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

Page 1

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

Page 2

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.

Page 3

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

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Index -3

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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

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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

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NOTES

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Index -6

Page 7

SAFETY

SECTION

Safety Section 1-1

Page 8

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)

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Safety Section - 2

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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)

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Safety Section - 3

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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)

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Safety Section - 4

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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)

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Safety Section - 5

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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)

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Safety Section - 6

Page 13

Section 1

A-BOOM

TOOL REQUIREMENTS

AND

PRE-DELIVER Y INSPECTION

CHECKLIST

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Section1 - 1

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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)

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Section 1 - 2

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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)

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Section1 - 3

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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.

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Section 1 - 4

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Tractor - Mower Component Location

For Check List

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Section1 - 5

Page 18

Section 2

A-BOOM

Wheel Weight

Inst allation

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Section 2 - 1

Page 19

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.

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Section 2 - 2

Page 20

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.

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Figure 3

Wheel Weight

1400 lbs.

Section 2 - 3

Page 21

NOTES

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Section 2 - 4

Page 22

Section 3

A-Boom

Front Pump &

Drive Shaft

Inst allation

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Section 3 - 1

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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.

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Page 24

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

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4 Threaded

Holes

Pulley Adapter

Part # 02979790

Figure 5

Section 3 - 3

Splined Clamp Yoke

/ Tube End

Flange Yoke

/ Shaft End

Drive Shaft

Assembly

Page 25

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

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Section 3 - 4

Page 26

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

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Driveshaft

Section 3 - 5

Pump

Assembly

1/16" to 1/8" Gap

between Pump &

Figure 12

Yoke (must)

Splined

Clamp

Yoke

Page 27

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

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Bolts (2)

Section 3 - 6

Figure 16

Page 28

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

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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

Page 29

NOTES

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Section 3 - 8

Page 30

Section 4

A-Boom

Frame Rail / High Frame

Setup / Pre- Assembly

Inst allation

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Section 4 - 1

Page 31

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. 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 this 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..

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Section 4 - 2

Page 32

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. The Rail Mounting Pad (See Figure 1 Item

4) is loose and not welded to the front of the Frame Rail untill final assembly.

Figure 1

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) 3 ------------- 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:

Item 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.

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Section 4 - 3

Page 33

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)

3,4

Item Part No. Qty Description

02970118 -- Frame Rail Stiffener Kit (Item 1 thru 4) 1 02970115 2 Rail Stiffener Weldment 2 02970086 1 Tube, Rail Stiffiner 3 02712500 4 Bolt, 1" NC X 4" GR8 4 5JRC1680 4 Locknut, 1" NC (Toplock) 5 02978499 2 Gusset Rail Support

Figure 2

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Section 4 - 4

Page 34

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 Mounting Tube Componnets

Machete High

Frame

RH Frame Rail

Front Shown

Figure 3

Item Part No. Qty Description

1 ---Ref----- 2 Mounting Tubes, (Length will Vary with Mount Kit).

02918600 4 Bolt, 3/4" X 2" Long (Not Shown)

00037200 4 Locknut, 3/4" Toplock (Not Shown 2 02966639 7 Bar Mounting Strap 2A 02966639 1 Bar Mounting Strap (Cut In Half) 3 00037200 8 Locknut, Toplock 4 02957039 8 Bolt, 3/4" X 10-1/2" Long 5 02966641 2 Angle Mount

Cut Off

6-3/4"

Width of Frame

Rail Tube

Frame Rail

(to Rear Axle)

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Section 4 - 5

Page 35

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.

Bolts (3 each side)

Angle Mount (2

each side)

Mounting Tube

Frame

Rail

Rear of

Frame Rail

(1 each side)

Mounting Bolt Holes

(2 each end)

Angle Mount

(2 each side)

Bar Mounting Strap Cut Off (2 each side)

Locknuts (3 each side)

Bar Mounting

Figure 4

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 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 will be 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.

Straps

Front

Frame

Rail

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Section 4 - 6

Page 36

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.

Hydraulic Tank

King Post

High Frame

Suction Line

to Pump

Oil Return Filter

Hydraulic Tank

Mounting Tube

Counter Weight

Mounting Tube

Oil Suction Filter

Tank Counter Weight Weldment

Figure 5

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.

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Section 4 - 7

Page 37

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). 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 remember. There are 4 bolts that go through Tractor Frame that will have to be removed before this can be mounted, 4 bolts from both sides (LH & RH) of the Tractor at the 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 the other side and remove the 4 Bolts from Tractor Frame Rail and install Machete Frame rail Supports using the 4 new Support Retaining Bolts. The Tank Support brackets connect to the Tractor. These will be mounted when the Frame Rail Supports are installed (See Figure 7).

