Alamo DSEB-D16-SAS, DSEB-D16 User Manual

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

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. Observe the rules of safety and common sense!

WARRANTY INFORMATION: Read and understand the complete Warranty Statement found in this Manual. Fill out the Warranty Registration Form in full and return it 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 provide enough detail to eliminate the need for contact of the Alamo Industrial Technical Service Dept. However, it should be understood that many instances may arrive where correspondence with the Manufacturer is necessary.

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

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

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

1. Hydraulic or Mechanical Trouble Shooting.

2. Request for Technical Information or Specifications.

3. Mounting or Fitting Problem.

4. Special Service Problem.

5. Equipment Application Problems.

6. Tractor Problem Inquiries.

HOW YOU CAN HELP:

Make sure the call is necessary! Most of the calls received may not be necessary if the Dealer Service Technician would do the following.

1. Check the Service Information at your Dealership provided by Alamo Industrial, This would include, Service Bulletins, Information Bulletins, Parts Manuals, Operators Manuals, Assembly Manual or Service Manual, many of these are available via the Alamo Industrial Internet site (www.AlamoIndustrial.Com). Attempt to diagnose or repair problem before calling.

2. If a call to Alamo Industrial is needed, Certain Information should be available and ready for the Alamo Industrial Service Staff. Such information as, Machine Model, Serial Number, Your Dealer Name, Your Account Number and Any other information that will be useful. This information is vital for the development of a prompt and correct solution to the problem. This will also help to develop a database of problems and related solutions, which will expedite a solution to future problems of a similar nature.

3. The technician may be asked to provide detailed information about the problem including the results of any required trouble shooting techniques. If the information is not available, The technician may be asked to get the information and call back. Most recommendations for repairs will be based on the procedures listed in the Service Manual / Trouble Shooting Guide 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

Index -3

INDEX - ASSEMBLY INSTRUCTION

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.............................................................2-2

Wheel Counter Weight Installation.................................................... 2-3

Section 3

Front Pump Drive Parts.....................................................................3-2

Crankshaft Pulley Preparation...........................................................3-3

Pump Driveshaft Assembly...............................................................3-3

Pump Driveshaft Half, Shaft End.......................................................3-4

Pump Mount Plate..............................................................................3-4 to 3-5

Pump Drive Shaft, Tube End.............................................................3-5

Pump Installation................................................................................3-5 to 3-6

Frame Rail Support Installation......................................................... 3-7

Page

Section 4

Frame Rail Pre- Assembly................................................................ 4-2 to 4-6

High Frame Parts...............................................................................4-7

Frame Rail Pre-Installation................................................................ 4-8 to 4-11

High Frame Pre-Installation............................................................... 4-12 to 4-16

Tack Welding Frame Assembly........................................................ 4-17 to 4-21

Remove Frame for Final Welding......................................................4-21 to 4-23

Section 5

Frame Rails Final Installation.............................................................5-2

Boom Rest Installation.......................................................................5-3

Axle Strap Installation.........................................................................5-4

Stabilizer Kit Installation.....................................................................5-4

High Frame Installation...................................................................... 5-5 to 5-8

Tie Up Hoses to Tractor Frame (Stack valve Hoses)....................... 5-8

Section 6

Hydraulic Tank Installation................................................................. 6-2

Hydraulic Tank Counter Weight Installation...................................... 6-2

Hydraulic Tank Oil Level Sight Gauge............................................... 6-3

Hydraulic Tank Decal Installation.......................................................6-3

Cab Decal Installation........................................................................6-4

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Index -4

INDEX - ASSEMBLY INSTRUCTION

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).................... 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 Parts......................................................................... 9-2

Install Joystick Mount to Seat............................................................ 9-3

Install Joystick Controler to Seat Bracket..........................................9-4

Tractor Floor Mat Removal................................................................9-4

Wire Harness to Tractor Connections...............................................9-5 to 9-6

Tractor Ignition Wire Connection.......................................................9-6

Connect Wire Harness to Joystick....................................................9-6

Tractor Floor Mat re-Install.................................................................9-6

