Alamo JD-5425, JD-5225, JD-5325, JD-5105, JD-5205 User Manual

...

SWITCHBLADE

Assembly Manual

JOHN DEERE

JD-5105 / JD-5205 / JD-5225 JD-5325 / JD-5425 / JD-5525

Cab / ROPS 2 WD & 4 WD

Published 05-05 Part No. 02982566

ASSEMBLY MANUAL

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 210-379-1480

TO THE OWNER/OPERA T OR/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 to 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.

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: 830-379-1480

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Index -1

INDEX - ASSEMBLY INSTRUCTION

Introduction

Manual Introduction............................................................................Index-1

Section 1 - Model Specifications

DO NOT DO LIST (IMPORTANT).....................................................1-2

Specifications.....................................................................................1-3 to 1-4

Using Torque Wrench with Adapters (Formula)................................1-5

Hose Fitting Torque Chart..................................................................1-6

Bolt Torque Chart...............................................................................1-6

Section 2 - Tractor Preparation

General Information........................................................................... 2-2 to 2-6

Section 3 - Pump & Driveshaft Installation

Pump & Driveshaft Schematic..........................................................3-2

Remove Engine Guards for Access to engine compartment........... 3-3

Remove Battery.................................................................................3-3

Remove & Modify Tractor Bolster Plate............................................ 3-3 to 3-5

Pulley Adapter Installation..................................................................3-5

Modify Tractor Bolster (Cut Driveshaft Hole).....................................3-6

Reinstall Tractor Bolster Plate...........................................................3-7

Reinstall Battery.................................................................................3-7

Reinstall Engine Side Shields............................................................3-7

Install Driveshaft.................................................................................3-8

Install Pump Mount............................................................................ 3-8

Install Drive Shaft Flex Coupler Assembly........................................ 3-8

Install Pump....................................................................................... 3-9

Page

Section 4 - Frame Installation

Frame & Sub-frame Mounting Bolts ID..............................................4-2

Remove Tractor RH Steps................................................................4-3

Remove RH Three Point Stabilizer Bracket......................................4-3

Install Frame Rail...............................................................................4-3

Reinstall Tractor RH 3 Point Stabilizer Bracket................................ 4-3

Install Sub-Frame Weldment............................................................ 4-3

Install Carriage Arm / Cutter Head Assembly................................... 4-4

Install Hydraulic Tank Assembly........................................................4-4

Install Operators Manual Cannister................................................... 4-5

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Index -2

INDEX - ASSEMBLY INSTRUCTION

Section 5 - Hyd Valve & Hyd Hose Section

Cylinder Control Valve........................................................................5-2

Hydraulic Hose Routing..................................................................... 5-3

Electrical Switches............................................................................ 5-3

Pump Hose Connections.................................................................. 5-4

Fill Hydraulic Tank with Oil................................................................ 5-5 to 5-6

Section 6 - Electrical Connections

Motor & Pump Electrical Connections...............................................6-2

Section 7 - Mechanical Adjustments & Repairs

Lead Adjustment................................................................................7-2

Pitch Adjustment................................................................................7-2

Cutter Bar Alignment..........................................................................7-2

Guard Adjustment..............................................................................7-2

Cutter Bar Adjustment....................................................................... 7-3

Wear Plates...................................................................................... 7-3

Clips.................................................................................................. 7-4

Knife Repair...................................................................................... 7-4

Knife Replacement........................................................................... 7-4 & 7-7

Cutter Bar Repalcement................................................................... 7-5

Knife Bar Replacement.................................................................... 7-6

Outer Shoe Replacement..................................................................7-8

Inner Shoe Replacement...................................................................7-8

Rock Guard, Clip & Wear Plate Replacement..................................7-8

Inner Shoe Weldment Replace........................................................ 7-9 to 7-10

Carriage Arm Replacement.............................................................. 7-11

Knife Drive Assembly Replacement................................................. 7-12 to 7-13

Page

Section 8 - Mounting Kit Component Identification

Mount Kit / Model Specifications....................................................... 8-2

Mount Kit Components...................................................................... 8-3 to 8-4

Pump / Driveshaft Component Identification.................................... 8-5

Component Parts Identification / Descriptions..................................8-6 to 8-9

Hydraulic Hose Schematic (RH Wing Only)......................................8-10

Hydraulic Hose Schematic (RH & LH Wing).....................................8-11

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Index -3

NOTES

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Index -4

Section 1

Model

Specifications

STATEMENT OF POLICY It is the policy of Alamo Group to improve its products where it is possible and practical to do so.

Alamo Group reserves the right to make changes or improvements in design and construction at any time without incurring the obligation to make these changes on previously manufactured units.

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Section 1 - 1

SPECIFICA TIONS - SWITCH BLADE

This manual was carefully prepared by Alamo Industrial in an effort to aid the repair technisian in keeping the performance of this mower up to the high standards for which it was designed. Its purpose is to cover safety and to give recommendations for the proper repar, care and operation of the mower. The repair person will want to be totally familiar with this manual so that they will be better able to handle day to day service adjustments, maintenance and any necessary repairs.

For the purposes of product improvement, Alamo Industrial Company reserves the right to make changes in design, material or specifications without notice and without liability therefore.