DO NOT remove these

Figure 6

Figure 7

Frame Rail

Support Brackets

3. Rail Support Gusset Mount. There

are two Bolts in the Tractor 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 Stiffener Kit and Part numbers for components.

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Section 4 - 8

Figure 8

Page 38

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). 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). Remember the LH is the one with the Counter Weight Mount Tubes welded onto it, (See

Figure 1)

6. 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).

Front Rail

Mounting Pad

P N. 02725900

Figure 9

Front Frame Rail

Mount Pad

Front Frame Rail

Support Mount

Figure 10

Figure 11

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Section 4 - 9

Figure 12

Page 39

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. The Frame Rails Mount to the rear Axle of Tractor. The RH Side has Longer Bolts than the LH Side does. This is because the Axle Mounted Boom Rest will 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. Install the other Frame Rail. The other frame rail will install the 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 tractor and to Frame rails it must be bolted together.

Figure 13

Figure 14

Figure 7

Use Extreme caution so that Frame Rail will not hit Cab or Hood & cause damage

Floor Jack and

Frame Rail

Rear Axle

Mount

Figure 15

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Section 4 - 10

Figure 16

Page 40

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 against the 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 Stabilizer kit to the Frame Rails with C-Clamps on both LH and RH (See Figure 19). You may leave the Floor Jack or remove it.

Figure 17

Stabilizer Gusset

Machete

Frame Rail

13. Align Frame Rails on Front Mount Pads.

Locate the 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 CClamp to hold it in place when aligned. Do this on Both the RH and LH side. (See Figure. 20)

Stabilizer up

against Gusset

C-Clamps

Figure 18

Frame Rail

(Front)

Front Rail

Mounting Pad

Stabilizer Kit

C-Clamp

1/4"

Shanked

Screwdriver

Figure 19

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Section 4 - 11

Figure 20

Page 41

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 level when lifted over Frame rails.

Figure 21

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

Figure 22

King Post

Pivot Pin

Magnetic Level

Front of

Tractor

Magnetic Level

Figure 23

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Section 4 - 12

Figure 24

Page 42

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) . 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 page (See Figure 29).

24-1/2"

Min

height

frame

Hood

Figure 25

5. Check High Frame for Level. Check

the two Magnetic Levels that you installed earlier. The Top Level should be from side to side of the Tractor (See Figure 27). The level on the King Post Pivot Pin should be level 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 at this 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.

Level

High Frame

Frame Rail

Figure 26

Level

Figure 27

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Section 4 - 13

Figure 28

Page 43

Pre-Installing High Frame: (continued)

12345678901234567890123456

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.

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 & 30)

Rail when aligned and leveled. (See Figure

29). Leave the Hoist connected to the High frame for safety and additional support.

Support

Plate

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Support

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.

Frame Rail Installation

The height of the High frame should be

Clamp the High frame to the Frame

Frame Rail

Horizontal Tube

High Frame

Horizontal Tube

Front

Mount

Figure 30

Frame Rail Tube & Frame Rail must be align parallel with each other up and down here

Figure 29

Machete High Frame

Vertical Tube

23456789012345678901234567890121

234567

Frame Rail leading to rear

Axle Housing of Tractor

Section 4 - 14

234567890123456789012345

2345678

Set High Frame in Line with

Frame Rail

Vertical Tube

as shown

Frame Rail

Vertical Tube

Page 44

Frame Rail Installation

Pre-Install Mounting Tubes for High Frame: (continued)

Machete High

Frame

RH Frame Rail

Front Shown

6-3/4"

Figure 31

Item Part No. Qty Description

1 ---Ref----- 2 Mounting Tubes, (Length may Vary with Mount Kit).

02918600 4 Bolt, 3/4" X 2" Long (Not Shown)

00037200 4 Locknut, 3/4" Toplock (Not Shown 2 02966639 6 Bar Mounting Strap 2A 02966639 2 Bar Mounting Strap (Cut one end off LH Rail only) 3 00037200 8 Locknut, Toplock 4 02957039 8 Bolt, 3/4" X 10-1/2" Long 5 02966641 2 Angle Mount (Front only)

Cut one end off

Mounting

Tube Width

Frame Rail

(to Rear Axle)

9. Install Mounting Tubes . Loosely bolt

the Front Angle Mount end of Mounting Tube (See Figure 32). Slide 1 Mounting Tube in on top of the Frame Rail on each side, the end that has the Angle Mount bolted to it goes to 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 Mounting Tube Height, this is the way that it will appear as looking over the Hood of the Tractor toward LH Side.