Tractor Cab Decal Installation........................................................... 9-7

Connect Wire Harness to Control Valve........................................... 9-8 to 9-13

Page

Section 10

Attaching Flail Axe Head.................................................................... 10-2 to 10-3

Attaching Ditcher Head......................................................................10-4

Attaching Timbercat Head................................................................. 10-5

Attaching X-Frame Square Head...................................................... 10-6

Section 11

Filling Hydraulic Tank w/Oil................................................................11-2 to 11-3

Section 12

Hydraulic Start Up Instructions.......................................................... 12-2

Post Assembly Check List................................................................ 12-3

Section 13

Boom Rest Plate Installation............................................................ 13-2 to 13-3

Boom Swing Stop Installation........................................................... 13-4

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Index -5

NOTES

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Index -6

SAFETY

SECTION

Safety Section 1-1

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. 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 assembling, 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 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. (SG-1)

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

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. (SG-3)

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)

PELIGRO!

Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. (SG-3)

INSTRUCTIVO!

!LEA EL INSTRUCTIVO!

LEA EL

WARNING!

DANGER!

WARNING!

Perform service, repairs and lubrication according to the maintenance section. Ensure the unit is properly lubricated as specified in the lubrication 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. (SG-35)

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. (SG-7)

Never work under the Implement, the framework, or any lifted component unless the Implement is securely supported or blocked up to prevent sudden or inadvertent falling which could cause serious injury or even death. (SG-14)

Use caution and wear protective gloves when handling sharp objects such as blades, knives, and other cutting edges. Be alert to worn component surfaces which have sharp edges. Sharp surfaces can inflict severe laceration injuries if proper hand protection is not worn. (SG-37)

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

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.

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)

Always wear safety shoes with steel toes when working on this equipment. It is recommended that the safety shoes have metatarsal guards.

WARNING!

DANGER! Always disconnect the wire leads from the mower valve solenoid before

DANGER!

When welding use Welding hood with the appropriate OSHA required protective lens, welding apron, and welding gloves.

performing service on the Tractor or Mower. Use caution when working on the Tractor or Mower. Tractor engine must be stopped before working on Mower or Tractor. The Mower Blades could inadvertently be turned on without warning and cause immediate dismemberment, injury or death. (SBM-12)

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

Safety Section - 4

SAFETY

DANGER!

WARNING!

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.

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. (SG-6)

Start tractor only when properly seated in the Tractor seat. Starting a tractor in gear can result in injury or death. Read the Tractor operators manual for proper starting instructions. (SG-13)

DANGER!

WARNING!

DANGER! All Safety Shields, Guards and Safety devices including

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 a piece of heavy paper or cardboard. Highpressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene. If oil does penetrate the skin, have the injury treated immediately by a physician knowledgeable and skilled in this procedure. (SG-15)

Always read carefully and comply fully with the manufacturers instructions when handling oil, solvents, cleansers, and any other chemical agent. (SG-22)

(but not limited to) - the Deflectors, Chain Guards, Steel Guards, Gearbox Shields, PTO integral shields , and Retractable Door Shields should be used and maintained 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 possibility of injury or death from thrown objects, entanglement, or blade contact. (SGM-3)

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Safety Section - 5

SAFETY

DANGER!

DANGER! Operate the Tractor and/or Implement controls only while properly seated

WARNING!

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. 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. (SG-27)

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. (SG-29)

Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. (SG-30)

WARNING!

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. W ash 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. (SG-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. (SG-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. (SG-38)

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Safety Section - 6

Section 1

A-BOOM

TOOL REQUIREMENTS

AND

PRE-DELIVER Y INSPECTION

CHECKLIST

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Section1 - 1

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 Safety air nozzle for blowing out Hoses and Fitting prior to assembly. (Required).

