angle Mount on the other end (front) of each Mounting Tube (See Figure 33). Notice the washer that is installed between the Angle Mount and Mount Tube, This is there because about a 1/16" Gap is needed between the Mount Tube Plate and the Angle Mount Plate.
Frame Rail Installation Tack Welding Frame Rails: 1. Tack Weld Frame Rails to Front Mounting Pads. Check to make sure that the Frame rail is still aligned on front rail Mounting Pad, Frame Rail should not interfere with the Mounting 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).
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.
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. This works best by weld a tack Weld in each corner of Angle Mount. (See Figure 40 & 41). All 4 of the Angle Mounts must be Tack Welded to frame rail now. Tack Weld in 4 Corners of Angle Mounts 7. Tack Weld Mounting Tubes to High Frame.
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.
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 it is 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.
Frame Rail Installation Remove High Frame for Welding.: 1. Remove Frame Rails. It is 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. Do Not Weld next to Bolt Holes, it will interfere Hex Heads of Bolts 2 2. Weld Front Mount Plate. Weld down each side between Bolt Holes.
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 approximately 5/8" of the base before attaching. Clamp Side Rails to Front Mount Supports. (See Figure 55). Tack-weld rails to Front Mount Brackets. After thorough check for horizontal and parallel location, weld a solid 1/4" fillet weld bead 8" long on both sides. (See Figure 56).
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 5 A-Boom Frame Rail & High Frame Final Installation A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
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 reinstalling 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). 2. Install the Bolts into the rear Axle Housing to support the rear of the frame rails.
Frame Rail Installation Re-Install Frame Rails to Tractor: (continued) 5. Install Axle Mounted Boom Rest. This will require two people, one to align the Boom rest with the Hoist and one to align the Bolt holes on the bottom to start them into the Axle Housing. (See Figure 5, 6 & 7) When the Bolts are installed into the Frame Rail & Boom Rest Plates and snugged up to Axle housing, install the RH Axle Mounting Strap (See Figure 8, 9 & 10). Do not tighten Bolts snug them only for now.
Frame Rail Installation 4 WD Re-Install Frame Rails to Tractor: (continued) 6. Install Stabilizer Crossmember. This will consist 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. RH Axle Strap 7. Weld Stabilizer Gusset to Rail Stiffener Weldment.
Frame Rail Installation 4 WD Re-Install High Frame to Tractor: 1. High Frame Paint. Re-Paint or 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.
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 not tighten them down yet (See Figure 18).
Frame Rail Installation 4 WD Re-Install High Frame to Tractor: (continued) 8. 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. A. Front Mounting Pad Bolts. There are 4 Bolts on each Pad the LH and RH, 8 Total (See Figure 22). Tighten LH & RH Side B. 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). C.
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).
Section 6 A-Boom Hyd. Tank, CWT & Decal Final Installation A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Hyd. Tank - CWT Installation Hydraulic Tank Hydraulic Tank Installation: 12 12 12 12 1. Caution. Care must be taken to keep Hydraulic System clean. Do not leave any openings in Tank while installing it, they must remain sealed untill ready to install a component 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.
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 & 32) Oil Level Sight Gauge Tank Decal Installation: 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).
Decal Installation Cab Decal Installation: 1 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 = # 02962107, Valve Operation - 5 Spool or # 02962024, Valve Operation - 4 Spool, (Install in lower Right Hand corner of Tractor Windshield).
Section 7 A-BOOM Boom Installation A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
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) Figure 1 2.
Boom Installation Boom Installation / Boom Hoses: (continued) Boom Retaining Pin & Nut 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.
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). Tank Return Hose Side Tank Suction Hose Side 2. Connect Pressure Hoses. There are two pressure hoses that connect to the Pump.