High Frame

Figure 32

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Section 4 - 15

(LH Side)

Mounting

Tube

Page 45

Frame Rail Installation

123456

Pre-Install Mounting Tubes for High Frame: (continued)

10. Install Front Angle Mount. Loosely

bolt the Front Angle Mount on the other end

between Plates on Front

Angle Mount end Only

(front) of each Mounting Tube (See Figure

Washer 1/8" thich inserted

33). Notice the washer that is installed be-

Angle Mount

tween 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. Putting this 1/8" thick washer on the front Angle Mount end only will allow for this Gap on both ends. (See Figure 33 & 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

Figure 33

welded to the Frame rails later. Do not do any tack welding till instructed to.

Mounting Angle

Washer Here

w/ Bolts & Nuts

Mounting Tube

Frame Rail

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23456789012345678901234567890121

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234567

Put a Spacer

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

Front

Support

Mount

Figure 34

Bar Mounting Straps

with Bolts & Nuts

234567

2345

234567

2345678234567890123456789012345

Machete High Frame

Frame

Section 4 - 16

Rail

2345678

Approx. 1/2"

from end

2345

Set High Frame in Line with

Frame Rail

Page 46

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 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). 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 Brackets 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 can be removed now. Remove the four mounting bolts and slide the Tube forward or back to get it out. (See Figure

39).

Gap Between

Frame Rail & Bolt

Head

Figure 35

Tack Weld Here

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

Figure 37

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

Section 4 - 17

Figure 36

Stablizer Gusset

DO NOT WELD

NOW

Figure 38

Tack Weld 4

places on each side

Page 47

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

Rear Axle End

Tack Weld here on both

sides Front and Back only

after alignment

Align Flush with Bottom

of Vertical Tube

RH Rail Stiffener Weldment (RH Side)

Rail Stiffener Tube Crossmember

LH Rail Stiffener Weldment

Figure 39

(LH Side)

Horizontal Tube

Gusset Rail Support

Tack Weld Here

after final

assembly only

LH Frame Rail is

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 & 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) & 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

Section 4 - 18

Page 48

Frame Rail Installation

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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.

7. 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 & RH Side (See Figure 42 & 43). These Tack Welds need to be done in an alternating pattern so Mounting Tubes do not Lift or move. There should not be any gaps between Frame Rails, High Frame or Mounting Tubes. Do this on LH and RH Frames.

Tack Weld in 4

Corners of Angle

Mounts

Figure 40

Mounting Angle

w/ Bolts & Nuts

Tack Weld Here

to Frame Rail

Front

Support

Mount

Bar Mounting Straps

with Bolts & Nuts

Figure 41

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

Tack Weld Mounting Tube Here

in 6 places 3 top & 3 bottom

Machete High Frame

Mounting Tube

23456

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2345

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23456789234567890123456789012345

Machete High Frame

Section 4 - 19

Frame

Rail

2345678

Approx 1/2

2345

from end

23456

Set High Frame in Line with

Frame Rail

Page 49

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 easier to see and it can be done after they are removed from tractor if you want.

These must be Tack welded in alignment when installed, so the holes are in line. If not in line the Bolt cannot be installed. Measure the distance from the Angle Mounting 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). Figure 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)

Tack Weld Here in 3 places on top and 3 places on bottom

Figure 42

Cut Straps

Here

Rear of LH Mount-

ing Tube toward

Cab

Measure

Distance Here

Upper Bar Mounting

Strap (Cut Off)

9. Tack Welded. (See Figures 31 through 45)

Figure 44

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

Recheck that all components are

Distance Here

Do Not

Weld Here

Measurement

Lower Bar Mounting

Strap (Cutt Off) Weld

Here

Figure 43

Measure

Transfer

to Here

Figure 45

Section 4 - 20

Lower Bar

Mounting Strap

(Cut Off)

Page 50

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. This is also recommended so Assemblies can be turned while welding to get maximum quality welds.

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 all the way around (See

Figure 49 & 50). These must be strong Welds.

Figure 46

Left Side of High

Frame &

Mounting Tube

Weld Solid all

the way around

Figure 47

Turning High frame to weld all the way

around Mounting Tubes.

Right Side of High

Frame &

Mounting Tube

Weld Solid all

Figure 48

Turning High frame to weld all the way

around Mounting Tubes.

the way around

Figure 49

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

Section 4 - 21

Figure 50

Page 51

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.

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 & 56)

3. Weld Front Angle Mount. Weld the Front Angle

Mount to the Frame Rail on the Sides running parallel to the Frame Rail, Not across Frame Rail (See Figure 52 & 58). Weld the Rear Angle Mount to Frame rail the same as the front (See Figure

53).