3. Complete Air Impact Sockets, 1/2" Drive and 3/4” drive (Recommended).

4. Torque Wrench, 400-ft lb. rating, can use a Torque Amplifier Wrench. (Required)

5. Complete Set of Hand Wrenches from 7/16" to 2" (Recommended).

6. Assortment of Screwdrivers, (Short ones and Long ones). (Required)

7. Electric Grinder or Air Grinder, Size according to needs (Required).

8. Burr Grinder, Electric or Air optional, for resizing Holes and removing Burrs from stamped

metal or stamped holes. (Required)

9. Welder, capable of welding up to 3/8" material, Use experienced Welder Personel. (Required)

10. Flame Proof or flame retardant Material to Cover and protect Tractor finish and components

during assembly. (Required)

11. A good fire Extinguisher on hand before any welding or grinding begins. (Required)

12. 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 area is clean. Material the size of a human hair can contaminate the Hydraulic System (Required).

13. A place to keep all Components separate and clean untill ready for them (Recommended)

14. Electrical Butt connectors and Electrical Pliers. (Required)

15. Paint Scraper to remove Paint before welding. (Recommended)

16. Floor Jack, 2-1/2 Ton capacity (Required)

17. An asortment of large C-Clamps (Required)

A-Boom (JD 6615/ 7615 Asy Instruction Manual) 07/03

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:

----- 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. (Item 1 page 1-5)

----- 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. lbs.

----- Front Rail Bolts are torqued to 170 ft. lbs. (Item 17 page 1-5)

----- Front Support Bolts are torqued to 240 ft. lbs. (Item 4 page 1-5)

----- Hydraulic Tank mounting Pins / Bolts in place correctly.

----- Boom Main Pins are torqued to 170 ft. lbs.

----- King Pin Retaining Nut is properly locked in place.

----- All Welds inspected toinsure proper welds and locations.

Hydraulic System:

----- 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.

----- Front Pump Shaft adapter bolts are tight. (Item 6 page 1-5)

----- 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)

----- The Pump Drive Shaft has correct alignment.

----- Suction Hose has no leaks or kinks.

Rotary Mower Head:

----- Skid Shoe Bolts are torqued to 120 ft. lbs. (Item 8 page 1-5)

----- Spindle Housing Bolts are torqued to 400 ft. lbs. (Item 9 page 1-5)

----- The Spindle Housing is properly lubricated. (item 10 page 1-5)

----- Motor Bolts are torqued to 120 ft. lbs. (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)

----- Blades Swing freely. (Item 14 page 1-5)

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

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 location)

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& 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 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

Section 1 - 4

Tractor - Mower Component Location

For Check List

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Section1 - 5

Section 2

A-BOOM

Wheel Weight

Inst allation

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

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 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. 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 provides anti-freeze to approx -50 deg. F. below 0.

Rotate Washer to Match Bolt

Circle dia. and Washer fits into

Wheel Weight Slot.

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 lbs. 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

Section 2 - 2

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. When Wheel Weight is centered in Wheel Secure Forklift and Set Parking Brake on Forklift. Insert one of the three bolts through Weight and Wheel (Rotate Wheel to align holes if needed). Install a Hex Lock Nut on inside. Insert the other two Bolts through Weight and Wheel and start the other two Locknuts. Do not tighten yet. (See Figure 2)

Figure 2

Wheel Weight Mntg

Lock Nut

5. Looking at the outside

make sure the three special Washers (Figure 1 Item 2) are aligned with the Slots in the Wheel Weight. Tighten the three Bolts now. You will need an assistant to hold the other Side while you are tightening the Bolts. While tightening Bolts, check to make sure the three special washers are seated correctly. If these Bolts are tightened and washer are not seated into the recess on Wheel Weight, damage will occur. (See Figure 3)

Wheel Weight

Special Washers

Mounting Bolts

Part # 02971569

(3)

6. Remove forklift away from

Wheel and Weight. Re-check tightness of Wheel Weight retaining Bolts. Bolts should torque to 500 ft. lbs.

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Figure 3

Wheel Weight

1400 lbs.