Hose Installation Pump / Tank Hose Installation: (continued) 3. Connect hose from Pump to Cylinder Control Valve. This will be the small hose connection on thr RH side of the pump (See Figure 10) for this hose, this hose cannot be connected to Cyl. Control valve untill later. Pressure from Cutter / Motor Valve to Motor Return Hose to Tank 4. Connect Hose from Cutter Valve to Motor.
NOTES A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 8 A-BOOM Standard Cylinder Control Valve Installation A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Cylinder Control Valve Installation Control Handle Assembly Installation : Dipper 1. The controller assemblies will be 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). Lift Swing 2. The "ON" / "OFF" Switch is bolted to the Control Handles. This is a good place but can be mounted somewhere else is desired.
"ON - OFF" Switch Installation Black Blue Solenoid Cutter Valve Push/ Pull Switch 10Amp Spade Fuse Red Wire Yellow or Orange Wire Acc Service Wire Quick Splice Ign Acc Line Connector Start Red & White or White Wire Billet Terminal Tractor Starter Off Acc Tractor Ignition Switch Figure 4 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
"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.
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.
Cylinder Control Valve Installation System Schematic (Typical 17' through 23' with 4 Spool Valve) Hyd. Pump Swing Cyl. Lift Cyl. 12 12 12 12 Dipper Cyl. Tilt Cyl. "A" Control Valve "B" Boom Entend (28') or Door Cyl. Option Motor Control Valve Hyd.
Cylinder Control Valve Installation Cylinder Hydraulic Control Circuit: (See Figure 2 & 3) A Hydraulic power for the cylinder control circuit is taken from the second (smaller) stage of the 1. 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.
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 will have 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.
Cylinder Control Valve Installation Flange Flange Sleeve Flat Washers Lock Washers Connecting Pin Retaining Pin Flange Bolts Spacer Rings Cable Eye Fitting Cable Eye Jam Nut Figure 4 Cable (Valve End Shown - Not included with Connection Kit) 3. 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 connection Kit. (See Figure 5).
Cylinder Control Valve Installation REMOTE CABLE OPERATION AND INSTALLATION: (continued) 4. Turn the cable eye Jam nut on the 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 in the spool and align the holes.
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 operate each individual valve section. The control handle assemblies are ordered as PN 02971243 Control Assembly - Controller End Installation Procedure: 1. Each controller assembly comes fully as- Figure 11 sembled. All required hardware etc. is included.
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 9 A-BOOM Optional Joystick - Wire Harness & Valve Installation A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Optional Joystick Mounting 9 8 6 1 2 3 Tractor Seat with Seat Cushion Removed Three Existing Holes 5 7 4 FIGURE 1 Item Part No.
Option Joystick Mounting Installing Joystick Mount to Tractor 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.
Joystick Mounting 2 WD & 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 Joystick Console. The Joystick Console holes are threaded so no Nuts are needed.
Joystick Mounting 2 WD & 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 cut to form 2 ends. You will need to locate the Ignition Switch Power Wire; this wire will have current only when Ignition Switch is on. This Wire will have a wire Tee’d into it. (See Figure 9) * 5. Wire Harness Through Cab.
Joystick Mounting 2 WD & 4 WD Installing Wiring Harness to Joystick: Battery Shown here is typical Ignition connection, Your Ignition may vary but the function will not. ACC Wire (Continued) Ignition 8. 9. Install Wiring Harness to Joystick. Pull the Wiring Harness up till it touches the bottom of the Joystick connection (See Figure 14). Align the Plug Guides (there are 1 wide and 2 narrow lugs) that prevent the plug from being installed wrong.
Joystick Mounting 2 WD & 4 WD Installing Warning and Instruction Decals: 1. FIGURE 16 Always clean 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. 2. Identify Decals. Lay all the Decals out and ID each one so you will know which is installed where.