4. Bar Mounting Strap. Weld these all the way

around, first check your measurements for placement. 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)

Do Not Weld next to Bolt Holes, it

will interfere Hex Heads of Bolts

Figure 51

Weld along sides of Angle Mount

and frame rail on both sides (this

applies to"A" & "B")

5. Frame Rail Stiffener Weldment. Weld the

Frame stiffener to Frame rail on both sides. (See Figure 24). Touch up or re-paint frame components after welding is completed. There are other components that need to be installed before you reinstall frame.

Figure 53

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

Figure 52

Figure 54

Section 4 - 22

Page 52

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). Note that any Step Type Counter Weight must clear the Left Rear Tire.

NOTE: There is a Tire Limit, This should be addressed when ordering the Mount Kit designed to fit with the specified Tire Size. If larger than Tires specified for Mount Kit are installed, mounting kit may not fit.

7. 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 be welded to help assure the integrity of the weld. Repaint / Touch-up welded parts after finished welding.

Figure 55

1/4"

Figure 56

Pigtail Bracket

Figure 57

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

Section 4 - 23

Weld here on

both sides.

Figure 58

Do not weld

Across the Tube.

Not Shown in

Actual Location

Page 53

NOTES

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

Section 4 - 24

Page 54

Section 5

A-Boom

Frame Rail & High Frame

Final Installation

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

Section 5- 1

Page 55

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. This is the same for LH & 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 & 7).

3. Install the Bolts into the front mounting

Plates on the LH and RH Side. Snug them only.

(See Figure 3).

Frame Rail

Mounting

Figure 1

Mounting to

Rear Axle

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 & 4).

Front Mounting

Pads

Figure 2

Rear Axle

Strap

Figure 3

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

Section 5 - 2

Figure 4

Page 56

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.

Boom Rest

Plate

Figure 5

Boom Rest

Weldment

Front

Right

Rear

Wheel

Side

Boom

Rest

Figure 7

Cab

Side

Boom

Rest

Figure 6

RH Axle Strap

Back

Figure 8

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

Section 5- 3

Page 57

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.

RH Axle Strap

Figure 9

Boom Rest

Figure 10

Install with Nuts on

top and Bolt Heads

on the bottom

Figure 12

Axle Strap Bolts

Figure 11

Stabilizer

Gusset

Weld Gusset to

Stabilizer on both

sides.

Figure 13

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

Section 5 - 4

Page 58

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. (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 welded to the Frame rails. (See Figure 15 & 16). Both sides must go down evenly.

4. Aligning Mounting Holes. The Holes in the Angle

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. There are 8 bolts and Nuts that must be installed into the holes of the Angle Mounts. Snug these

Figure 14

Aligning on the LH side

between the front and rear

angle mount.

Figure 15

Aligning on the RH side

between the front and rear

angle mount.

Figure 16

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

Section 5- 5

Figure 17

Page 59

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). 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 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.

Figure 18

7. Tighten High frame Mounting Bolts. Tighten

the 8 Bolts and Nuts for the Mounting Tubes (See Figure 18 & 19). Tighten the Bolts for the Bar

Mounting Straps, These bolts must be tighten so 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 & 21).

Welded on Bar Mounting Strap

Mounting

Tube Bolts

Mounting

Tube

Frame

Rail

Bolt

Figure 19

Figure 20

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

Section 5 - 6

Figure 21

Page 60

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.

Front Mounting Pad Bolts. There are 4 Bolts on each Pad the LH and RH, 8 Total (See Figure

22).

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).

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 & 25).

Tighten LH & RH

Side

Figure 22

Tighten LH & RH

Side

D. 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 (See Figures 1 through

27).

Tighten LH & RH

Side

Figure 24

Figure 23

Tighten LH & RH

Side

Figure 25

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Section 5- 7

Page 61

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).

2345678

Mounting Angle / Mounting

Tube Bolts & Nuts

Frame Rail

Mount

Plate Bolts

Front

Support

Mount

Bar Mounting Straps

with Bolts & Nuts

Bar Mounting Strap

Wleded to Frame

Mounting Tube

23456

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2345678

2345

2345678

Machete High Frame

2345678

Approx 1/2" from end of

2345

frame rail

2345

Tank

Mounting

Tubes

Figure 26

Frame

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 hoses or wire harness, gather this excess 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

Section 5 - 8

Page 62

Section 6

A-Boom

Hyd. Tank, CWT & Decal

Final Installation

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

Section 6 - 1

Page 63

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 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. The Mounting Tubes are welded to the Frame rail and to the Hydraulic Tank (See Figure 28 & 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 Locknuts to the inside . Installing the Bolts this way will make them easier to tighten up (See Figure 28 &

29). Install both bolts as shown (See Figure 28). Snug the Bolts, don't tighten them yet.