READ THIS BEFORE BEGINNING ASSEMBLY, REPAIRS OR TESTING:

The Switch Blade: The Switch Blade has an independent hydraulic system

to operate the motor and the cylinder system. This system uses a tandem pump for hydraulic supply and its own independent oil reservoir. Use caution

not to contaminate this system.

DO NOT

1. DO NOT short any wires across or allow them to be shorted out.

2. DO NOT attempt to jump across any wires or supply them with alternate power source.

3. DO NOT install higher rated fuses than are recommended by manufacturer.

4. DO NOT attempt to repair or adjust a component that is not intended to be repaired, example

sealed components as there are no serviceable components inside.

5. DO NOT let anyone attempt any testing or repairs unless they are an experienced and

qualified technician. Technicians must have proper tools, gauges, meters etc. to perform proper

diagnosis and/or repairs.

6. DO NOT perform any repairs with dirty tools or in dirty area. When working on hydraulic

components keeping system clean and free of contamination is important.

7. DO NOT start or engage system if the oil level is not at the proper level or condition. Never

start or run unit low or out of oil. If installing new pumpnever start engine unless pump & system

has been filled with oil, starting a pump dry will damage it.

8. DO NOT install / add any oil unless you know it is the correct type and the container is clean.

Make certain the oil is not contaminated with dirt or any liquid.

9. DO NOT Make repairs if it is going to be unsafe for you or the people around you, it is the

repair persons responsibility to secure the tractor and the surrounding work area. Tractor

should be disabled in a way that it cannot be started until the repair technician is ready to do so.

10. DO NOT use teflon tape or other pipe joint tape on fittings or hose connections. For pipe

threads, use a pipe thread sealant compound suitable for hydraulic service on OD thread.

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Section 1 - 2

SPECIFICA TIONS - SWITCH BLADE

The OCCUPATIONAL SAFETY AND HEALTH ACT (1929.51 Subpart C) makes these minimum safety requirements of tractor owners and operators:

Required of the Owner:

1. Provide a Roll-Over-Protective Structure that meets the requirements of this Standard;

2. Provide Seat belts that meet the requirements of this paragraph of this Standard SAE J4C;

3. Ensure that each employee uses such Seat belt while the tractor is moving;

4. Ensure that each employee tightens the Seat belt sufficiently to confine the employee to the protected area provided by the ROPS.

Required of the Operator:

1. Securely fasten seat belt if the tractor has a ROPS.

2. Where possible, avoid operating the tractor near ditches, embankments, and holes.

3. Reduce speed when turning, crossing slopes, and on rough, slick, or muddy surfaces.

4. Stay off slopes too steep for safe operation.

5. Watch where you are going - especially at row ends, on roads, and around trees.

6. Do not permit others to ride.

7. Operate the tractor smoothly - no jerky turns, starts, or stops.

8. Hitch only to the drawbar and hitch points recommended by the tractor manufacturer.

9. When the tractor is stopped, set brakes securely and use park lock, if available.

Safety Recommendations!

It is the business philosophy of Alamo Industrial Company to manufacture safe products for use by our customers. In the interest of your safety, we are bringing to your attention practices that can avoid serious injury. It is our belief that trained operators can avoid painful experiences by carefully reading and adhering to the following recommendations. As a repair technician do not modify this product in any way that will make this unsafe for the operator or anyone else around it.

WORK SAFELY. Most of the repairs can be performed by one man, but some of the parts are very heavy. GET HELP IF YOU NEED IT. Use the right tools for the job. A floor jack or hoist will be a big help, but make sure they are in safe condition. Keep the floor free from oil and grease so you don't slip. WEAR SAFETY GLASSES, SAFETY SHOES AND GLOVES and make sure your helper does too.

This machine can be dangerous if not operated safely. Do not operate it until you have read and

understand all safety and operation recommendations in Operators, Assembly, Service manuals.

DANGER

trying to operate this unit in tight places or around other objects or people. tractor engine and be certain all rotating or moving mechanisms have stopped before attempting to get

near mower. Make certain that tractor is secured in a way that it can only be started if you are ready for it to. This could include remove key and put it in a secure place. Disconnect battery cable which should be done before any repairs or service is started.

Know the equipment, learn to operate it correctly in a safe, level, open secure area before When stopping, shut off the mower, disengage PTO, Engage Tractor Parking brake. Shut off

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 1 - 3

SPECIFICA TIONS - SWITCH BLADE

Standard Specifications: Switch Blade 5 ft. & 6 ft.

Break-A-Way Control............................................. Break-A-Way Pressure Contol Valve Block

Break-A-Way Relief................................................ 1500 psi Relief

Break-A-Way...........................................................Hydraulic Rotary Actuator, Self Returning

Cutting Size.............................................................Up to 1/2" in Dia. Material

Cutting Width...........................................................5 ft. or 6 ft. Option

Drive System...........................................................Hydraulic Motor

Hydraulic Cylinder Control.......................................Two Spool Control Valve

Hydraulic System.................................................... Self Contained

Hydraulic Tank.........................................................Steel Manufactured Type w/ Built in Mount

Hydraulic Filter.........................................................Standard, Tank Mounted

Hydraulic Oil Return Pressure Gauge.....................Standard, Tank Mounted

Hydraulic Hoses...................................................... High Pressure Standard

Hydraulic Hose Length............................................ Varies with the Tractor Model

Knife Drive...............................................................Planetary Drive Assembly

Knife Rock Guards..................................................3" Heavy Duty Industrial Bolt On

Knife Speed Control..........................………...........Pre-Set Governor

Knife Type................................................................Serrated Edge Standard

Lift & Fold.................................................................Hydraulic Cylinders Standard.