Section 2 - 3

NOTES

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Section 2 - 4

Section 3

A-Boom

Front Pump &

Drive Shaft

Inst allation

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Section 3 - 1

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. All 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 & Washers

JD Tractor Crankshaft Pulley

JD Tractor Frame Rails

Pump

8,9

Item Part No. Qty Description

1 02976087 ar Front Pump Plate (Standard) Shown

02979080 ar Front Pump Plate (Optional w/ Pump Guard) 2 02979790 1 Pulley Adapter 3 02973712A 1 Driveline Assembly 4 02975669 4 Bolt, 20 mm 2.5P X 60 mm GR 10.9 5 02971158 4 Lockwasher, 20 mm 6 02976344 4 Bolt, 7/16" NC X 1-1/4" GR 8 7 00022200 4 Lockwasher, 7/16" 8 02892000 2 Bolt, 1/2" NC X 1-1/2" GR8 9 00001300 2 Lockwasher, 1/2" 10 02978480 2 Spacer, Pump Plate (JD 6615 Series)

JD Tractor Front Casting

Figure 1

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

Section 3 - 2

Pump / Drive Assembly Instructions

Installing Pump Drive Components:

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). The Non-treaded holes are used to mount the Adapter to the Pulley using bolts # 02979791 (10mm 1.5 P X 35mm Gr.10.9) & Lockwasher # 00755954 (10 mm). Do not use 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 Adapter. Note that the Universals of the Driveshaft are in time. When installed in tractor they should be in time as shown, both Yokes the same.

Plastic Plugs

Figure 2

Front Cover Removed

Pump Plate Mounting Holes

Figure 3

Front Cover

Cover

Retaining

Bolts (2)

Non-Threaded

Holes

Figure 4

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

4 Threaded

Holes

Pulley Adapter

Part # 02979790

Figure 5

Section 3 - 3

Splined Clamp Yoke

/ Tube End

Flange Yoke

/ Shaft End

Drive Shaft

Assembly

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.

Shaft 1/2 Assembly

w/ Flanged Yoke

Tractor

Radiator

Figure 6

Tractor Engine

Left Hand front side

of Tractor

Installing Pump Mount Plate & 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 Chart).

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 7

Tube End of

Driveshaft

Splined

Clamp Yoke

Figure 8

Spacer (2)

Standard Pump

Mount Plate

Shown

Standard

Pump Mount

Plate

Shown

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Section 3 - 4

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.

Bar to Hold Drive Shaft

Installing Pump:

1. Install Pump into Splined Clamp Yoke. Slide

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.

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 cannot touch the Pump Housing; it will damage the Housing and the Yoke if it does. This is a very critical adjustment (See Figure 12).

3. Tighten Clamp Yoke. After Gap between

Yoke and Pump has been adjusted tighten the Bolts & Nuts on the Clamp Yoke (See Figure 12 & 13). Check Pump to Yoke Gap once more. Keep Pump Supported do not let it hang on Yoke.

Driveshaft, Spline

Clamp Yoke End

Figure 9

Bar to Hold

Driveshaft

Loosen

Clamp

Yoke Bolt

Figure 10

Align Splines of

Pump Shaft w/

Splines of Yoke

Bar to Hold

Figure 11

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Driveshaft

Section 3 - 5

Pump

Assembly

1/16" to 1/8" Gap

between Pump &

Figure 12

Yoke (must)

Splined

Clamp

Yoke

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. 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. There is

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 untill they 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.

Figure 13

Gap ? Check, this must have a gap

between Pump & drivesahft

Figure 14

Pump Retaining

Figure 15

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Bolts (2)

Section 3 - 6

Figure 16

Pump / Drive Assembly Instructions

Install Front frame Rail Support s:

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. They will not interchange 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 & 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.

Tractor Frame Rail

Bolts(5)

Figure 17

Right Hand Frame rail

Support Shown

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 bolts; Install the Front Frame Rail Support. Tighten the 4 bolts through Tractor Frame Rail. (See Figure 19).

Figure 19

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Figure 18

Mounting Plates on

Front Frame Rail Support, the longer part toward front on

RH and LH side

RH Frame

Rail Support

RH Tank

Mount Bracket

Section 3 - 7

NOTES

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03

Section 3 - 8

Section 4

A-Boom

Frame Rail / High Frame

Setup / Pre- Assembly

Inst allation

A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03

Section 4 - 1

+ 89 hidden pages