Hydraulic

Tank

Locknut

Frame

Rail

Mounting

Bolt

Figure 28

LH Frame

Rail

Figure 29

Mounting

Bolt

CWT

Mount

Tubes

Counter

Weight (CWT)

Counter

Weight Bolt

on Cover

Hyd. Tank

Mounting

Tubes w/ Bolts

2. Counter Weight Cover (CWT). The Counter

Weight Cover will bolt to counter weight. (See Figure 28 & 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.

Figure 30

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Section 6 - 2

Page 64

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)

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). Counter Weight must be Installed befor Boom is mounted to King Post.

2. Decal Part Number. (See Figure 32, 33, 34)

1 = # 02966305, 2 = # 02958241, Operators Safety Decal 3 = # 02977417, Operators Manual Inside 4 = # 1458392, Red Reflector 5 = # 1458392, Yellow Reflector (mount in front of CWT Cover) 6 = # 00756059, Warning - Oil Leak 7 = # 02957827, Danger - Multi Hazard (Rotary) or

# 002369, Danger - Multi Hazard (Flail) 8 = # 02965262, Warning - Hose Burst 9 = # 002508, Alamo Industrial Logo - Small (on front upper Tank) 10 = # 00769394, Alamo Industrial Logo - Large

Most Decals should already be installed when Tank Asembly is shipped.

Attention - Universal Tractor Hydraulic Oil

Figure 31

Top of Tank

Figure 32

Oil Level

Sight Gauge

Figure 33

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

Oil Level

Sight Gauge

Figure 34

Section 6 - 3

Page 65

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 = # 02962107,

Valve Operation - 4 Spool, (Install in lower Right Hand corner of Tractor Windshield). (See Figure 35)

2 = # 02967827,

of Left side window). (See Figure 36)

3 = # 02965262,

of Left Side window). (See Figure 37)

4 = # 02964677, Warning - Boom Rest (install in upper right corner

Right Side Window). (See Figure 38)

5 = # 02963524, Attention - Boom Swing (install in upper right

corner Right Side Window). (See Figure 38)

6 = # 00763977, Notice to 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"

"OFF" Switch (See Figure 35)

These Decals will need to be installed by the person 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.

Valve Operation - 5 Spool or # 02962024,

Danger Multi-Hazard (install in upper right corner

Warning - Hose Burst (Install in upper left corner

Figure 35

Figure 36

Figure 37

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

Section 6 - 4

Figure 38

Page 66

Section 7

A-BOOM

Boom Inst allation

A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03

Section 7 - 1

Page 67

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. 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 lay 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 Turning Arm. Attach Lockwasher (4), Washer (5) and Bolt (6) and tighten (also see Parts Section on the Boom Assembly) (See Figure 3, 4 & 5)

Note: Additional support may be need at the end of the Boom to aid in installation.

Approximate Lift pont

Hoses

Boom

Figure 2

Lifting Lugs weld on here

3,4,5,6

8,9,10

Figure 3

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Section 7 - 2

Page 68

Boom Installation

Boom Installation / Boom Hoses:

(continued)

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 & 7).

6. Leave Boom Supported by Hoist untill

Boom is connected to King Post and all cylinders attached. (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 internal components covered with Oil. If boom is raised by hoist while these hoses are disconnected oil may be forced out of collapsing end of cylinder.

Boom

Retaining Pin

& Nut

Figure 4

Lifting Lugs weld on here

Figure 5

Attach Swing

Cylinder to King

Post and High

Frame

Figure 6

A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03

Section 7 - 3

High Frame

(Swing Cylinder Mount)

Swing Cylinder

Butt End

Figure 7

Front

Swing

Hole

Rear

Swing

Hole

Page 69

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 & 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.

Tank Suction

Hose Side

Figure 8

Tank Return

Hose Side

Front of Tank &

Front of Tractor

To Pump

Figure 9

Hose Ring

From Tank

SUCTION HOSE

Hose Ring

Pump Pressure

Hose to Cutter

Motor Control Valve

Figure 10

Tank Suction

Hose from Hyd.

Tank

Pump Pressure

Hose Side to Cyl.

Control Valve

Pump Pressure

to Cutter / Motor

Valve

Pump Pressure

Hose to Cutter

Motor Control Valve

Figure 11

A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03

Section 7 - 4

Figure 12

Page 70

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.

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).

Pressure from

Cutter / Motor

Valve to Motor

Return Hose

Figure 12

Return Hose

to Tank

from Motor

7. 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).

Return Hose

from Cutter

Valve to

Figure 14

Tank

Return Hose

from Cutter

Valve to

Tank

Figure 13

Tank Return Hose to Tank

Return Filter Housing

Return Hose

Pressure Gauge

Figure 15

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Section 7 - 5

Page 71

NOTES

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Section 7 - 6

Page 72

Section 8

A-BOOM

S tandard

Cylinder Control

Valve Installation

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Section 8 - 1

Page 73

Cylinder Control Valve Installation

Control Handle Assembly Installation :

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).