Motor Control...........................................................Electric over Hydraulic

Motor Control...........................................................Electric “ON” or “OFF” Selection

Motor Function.........................................................Electric Reversible Drive Direction

Mount Type..............................................................Side Mount to Tractor Standard

Mounting to Tractor..................................................Factory or Field Mount Option

Operators & Parts Manual.......................................Standard, Extra Copies Optional

Paint.........................................................................Yellow Standard, Special Colors Optional

Pump Guard............................................................Optional

Pump Mounting........................................................Tractor Engine Driven

Pump Size...............................................................2 Size Option (CID)

Pump Type..............................................................Tandem Gear Pump

Pump Pressure..........Motor Circuit........................ 1750 psi @ 9 to 10 gpm

Cylinder Circuit................... 3000 psi @ 3.5 to 4.5 gpm

Skid Shoe Replacement..........................................Bolt on

Skid Shoe Size........................................................Standard 3/16" Abraision Resistant Alloy

Skid Shoe................................................................ Standard w/ AG Shoe & Swathboard Option

Transport Locks......................................................Standard, Manual Lock

Transport.................................................................Hydraulic Lifting and Folding

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 1 - 4

USING AN ADAPTER WITH A TORQUE WRENCH

Figure 1

If an adapter is attached to the drive of a torque wrench, the wrench will not give actual torque

indicated by the setting of the handle. A simple formula however, allows you to figure out what the setting should be to deliver a predetermined amount of torque at the end of any adapter to the fastener.

The following letters are defined as: A = Length of the torque wrench when set at the middle scale setting (inches).

B = Length of adapter (inches from center hex bolt to center of torque wrench square shaft. C = Desired torque at end of extrusion D = Setting for accuracy within + or - 6%.

Here is a typical problem. You have an adapter that adds 10.0 inches to a torque wrench length (dimension B) What should the setting be to obtain 320 ft. lbs. of torque at the end of the adapter.

A = 22.57 inches (length from adapter mounting point torque wrench to center of grip / handle) B = 10.0 inches (Length from adapter mounting point of torque wrench to center of hex slot). C = 320 ft. lbs. torque (desired torque at end of extension). D = Unknown (setting you need to set torque wrench to = 320 ft. lbs for accuracy). (A) (22.57) (22.57) C = ------------------- or 320 ----------------------- = 320 ------------------ = 320 X 222 ft. lbs. (A + B) (22.57 + 10.0) (32.57)

Your Answer (D) is a setting of 222 ft. lbs. on the torque wrench will give 320 ft. lbs. of torque at the bolt. By using the above formula an accuracy of + or - 6 % of the desired torque will result at the end of the adapter due to length change during grip adjustment.

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 1 - 5

SPECIFICA TIONS - SWITCH BLADE

HOSE END FITTING TORQUE SPECS:

Hose End Type: 37 Degree Angle End Steel Hose End Fittings*

Dash Nominal Cyl. Torque Torque Size Size (in.) in. lbs. ft .lbs.

-4 1/4" 140 12

-6 3/8" 230 19

-8 1/2" 450 38

-10 5/8" 650 54

-12 3/4" 900 75

-16 1" 1200 100

-20 1-1/4" 1600 133

-24 1-1/2" 2000 167

-32 2" 2800 233 * Straight Threads do not always seal better when higher torques are used. Too much torque causes distortion and may lead to leakage. DO NOT over torque fittings and DO NOT allow any contaminants to enter system through fittings when installing them.

TORQUE VALUES - BOLTS: Recommended Torque, Ft. lbs. & (Nm)

IMPORTANT! Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE, Component

Application Torque will vary depending on what is bolted down and the type material (Metal) that is being bolted together. Thread condition and lubrication will vary Torque settings.

Bolt Dia.

inch

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4

Inch Sizes

2 (B)

Plain Head

Not Used Not Used Not Used 35 (47) 55 (75) 75 (102) 105 (142) 185 (251) 160 (217) 250 (339) 330 (447) 480 (651)

5 (D)

3 Dashes

10 (14) 20 (27) 35 (47) 55 (75)

85 (115) 130 (176) 170 (230) 300 (407) 445 (603) 670 (908)

910 (1234)

1250 (1695)

8 (F)

6 Dashes

14 (19) 30 (41) 50 (68) 80 (108) 120 (163) 175 (230) 240 (325) 425 (576) 685 (929) 1030 (1396) 1460 (1979) 2060 (2793)