Wire Harness / Valve Mounting 2 WD & 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 harness runs along with the hydraulic Hose from the Tractor Stack Valve to the front of the tractor. Do Not tie the Harness or Hoses to the Tractor frame rail at this time. 2. Wire Harness & Front Rail Support.
hPhoPht Wire Harness / Valve Mounting 2 WD & 4 WD Installing Wire Harness To Valve: (Continued) Plug Gaskets 5. Wire Harness Terminal Identification. The Wire Harness Terminal Plugs are marked in writing 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.
Wire Harness / Valve Mounting 2 WD & 4 WD Installing Wire Harness To Valve: (Continued) 8. Solenoid Lock Valve Connection. Solenoid Lock valve is mounted on the Valve Tilt Port on the RH Side (See Figure 27). Find the two wires in harness that has eye terminals on them. Connect them to the Solenoid Lock Valve (See Figure 27) Solenoid Lock Valve 9. Servo Control Manifold Solenoid. Locate the last Plug in the harness. This Plug is a two wire self sealing push connector.
Joystick Plug (Bottom of Joystick Console) Joystick w/ Push/Pull Motor Switch & Rocker Master Switch FIGURE 30 C K Red N D Ign Acc B Brn/Blk Org/Blk 5 E R Motor Relay X Wht/Red X B 7 3 T T B X X 1 3 4 6 2 D 8 5 1 B Grey/Blk 7 6 4 Pwr Motor Push / Pull Switch With D Momentary Start G 10 AMP Grnd Master Switch D P Start Wht/Blk 2 Yel X-Output D S Rocker Switch Y-Output J Grn Red - Negatve B Z-Output + Positive Danfoss Command Circuit (Joystick) B J D C K Vi
Wire Harness (Joystick Console Plug to Valve) Actual Pin Location is Shown for Plug in Wire Harness Plug (New Style) this Illustration Narrow FIGURE 31 Notch (2) P N R Brn M S D L Brn C E K B U F J G H G Start Solenoid Loop E V X B T A W A Wide Notch (1) (+) 12V T Piston Pump Solenoid R D (-) Grnd H Red Blk J L U Blk C Blk Red Blk V K F Soleniod Lock Valve Blk Red M W Red R H S Grnd 2 1 3 Grnd 2 1 3 Grnd 2 1 3 Grnd 2 1 3 SWING LIFT DIPPER TILT A-Boom
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 basically 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.
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 10 A-BOOM Head Installation (Optional Heads) A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Optional Mower Head Installation Attaching Flail-Axe Head: Hose #1 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. 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. Hose #2 Figure 1 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.
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).
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).
Optional Mower Head Installation X-Frame Square Head Attachment: FIGURE 30 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. Figure 7.
Section 11 A-BOOM Fill Hydraulic Tank A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Section 11 - 1 © 2003 Alamo Group Inc.
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 Suction 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.
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 & 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.
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 12 A-BOOM Hydraulic Start-Up Procedures A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Start-up Instructions: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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 ABoom. Keep all decals clean and readable. Replace lost or damaged decals.
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.
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Section 13 A-BOOM Boom Rest Plate and Boom Swing Stop Installation A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
Boom Rest Plate & Hook Installation Boom Rest Plate installation: 1. Boom rest Mounted. Boom rest should already be mounted and tighten down to Tractor from earlier assembly section. At the top of the Boom rest there will be a Boom rest Plate bolted to Boom rest, this should be mounted out to the Far right side.. (See Figure 1) Boom Rest Plate 2. Boom Rest Weld on Transport Plate.
Boom Rest Plate & Hook Installation Boom Rest Plate installation: Boom 5. Marking Boom. Use a Black (or color desired) to mark the Boom, Make a Line on the Boom parrelel with the Bolt on Boom Rest across the Boom, (See Figure 5 & 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).
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). Boom Swing Stop Lug High Frame 2.
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
NOTES A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc.
A-Boom (JD 6615 & JD7615) Assembly Manual 2003 Edition P/N 02980169 A-Boom (JD 6615 Asy Instruction Manual) 05/03 © 2003 Alamo Group Inc.