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 case of emergency needs. (See Figure 1)

3. The Arm Rest is bolted to the Control

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 harness through it. The opening around cables through rubber 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)

Dipper

Extend

Lift

Tilt

Swing

"ON" "OFF"

Switch

Figure 1

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).

Figure 2

Figure 3

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Section 8 - 2

Page 74

"ON - OFF" Switch Installation

Black

Orange Wire

Acc

Service

Wire

10Amp

Spade Fuse

Yellow or

Quick

Splice

Blue

Push/

Pull

Switch

Red Wire

Line

Connector

Solenoid

Cutter

Valve

Red

White

Wire

Ign

Acc

Start

Terminal

Off

Acc

Tractor Ignition

Switch

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Section 8 - 3

Billet

Tractor

Starter

Figure 4

Page 75

"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:

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 all the 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 Standard 4 Spool that is remote cable Controlled, The 28 ft model

used a 5 Spoo

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 head or the Boom Extension Cylinder on the 28-ft Model. (See Figure 5 & 6)

l valve with the 5 Th. Spool operating the Boom Extension. THIS SECTION

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Section 8 - 4

Page 76

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

Return

Inlet Cover

Handle

Swing

Figure 5

3. The Control valve will bolt on the top of the

High Frame on the right hand side. There is a tab 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 already 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.

Lift

One Way Restrictors

Dipper

5 Spool Valve Shown

Tilt

Figure 6

"B' Side

Ports

"A" Side

Ports

End Cap

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Section 8 - 5

Page 77

Cylinder Control Valve Installation

System Schematic

(Typical 17' through 23' with 4 Spool Valve)

Hyd. Pump

"A"

"B"

Motor

Control

Valve

Swing Cyl.

Lift Cyl.

Tilt Cyl.Dipper Cyl.

Control Valve

Boom Entend (28')

or Door Cyl. Option

Motor Return

Hyd.

Tank

Filter

M 1

M 2

Figure 2

Motor Pressure

Hydraulic Motor

Cylinder Hydraulic Control Circuit: (See Figures 2 & 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 installed between 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.

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Section 8 - 6

Page 78

Cylinder Control Valve Installation

Cylinder Hydraulic Control Circuit: (See Figure 2 & 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, & 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 manual operation is performed with the use of normal directly attached valve handles or through the

use of cables and remote mechanical levers. it is to operate the Boom Extension on the 28 ft; Boom or to operate a hydraulic activated Door on

some heads. The 5 th spool will be located between the Dipper and Tilt Spool shown in figure 3. (See Figure 15 later in this book)

5. 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.

* 4 Spool or * 5 Spool, open center, sectional, manually operated valve. The

* The 5 Spool has one more Spool than shown below,

Spool Detent Assembly

Tilt

* Boom Extend

or Door

Dipper

Lift

Swing

Return to Cutter/Motor Valve

Figure 3

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

Section 8 - 7

"A" Port Side"B" Port Side

Control Cable Attachment

Tilt

Dipper

Lift

Swing

Main Relief

Pressure from Pump

Page 79

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. 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 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 & 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 type 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 limited to 48,60,72 and 102 inches.

2. To install the 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.

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Section 8 - 8

Page 80

Cylinder Control Valve Installation

Flange

Flange Sleeve

Flange Bolts

Flat Washers

Lock Washers

Connecting Pin

Retaining Pin

Spacer Rings

Cable Eye Fitting

Cable Eye Jam Nut

Cable (Valve End Shown - Not

included with Connection Kit)Figure 4

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).

Figure 5

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Section 8 - 9

Page 81

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. 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 connecting 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).

Figure 6

7. Tighten the Jam Nut onto 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 Assembly under the flange (See Figure 11)

Figure 7

Figure 8

Figure 9

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

Section 8 - 10

Figure 10

Page 82

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-

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. To attach 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. Allow the 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 at the valve end may be required too ensure that the spool returns to neutral when the controller is in the neutral position. (See Figure 14)

Figure 11

Tractor Front

Figure 12

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 provides the centering capabilities of the controller and the valve spool. Lack of centering at the

controller is normally attributed to poor adjustment 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. Also the "ON" and "OFF" Switch will bolt to the Handles (See Figure 15)

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

Section 8 - 11

Figure 13

Figure 14

Page 83

NOTES

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

Section 8 - 12

Page 84

Section 9

A-BOOM

Optional Joystick - Wire

Harness & Valve

Inst allation

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

Section 9 - 1

Page 85

Optional Joystick Mounting

Tractor Seat with Seat

Cushion Removed

Three Existing Holes

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 8 ------------- 1 Joystick (Shown as Illustration Only) 9 ------------- -- Tractor Seat

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

Section 9 - 2

Page 86

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. If a custom Seat or for some reason these three 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" Locknuts on the Bolts from the Bottom. Tighten the three Bolts and nuts.