ALWAYS

CHECK

MARKINGS

TOP

OF BOLT HEAD

OTHER

BOLT

DESCRIP-

TIONS

Bolt Dia. mm

6 8 10 12 14 16 18 20 22 24 27 30 33 36

Metric Sizes

4.8

5 11 20 37 60 92 118 160 215 285 450 600 800 900

8.8

7 20 40 70

100 155 216 270 330 500

875 1200 1600

2100

10.9

12 25 58 105 140 200 280 355 430 700 1000 1700 2300 3000

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 1 - 6

Section 2

Switch Blade

John Deere

JD-5225, JD-5325

JD-5425 & JD-5525

CAB / ROPS 2 WD & 4 WD

General Information

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 2 - 1

General Information / Installation Requirements

INTRODUCTION: In Most diagrams there are Component Part Numbers Listed, Item numbers

and Descriptions, This is because most parts shown as breakdown in drawings are for location & identification and if available as replacement parts will be listed in the Parts/Operators Manual which are to be used with this assembly manual.

BEFORE STARTING ASSEMBLY: (READ THIS)

Clean surrounding area completely before uncapping any connections or Lines. NO DIRT OR

DEBRIS CAN BE ALLOWED ON OR NEAR HYDRAULIC SYSTEM IF IT IS BEING WORKED ON, ANY DIRT OR CONTAMINANTS IN SYSTEM NO MATTER HOW SMALL WILL DAMAGE SYSTEM!

2. After cleaning around all connections thoroughly, Do not disconnect any connections, Lines, Hoses,

on the Pump, Valve or Tank. Plug all hoses and Lines on Tractor and on Pump, open Lines. NO Contamination Should be allowed into system at all.

3. Clean Area, Clean all Tools, Pans etc. The cleaning of Area and Tools MUST be done before moving

(Cleaned) unit there for assembly.

4. If parts need cleaning, use compressed Air to dry parts after washing (Compressed air must be

filtered and moisture free). lint and/or dust contamination. DO NOT USE Compressed Air to spin any component (Such as Bearings or Plates) as this will damage them and could be dangerous.

DO NOT wipe them dry with Paper Towels or Cloth as these will leave

5. Always use new Seals when assembling Hydraulic system, Lubricate the new rubber Seals with

a Petroleum Jelly, (Vaseline) before installing them.

6. Torque all Bolts over Gasket Joints. Then repeat the Torque sequence to make sure Bolts are tight,

some times Gaskets can give a Torque reading that is OK but is not, so always recheck Torque.

DO NOT leave any

TOOLS THAT MAY BE NEEDED:

The tools you will need at the assembly site are as follows:

1. Impact wrench or socket and ratchet set.

2. Rubber mallet.

3. Box-end, Allen, and adjustable wrenches.

4. Alignment pins.

5. Forklift or hydraulic floor jacks with rolling back boards.

6. Small chain hoist or block-and-tackle.

7. Multidirectional Levels.

8. Hydraulic Filter Buggy or Cart.

9. Safety shoes, safety glasses, and gloves. A hard hat should be worn by anyone working under any raised component.

RECOMMENDED GAUGES FOR DIAGNOSTICS:

1. Inlet Vacuum: 30 PSI to 30 in Mercury (207 bar to 0 bar)

2. System Pressure Gauge: 6,000 PSI (700 bar)

3. Charge Pressure Gauge: 0 to 500 PSI (0 to 25 bar)

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 2 - 2

General Information / Installation Requirements

GENERAL INFORMATION:

Remember to follow each step closely and cautiously. Be aware of all support personnel at all times. Keep the assembly area as clean as possible; clean up all spills when they occur. An uncluttered assembly area and a crew that is sensitive to the hazards involved in putting this implement together will help prevent accidents. Keep all unauthorized personnel from the area. Do not allow children near the assembly site nor allow them on or near the tractor after assembly. There is no safe place for anyone except the operator on the tractor and those assisting with the assembly.

To help you assemble your new Machete Boom and mount it to your tractor, a detailed assembly instruction Manual is being provided with the mount kit to provide detailed instructions and part numbers. Please consult this document for specific information. When needed, you can get additional information or clarification from Your Dealer or Alamo Group Customer Service.

This publication provides general information not specifically for your case or tractor, but, in connection with the drawings, this publication offers you some valuable assistance - please read it thoroughly.

These mount kits are made for selected tractors with standard configurations. Only the noted options and tire sizes listed in the Mounting Specifications will work with these mount kits. Other options, front axles, or different tire sizes may prevent the mount kit from fitting your nonstandard tractor. Alamo Group cannot take responsibility for these problems or any modifications made to the unit.

Throughout these instructions, references are made to right or left directions. Right and left are determined by sitting on the tractor seat and facing the direction of travel forward always.

This is the Safety-Alert symbol. When you see this symbol on your machine or in these instructions, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.

DANGER! A signal word - DANGER, WARNING, or CAUTION - is used with the Safety Alert

symbol. DANGER identifies the most serious hazards.

WARNING! Safety signs with signal word WARNING are typically used to point out more

serious hazards.

CAUTION! General precautions are listed on CAUTION safety sign. CAUTION also calls

attention to safety messages in these instructions.