FIGURE 2

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.

FIGURE 4

FIGURE 3

FIGURE 5

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Section 9 - 3

Page 87

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. Tightened the two retaining Bolts (See Figure 1 Item 3 and Figure 2).

FIGURE 6

Installing Wiring Harness for Joystick:

1. It is recommended that the Wires for

Joystick be connected at the Tractor Ignition Switch. But they can be connected as explained below. If connected as shown below Wires must be traced to find the correct wires.

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). Holes in Floor Mat, as it will NOT be required. You will also find a large oblong shaped rubber plug, this will be pulled up later but it is not necessary at this time.

DO NOT Tear or Cut any

FIGURE 7

3. Tractor Wiring Harness. Under the

Floor Mat on the right hand side you will find a Tractor Wiring Loom Running across Floor, remove the plastic cover that is over the wire loom. Using Tractor Manufacturers Service Manual Identify Which Wire is in this Loom.

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

Section 9 - 4

Wire Cover

FIGURE 8

Page 88

Joystick Mounting 2 WD & 4 WD

Installing Wiring Harness for Joystick:

4. Wires to be Connected. You will need to

find the wire from the switch that 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. There is a

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 not in 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 because of the different places they can be connected on various models.

(Continued)

activates the

FIGURE 9

Starter Wires

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).

FIGURE 11

Rubber Plug

FIGURE 10

FIGURE 12

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Section 9 - 5

Page 89

Joystick Mounting 2 WD & 4 WD

Installing Wiring Harness to Joystick: (Continued)

8. Ground Wire. The Black

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 connected to the frame below the cab. If grounding to the Cab floor connect ground now.

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. Screw the plug retainer onto the Joystick Plug, this will be hand tightened.

Battery

ACC Wire

Tractor

Ignition Switch

Brown Wire of Harness

Joystick Wiring

Harness

Shown here is typical Ignition connection, Your Ignition may vary but the function will not.

Ignition

Starter

Red Wire of Harness

Brown Wire of Harness

Black Wire Ground

Tractor Ignition Wire

Cut Tractor Starter Wire to Starter Solenoid and reroute through Joystick Harness Brown wires.

FIGURE 13

FIGURE 14

FIGURE 15

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). Put the floor mat down as it was originally. When finished floor mat should be as smooth as it was before installation.

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Section 9 - 6

Page 90

Joystick Mounting 2 WD & 4 WD

Installing Warning and Instruction Decals:

1. 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. 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

FIGURE 16

02967827

FIGURE 17

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)

5. 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)

7. 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)

02965262

FIGURE 18

02963524

00763977

02964677 02965093

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

Section 9 - 7

Page 91

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. to the Tractor frame rail at this time.

2. Wire Harness & 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 Figure 20). Do not tie any hoses or wire harness at this time. front RH side untill it reaches the front of the Tank (See Figure 21)

Do Not tie the Harness or Hoses

Run Wire Harness along the

FIGURE 19

Wire Harness runs along

Tractor Frame Rails

Run Wire Harness

behind frame support

4. Gaskets on Valve Terminals. There

are 5 wire terminals on Valve, A Gasket will have to installed on each one. These gaskets 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 & 23). These Gaskets must be used.

Wire

Harness

FIGURE 20

Plug

Gaskets

FIGURE 21

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

Section 9 - 8

FIGURE 22

Page 92

Wire Harness / Valve Mounting 2 WD & 4 WD

Installing Wire Harness To Valve:

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. You

will need to feed wire harness under the fitting across tank (See Figure 24) lay the Plugs out in the Order they are to be installed starting at the bottom terminal.

7. Terminal Connections. Make sure that each

terminal Plug on Valve has had the Gasket installed 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 2 nd Plug Up Lift Terminal 3 3 rd Plug Up Dipper Terminal 4 4 th Plug Up Tilt Terminal 5 Top Plug Door Terminal Connect and tighten all 5 terminal plugs one at a time till all 5 are connected. (See Figure 26)

(Continued)

Plug Gaskets

FIGURE 23

Terminal

Plugs

FIGURE 24

Photo without Pump & Hoses

shown for illustration only

Door

Tilt Dipper

Lift Swing

FIGURE 25

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

Section 9 - 9

Short Handle

Phillips

Screwdriver

FIGURE 26

Page 93

Wire Harness / Valve Mounting 2 WD & 4 WD

Installing Wire Harness To Valve:

8. Solenoid Lock Valve Connection. Sole-

noid 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)

9. Servo Control Manifold Solenoid. Lo-

cate the last Plug in the harness. This Plug is a two wire self sealing push connector. the Control manifolds Solenoid is located on the top of the Pump and activates the Pump when engaged. (See Figure 28 and 29).

A-BOOM, Disregard this Section

10. Wire Harness Completed. Pull the Wire

harness back toward Cab to remove any excess slack, only enough to remove slack not to make Wire Harness tight. Do Not tie wire harness or hoses to Tractor Frame Rails Yet. Tying Wire Harness and Hose up out of way will be done later. The Wiring Schematic is shown in this book as a reference only, the wire harness will come to you assembled and ready to mount. The only wires that will have to be altered are the wires inside that connect to the existing Tractor Wires. These inside wires are intentionally left long so they can be cut as needed. None of the wires with the factory plugs will have to be cut.

(Continued)

NOT USED ON

Solenoid

Lock Valve

FIGURE 27

Servo Control

Manifold Solenoid

Plug

FIGURE 28

11. See the next two pages for Wiring Sche-

matic, this is listed as reference only. Pin locations in schematic are actual pin locations in Plugs. Plugs are marked with the letters as shown. This schematic is listed to assist you in tracing wires through harness if needed. Do not change or modify the harness plugs in any way.

FIGURE 29

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

Section 9 - 10

Servo Control

Manifold Solenoid

Page 94

Joystick Plug (Bottom of Joystick Console)

Joystick w/ Push/Pull Motor Switch & Rocker Master Switch

Dbl Trigger Switches

Danfoss Command

Circuit (Joystick)

+ Positive

Wht/Blk

Master Switch

Grnd

J D

Z-Output

DJ C

Y-Output

- Negatve

Wht/Red

Violet

Red

X-Output

Wht/Violet

Rocker Switch

R D

Org/Blk

Grey/Blk

Grn

Brn/Blk

FIGURE 30

Yel

Red

Ign

Acc

Pwr

Motor Push / Pull

Switch With

Momentary Start

Start

Motor

Relay

10 AMP

Wide

Notch

(1)

Actual Pin Location

IS SHOWN in this

Illustration

Narrow

Notch (2)

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

Section 9 - 11

Page 95

Wire Harness (Joystick Console Plug to Valve)

Actual Pin Location

is Shown for Plug in

this Illustration

Narrow

Notch (2)

Wire Harness Plug (New Style)

FIGURE 31

(+)

12V

Brn

Start

Solenoid

Loop

Piston Pump

Solenoid R

Wide

Notch (1)

(-)

Grnd

Red

Blk

Grnd

LIFT

Red

Blk

Grnd

DIPPER TILT

Section 9 - 12

Blk

SWING

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

Red

Blk

Red Red

Grnd

DOOR/ EXTEND

Soleniod Lock

Valve

Grnd

Page 96

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. Pump

Pump Pressure Port

Pressure Gauge

Port

5 Spool

Valve

(Handles

Shown as

Illustration

Only)

FIGURE 32

Starter Solenoid

(Brown)

Solenoid Lock

Valve

A A A

Ground

(Black)

Voltage Supply

(Red)

Tank Return Port

Inlet Section

Swing

Lift

Dipper

Tilt Door / Extend

Junction Box

(Joystick)

Clamp

Pump Solenoid Connector

1 : Swing 2 : Lift 3 : Dipper 4 : Tilt 5 : Door / Extend

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

Section 9 - 13

FIGURE 33

Page 97

NOTES

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

Section 9 - 14

Page 98

Section 10

A-BOOM

Head Installation (Optional Heads)

A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03

Section 10 - 1

Page 99

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. 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 #1

Hose #2

2. Install 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 leaking Hydraulic Fittings. If fluid still leaks, loosen the fitting, apply a pipe thread compound to the end threads and tighten. Care must be taken when tightening can cause the fittings to crack and require 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 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 withing a few hours by a doctor familiar with this type injury or gangrene may result.

4. Hoses should not interfere with mower op-

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.

Figure 1

45° Elbow (02960411)

Hose #1

Figure 2

Hose #1 (02972573)

Hose #2 (02972574)

90° Tube Elbow (02960409)

Hose #2

* 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

Section 10 - 2

Figure 3

Page 100

Optional Mower Head Installation

Attaching Flail Head:

1. With a Forklift or Hoist, lower the boom Weldment on the Flail Head. Align the boom W eldment

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. T ighten 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. 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"

Female - JX & Male

JX90 deg. Elbow

# 02960407

15 deg.

View "A"

02961074

Boom

02961074

45 deg.

Boom

Figure 4

02961074

A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03

Section 10 - 3

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

Specifications and Main Features

Frequently Asked Questions

User Manual