Tractor, Area Cleanliness

The Tractor, all tools and work area must be clean of dirt and debris when assembling any hydraulic components. DO NOT leave any hydraulic component open to the elements. DO not use any containers for fluids that are not clean and free of any other liquids. DO NOT use rags/cloth that has lint or fuzz on them when working on hydraulic components. Keep all hoses capped until you are ready to connect them.

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 2 - 3

General Information / Installation Requirements

WARNING!

Disconnect the negative lead (ground) from the battery terminal to prevent any damage to the electrical system.

LEVELING TRACTOR:

TRACTOR MUST be on level ground before assembly is begun. The tractor must be level, All tires

must have the proper amount of air in them as per tire and/or Tractors manufactures recommendations.

DO NOT level tractor by over inflating tires. The tractor can be leveled by jacking it up and putting it on

jack stands if needed, but this will mean the tractor will be un-level when they are removed. If the tractor does not sit level you must find out why so mower will be level when mounted, if it is mounted with the tractor un-level the mower will be un-level when tractor is leveled.

Replacement Oil Filter

A replacement filter element for return filter assembly should be of the correct type when replaced. This Mower unit's hydraulic components have been carefully cleaned and packaged at the factory to prevent contamination from entering the system. However, dust and dirt particles may enter into the sealed components through transportation, handling, rain, or just sitting in a dirty or harsh environment. Therefore to assure that the hydraulic system is properly clean, please prepare the area where the unit is to be assembled. The area should be on a hard concrete floor that has been swept clean of all dust and contaminants. Unpacked the Mower unit carefully so that the seals on the hydraulic components are not broken or pulled off.

WARNING!

Before attempting to assemble the mower to the tractor, move the tractor to a clean solid surface, preferably a concrete shop surface with an over head crane. The crane should have a rated capacity to lift the heaviest component or assembly. A 5-ton crane is recommended for the assembly work. If a smaller crane is used, be sure not to exceed the rated capacity of the crane. Q Always follow all OSHA crane operating and inspection rules, regulations,

inspection requirements, and recommended practices when using the crane.

Q Never work under any component that is lifted by the crane unless it is also

supported by appropriate stands that are capable of supporting the component.

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 2 - 4

General Information / Installation Requirements

WARNING!

Wear personal protective equipment when assembling the mower. As a minimum that should include:

Q Safety Glasses Q Safety Shoes Q Gloves Q Hard Hat Q Hearing Protection Q Welding Helmet

Before attempting to assemble ensure that the tractor engine is off and the tractor transmission is in the park position with the parking brake engaged.

Q Remove the engine key and keep it in your pocket to prevent inadvertent

starting or movement of the tractor.

Q Place wheel blocks in front and behind the tractor wheels to prevent the tractor

from moving.

Q Never attempt to start the tractor unless properly seated in the tractor seat

with the seat belt fastened around you.

Q Never attempt to operate the tractor and mower controls unless seated in

the tractor seat with the seat belt fastened around you.

Securely block up and support the tractor before attempting to loosen and move the tires. Failure to properly block up the tractor can result in the tractor to suddenly move or fall, crushing you or another worker. Q Never work under any raised component or any component that is not

securely blocked up or supported.

WARNING!

Many components of this mower are very heavy and must be handled by proper material handling equipment. Do not lift components that weight over 50lbs by yourself. Q Use an overhead crane, forklift, or other coworkers to lift heavy items. Ensure

lifted components are securely supported.

Q Never walk or work under a lifted component.

Use extreme care when moving, handling or adjusting the tractor tires. The tires are extremely heavy and could fall and crush you

Q Use an overhead crane or forklift to move the tires. Q Properly fasten the tires to the material handling equipment to prevent the tire

from falling. The hydraulic oil is under high pressure and a hydrauli leak can cause oil to be injected under the skin.

Q Before starting the tractor ensure all hydraulic connections have bee tightened Q Never check for leaks with your hands. Use a piece of wood or cardboard to

check for the leak making sure your hands and face are kept away from the

leak area.

Q Repair any leaks before operating the equipments Q Clean up all oil that has leaked according to the requirements of the oil supplier.

Oil residue on the ground can result in unjury from slipping or falling.

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 2 - 5

General Information / Installation Requirements

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) See Mount Kit Specification and Component Identification Section to help ID Components.

All the component that are received should be check and sorted as to what they are. Shown below is a general example of the components laid out, this is not a lay out of the components in this mount kit.

WARNING

DO NOT WELD On This Unit During or After Installation:

DO NOT WELD any components or items on this unit after the installation has begun. The use of electronic modules and components that could be damaged by welding. Before doing any welding check the Tractors Opertion, Repair, Service or any other manual from the tractor manufacturer to find any special electronic or special proedures about the tractor electronics. Taking a few minutes to check could save you from a major damage to the electronics.

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 2 - 6

Section 3

SWITCHBLADE

John Deere

JD-5105, JD-5205

JD-5225, JD-5325

JD-5425 & JD-5525

CAB / ROPS 2 WD & 4 WD

Pump & Drive Shaft

Inst allation

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 3 - 1

Pump / Driveshaft Schematic - 5425 & 5525

Tractor Engine Pulley

Coupling Flange, P/N 0062000 ( 3/4" Bore w/ 3/16" keyway, 1/4" setscrew )

Setscrew, P/N 02957080

Flange Mounting Bolts & Locknuts (4 ea.)

( Included W/ Center Coupling )

Bolts, P/N 00023100 Lockwasher P/N 00012101 Locknuts, P/N 00015800

Drive Shaft, 3/4" w/ 3/16" Keyway X 7/8" w/ 13 spline

Flange, P/N 02974359 ( 5/8" Bore w/ 9 Spline )

7/8" X 13 Spline3/4" w/ 3/16" Keyway

P/N 02982530

Pulley Adapter,

P/N 02973992

Use Existing Bolt & Lockwasher From Crankshaft Pulley

( 4 ea.)

23456

Hub Bolts, P/N 02976344 Lockwasher, P/N 00022200

Center Coupling, w/ Nut & Bolt Set

234

Hub, P/N 02702900

( Set Of 4 Bolts)

Pump Assembly

Pump Mount,

P/N 02979436

Bolts, P/N 02975692 Lockwasher, P/N 02971158

Pump Drive Schematic:

This Section covers the installation of Pump Drive Components, Pump Assembly Some precautions that must be followed during the Assembly Process before unit is ever started for the first time.

NOTE: Shown above is the pump - drive component schematic. There are some items from the tractor that will be reused and some items that are only available as an assembly. The tractor from the manufacturer has a thin spacer bolter to the crankshaft pulley, remove this spacer and reinstall the spacer from Alamo Industrial using the same four bolts that mounted the tractor factory spacer.

Switch Blade (JD-5105-5205-5225-5325- 5425-5525, Asy. Man) 05/05

Section 3 - 2

Pump / Driveline Schematic - 5225 & 5325 CAB/ ROPS

Tractor Engine Pulley

Coupling Flange, P/N 0062000 ( 3/4" Bore w/ 3/16" keyway, 1/4" setscrew )

Setscrew, P/N 02957080

Flange Mounting Bolts & Locknuts (4 ea.)

( Included W/ Center Coupling )

Flange, P/N 02974359 ( 5/8" Bore

Bolts, P/N 00023100

w/ 9 Spline )

Locknuts, P/N 00015800

Drive Shaft, 3/4" w/ 3/16" Keyway X 7/8" w/ 13 spline

P/N 02983085

Crankshaft Pulley

Adapter Bolts (4 Req.)

7/8" X 13 Spline3/4" w/ 3/16" Keyway

234567

Center Coupling, w/ Nut & Bolt Set

Pulley Adapter,

P/N 02982837

234

( Set Of 4 ea. )

234

Pump Assembly

Pump Mount,

P/N 02979436

Bolts, P/N 02975692 Lockwasher, P/N 02971158

Pump Drive Schematic:

This Section covers the installation of Pump Drive Components, Pump Assembly. There are some precautions that must be followed during the assembly process before unit is ever started for the first time, Read the entire section on start up proceddures before starting tractor. Starting Tractor with pump dry will damage pump.

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 3 - 3

Pump / Driveline Schematic - 5105 & 5205 CAB/ ROPS

1234

Tractor Engine Pulley

Coupling Flange, P/N 0062000 ( 3/4" Bore w/ 3/16" keyway, 1/4" setscrew )

Setscrew, P/N 02957080

234

Flange Mounting Bolts & Locknuts (4 ea.)

( Included W/ Center Coupling )

Flange, P/N 02974359 ( 5/8" Bore

Bolts, P/N 00023100

w/ 9 Spline )

Locknuts, P/N 00015800

Drive Shaft, 3/4" w/ 3/16" Keyway X 7/8" w/ 13 spline

P/N 02983411

Pulley Adapter,

Crankshaft Pulley

Adapter Bolts (4 Req.)

7/8" X 13 Spline3/4" w/ 3/16" Keyway

Center Coupling, w/ Nut & Bolt Set

P/N 02983251

234

( Set Of 4 ea. )

234

Pump Mount Plate, P/N 02983152

Pump Assembly

2345

234

Bolts, P/N 02975692 Lockwasher, P/N 02971158

Pump Drive Schematic:

Switch Blade (JD-5105-5205-5225-5325- 5425-5525, Asy. Man) 05/05

Section 3 - 4

Pump & Drive Shaft Installation:

The Tractor will need modification to some of its components before mounting the Switch Blade Mower Assembly. Perform thess modification before attemting any of the unit assembly instruction.

1. Raise the Hood of tractor to remove Bat-

tery. Lift the Tractor Hood, the battery is located under the hood and in front of the radiator (See Figure 1 & 2). The battery will need to be disconnected and removed from the tractor, also the battery hold down strap (See Figure 2). The Battery can be set on the floor (Concrete) only for a short period of time, if it is going to be set up for a while the battery should be set on a wood surface for storage and a trickle charge connected to it to protect it from discharge. Always store the battery away from flames, sparks or any extreme heat.

2. Remove Engine Side Cover. There are

side covers that bolt to the radiator that block access to the front of the engine. The LH or the RH side cover will need to be removed (See Figure 4 the LH side is shown). Save the mounting bolts as they will be reused when cover is reinstalled.

Figure 1

3. Remove the lower Bolster Cover Plate.

The lower bolster cover plate is accessible from the bottom side of the tractor behind the bolster and engine (See Figure 5). This plate bolts to the top plate that is under the radiator, the lower plate must be completely removed from the under side and will not be reused. Note: the front axle pivot pin is shown as referenc only, DO NOT remove it.

Figure 3

Figure 2

Engine Side

Cover (LH

Side Shown)

Figure 4

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 3 - 5

Pump & Drive Shaft Installation:

4. Remove Tractor Upper Bolster Cover Plate. The tractor bolster upper cover will need to be

modified and will have to be removed from the tractor to perform this modification. The radiator will need to be unbolted from the bolster BUT NOT removed from tractor. DO NOT disconnect any hoses for

radiator, air conditioning condenser ,oil cooler or any electrical wiring, IT WILL NOT BE REQUIRED. The Battery should already be removed, if not see step one. The radiator has two bolts on each side that mounts down to the bolster cover plate (See Figure 7). There are two on each side LH & RH. Also notice the side protection shield is still installed on the RH side (See Figure

7), it is easier to work with these shields removed but can be done with them left on.

5. You will need some one to help you re-

move the cover from under the radiator. Have some one lift the radiator and other components while the cover is removed out toward the front of the tractor. An over head hoist / crane can be used to lift and support radiator, air conditioning condenser and oil cooler, BUT EXTREME CAUTION MUST be used not to damage the components when lifted.

Upper Plate

Under Radiator

Lower Plate

Above Front Axle

Front Axle

Pivot Pin

Figure 5

Two

Mounting

Bolts

Upper Plate

6. With the cover removed set the radiator

and components back down on the tractors bolster, do not bolt them down, they will sit there fine as the hoses will not let them fall (See Figure 8). Note the electrical wiring that is left laying across bolster, no electrical connections other that the battery need to be disconnected to remove the cover..

Upper Plate Side Retainining Bolts

Upper Plate Front

Retainining Bolts

Figure 6

Figure 7

Switch Blade (JD-5105-5205-5225-5325- 5425-5525, Asy. Man) 05/05

Section 3 - 6

Figure 8

Pump & Drive Shaft Installation:

7. Bolster Cover Modification. The cover will have to be cut, this is to allow the pulley adapter for

the drive shaft clearance. Lay the cover where you can mark it for cutting (See Figure 9). This shows the cover turned around from the way it was removed and is laying on the front tire for marking cut.

A. Find the front from the rear of cover. B. Mark a half circle as shown in figure 9. C. This half circle should be a minimum

of 3 inches deep and 5 inches wide

8. Cut Bolster Cover Plate. Make certain that

the Engine end of cover is cut. How you cut this is the technicians choice, we recommend a torch or a plasma cutter (See Figure 10). After the half circle is cut out of cover, use a grinder to clean the edges to eliminate any sharp edges (See Figure

11). After Cover has been cut and cut edges cleaned up set cover aside for now.

9. Install Engine Pulley Adapter. The Engine

pulley adapter will bolt to the crankshaft pulley of the tractor. Looking at the front of the engine at the crankshaft pulley there are four bolts and washers retaining a plate to the front of the pulley, this spacer comes already on the tractor but will not be used. Remove these four bolts removing the spacer. The spacer will not be used but the four bolts and washers will. Install the furnished pulley adapter (See Figure 12 & 13 P/N 02973992 & P/N 02702900 splined adapter for JD-5425 & 5525) (See Figure 13A & 13B P/N 02982837 for JD-5225 & 5325) to the front of the crankshaft pulley with the tractor four bolts and washers (See Figure 12, JD-5425 &-5525 Shown). Tighten the four bolts down to John Deere specifications as specified in the John deere Manual pertaining to these four bolts.

Figure 9

Figure 10

FRONT END

TOP

Cut Out

Here

ENGINE

END

10. Install Spline Hub to Pulley Adapter.

NOTE; This spline bolt on hub will apply to JD5425 & 5525 Only). The Splined Hub (P/N

02702900) bolts to the pulley adapter (See Figure

13). The Hub has 7/8" X 13 Spline center with four mounting bolts & Lockwashers (P/N 02976344 Bolt, Hex Head 7/16"-NC X 1-1/4" - PL - GR8 and P/N 00022200 Lockwasher 7/16" PL). Torque the mounting bolts to 65 ft. lbs. (See Figure 13).

NOTE: JD-5225 & 5325 will have the splined adapter sleeve welded to the Pulley adapter (See Figure 13A & 13B).

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 3 - 7

Figure 11

Pump & Drive Shaft Installation:

11. Modify Tractor Bolster Front. The bolster

of the tractor will need a hole cut into it that aligns with the engine crank shaft, this hole should be cut with a hole saw to prevent jagged edges. The bolster has a DIMPLE in it in the front to show where the center of the crankshaft is (See Figure

14), this dimple is cast into the bolster when it is made. Using a Minimum of a 1-1/2" dia. hole saw cut a hole into the bolster using this dimple as a centering reference point (See Figure 15). It is best to cut this hole before reinstalling bolster cover, but if you have already reinstalled it us a 2" X 4" wood block to hold cover up away from bolster (See Figure 15) noting cover is not bolted down. After hole is cut in bolster note that the hole is not closed at the top, the amount open at the top will vary with the size hole cut. A 7/8" drive shaft will go through this hole, Alamo Industrial recommends a 1-1/2" dia hole minimum.

12. Reinstall Bolster Cover. The bolster cover

will install in the same manner as it was removed see previous steps 4 and 5. Make certain that no electrical wires are where the should not be. Use the same bolts that were removed to reinstall cover. Before bolting the cover down you will need to check the fit where you cut the half circle out to clear crankshaft pulley adapter and splined hub, this should be checked from the top and the bottom (See Figure 17 & 18).

JD-5425 & JD-5525

Shown

Figure 12

Spline Hub

P/N 02702900

JD-5425 & JD-5525

Shown

Crankshaft

Pulley

Adapter P/N

02973992

Existing 4

Bolts &

Washers

Hub Mountiing Bolts

and Washers (4 ea)

Figure 13

Pulley Adapter P/N 02982837

For JD-5225 & JD-5325 Shown

Figure 13A

Figure 13B

Switch Blade (JD-5105-5205-5225-5325- 5425-5525, Asy. Man) 05/05

Section 3 - 8

For JD-5225 & JD-5325 Shown

Tractor Engine Pulley

234

CCCCCCCCC

2345

CCCCCCCCC

234

Bolts & Lockwasher (Qty 4 ea.)

Pump & Drive Shaft Installation:

13. Check Modified Bolster Cover for fit. Make certain the cover will not hit the crankshaft pulley,

pulley adapter or the splined hub (See Figure 17 & 18). If cover will not hit install the retaining bolts into the cover that were removed when cover was taken off. Leave bolts loose until all bolts have been

in stalled this will allow the cover to be moved around for alignment. Once all the bolts are installed tighten all the cover retaining bolts. Caution must be used to make certain that any hoses or wiring of tractor are routed correctly and will not be damaged because they have been moved around or kinked.

14. Re-install Battery. The battery can be rein-

stalled now along with the battery hold down. DO NOT reconnect the batter cables to the batter at this time.

15. Re-install Engine Side Shields. Re-install

LH and RH side engine shields that were removed. Use the same mounting hardware that was removed (See Figure 21).

Crankshaft

Alignment

Dimple

Figure 14

Figure 15

Bolster Plate

modification Cut

Out Seen From

Top

Cut

Hole

Figure 16

Bolster Plate

modification Cut

Out Seen From

Bottom

Axle

Pivot Pin

JD-5425 & JD-5525

Shown

Figure 17

Switch Blade (JD-5105-5205-5225-5325-5425-5525, Asy. Man) 05/05

Section 3 - 9

Figure 18

Pump & Drive Shaft Installation:

16. Install Machined Pump Mount Plate The machined pump mount plate (P/N 02979436) bolts to

the front of the bolster in the four existing threaded bolt holes (See Figure 22). These bolt holes will have plastic plugs in them that will need to be removed (See Figure 14). The pump mount Plate (P/N 02979436 ) bolts to the tractor with 4 mounting bolts (Bolt P/N 02975692 -

50MM PL GR10.9

Figure 25).

, Lockwasher P/N 02971158 - M20) tighten these four bolts down at this time (See

17. Install Pump Drive Shaft. The pump Drive Shaft

has a 7/8" X 13 spline end and a 3/4" w/ 3/16" keyway end (See Figure 23 & 23A). The 7/8" x 13 spline end goes toward the engine and fits into the spline hub that was bolted to the crankshaft (See Figure 13, 13A & 13B). Coat the splined end of shaft with an anti-sieze compound before inserting it into the splined hub.

Hex Head M20-P2.5 X

18. Install Flex Coupler Assembly. The flex coupler

assembly P/N 02975188 (See Figure 24) is an assembly with center coupler, both flanges and bolt nut sets. One coupler is 3/4" w/ 3/16" keyway and setscrew while the other (pump side) is 5/8" X 9 Spline. Loosen the setscrew and coat the keyed shaft end with a anti-seize compound before installing coupler. Slide the coupler onto the driveshaft with the 5/8" X 9 spline coupler outward toward where the pump will mount. (See Figure 25).

19. Install Pump Assembly. The pump assembly

bolts to the machined pump mount. First coat the spline shaft of the pump with a anti-seize compound. Slide the pumps splined shaft into the spline coupler. The pump is retained with two bolts, P/N 00023100 (3/8" X 1-1/2"), two Locknuts P/N 00015800 (3/8") and 2 Lockwashers P/N 00012101 (3/8") (See Figure 26). NOTE: Pump will always be installed with the Suction Port to the LH (Driver Side) of the tractor as shown (See Figure 26).

Bolster

Cover

Figure 19

Battery Hold

Down

Figure 20

Bolster

Cut Out to allow

driveshaft clearence

Hood Latch

Bracket

P/N 02979436

Machined Pump

Mount Plate

Engine

Side

Shield

Shown

Figure 21

Switch Blade (JD-5105-5205-5225-5325- 5425-5525, Asy. Man) 05/05

Section 3 - 10

Figure 22

+ 74 hidden pages