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

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Page 1

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

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Page 3

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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.

Page 5

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

Page 6

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

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Index -2

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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

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Index -3

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NOTES

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Index -4

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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

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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

Page 11

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

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Section 1 - 3

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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

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Section 1 - 4

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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.

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Section 1 - 5

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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

Page 15

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

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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)

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Section 2 - 2

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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.

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Section 2 - 3

Page 18

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.

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Section 2 - 4

Page 19

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.

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Section 2 - 5

Page 20

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

Page 21

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

Page 22

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

Page 23

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

Page 24

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

Page 25

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

Page 26

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

Page 27

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

Page 28

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.)

Page 29

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

Page 30

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

Page 31

Pump & Drive Shaft Installation:

20. Pump Hose Connections. The pump hose connections should not be connected until later so

they will not be in the way. Leave all fittings on pump covered and sealed (See Figure 26), the fittings are left covered and sealed to prevent them from getting contamination into hydraulic system. The hose will be connected to pump in a later step. The Fittings should be installed onto the pump as shown and in sequence as shown (See Figure 26).

7/8" x 13

Pump Fittings (Figure 26)

Item Part No. Qty Description

1. 02975187 1 Adapter, Elbow 12MB-8ML45

2. 02968850 1 Adapter, Straight 8MB-6MJ

3. 02975186 1 Adapter, Straight 16MB-12FP

4. 0022400 1 Adapter, Elbow 12MP-12FP90

5. 000849 1 Adapter, Elbow, 12MP-12FP45 6 0222100 1 Hose Bib, #16 Hose - 12MP

3/4" w/ 3/16" Keyway End

Figure 23

Spline End

Typical

Drive Shaft

Figure 23A

Figure 24

Motor Pressure

Port

Cyl - Valve

Pressure Port

Figure 25

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

Section 3 - 11

Figure 26

P/N 02975188

Flex Coupler Asy.

Suction

Port

Page 32

Drive Shaft Installation - 5105 & 5205 (ONLY)

Drive Shaft Installation:

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

As you will notice after drilling the 1-1/2 hole into the front bolster there is another part of the tractor that will also need to be modified. Right behind the bolster casting there is a part of the front axle that will have to be grinded out as shown in (Figure 1). These procedure is needed in order to allow for driveline clearance, as you will notice the driveline has also been modified for this particular application only. As you can see getting to the part that needs grinding is not going to be easy. After observing your situation and after reading the two procedures mentioned below you need to determine which way you feel is better for you. First, you can raise the hood and disassemble the battery and the radiator, basicly the same procedure you have to do with the other models in this manual. Once you remove the plate then you will have access with an angle grinder or a die grinder to remove material needed to allow driveline clearance. Second, our installer chose to use a die grinder with a 3/4" grinding bit and welded a piece of 1/4" rod to the bit approximately 8"lg. and then reached in there and started grinding, he felt that it was the better way to go about it verses disassembling all the components on top of the plate and having to remove it also.

This hole

cut

w/1-1/2"

hole saw

for

driveshaft

access

crankshaft

pulley

Figure 1

This is the

area that

must be

ground

down for driveshaft clearance

JD-5105

JD-5205

ONLY

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

Section 3 - 12

Page 33

Section 4

Switchblade

John Deere

JD-5225, JD-5325

JD-5425 & JD-5525

CAB / ROPS 2 WD & 4 WD

Frame Installation

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

Section 4 - 1

Page 34

Frame Installation

Frame Weldment,

Mount Bolt Location & Sizes

Item Part No. Qty Description 1 02982525 1 RH Frame Weldment (JD-5425 & JD-5525)

02983050 1 RH Frame Weldment (JD-5235 & JD-5325)

2 02976342 4 Bolt, Hex Head M16-P2.0 X 55MM - PL - GR10.9

00756077 4 Washer, 5/8"

3 0665400 1 Sub-Frame Weldment

00753753 4 Bolt, Hex Head 5/8"-NC X 2" - PL - GR8 00695100 4 Locknut, Toplock 5/8"

4 00023100 4 Bolt, Hex Head 3/8"- NC X 1-1/2"

00011100 4 Flatwasher, 3/8" 00015800 4 Locknut, Toplock 3/8"

5 02975692 4 Bolt, Hex Head M20-P2.5 X 50MM - PL - GR10.9

02971158 4 Lockwasher, 20MM

Figure 1

1. Identify and locate the frame rail (Item 1 Figure 1), Sub-frame Weldment (Item 3 Figure 1)

and the Bolts, Washer and Nuts as listed in Figure 1. The tractor will have plastic plugs in the tractor housing, these plastic plugs will need to be removed.

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

Section 4 - 2

(Page Rev 01-23-06)

Page 35

Frame Installation

2. Remove RH Side Steps. The steps on the

RH side of the tractor will be removed and not used so as not to interfere with the clearence of the mower head. (See Figure 3).

3. Remove 3-Point Stabilizer Bracket The

RH side 3 point stabilizer bracket will be unbolted from the tractors rear axle housing (see Figure

2). Leave the stabilizer off for now.

4. Install Frame Rail to Tractor. The frame

rail (Item 1 Figure 1) will be slid under the tractor on the RH side. Make certain the plastic plugs have been removed from tractor frame, two at the front bolster and two mid frame. Do NOT tighten the frame mounting bolts until all the bolts have been installed as frame will need to be moved slightly for alignment as the bolts are installed. The frame can be installed by balancing the frame on a floor jack, if using this method it is recommended two people perform this to prevent the frame from falling. Raise the frame up to the tractor frame, install the two front bolts and washers (Item 5 Figure 1). Remember do not tighten these bolts until all the bolts in frame have been installed.

Figure 2

Figure 3

5. Re-Install 3-Point Stabilizer Bracket The three point stabilizer bracket will be reinstalled

under the rear frame at the rear tractor axle. (Item 2 Figure 1). Install frame mounting bolts and lockwashers, once these four bolts (through 3 point stabilizer and frame rail ) have been installed all the frame bolts can be tightened. NOTE: the bolts at the rear of the frame are 16 mm and the bolts at mid frame and front are 20 mm and will have different torque values, check tractor specifications and /or restrictions for the torque of bolts in the holes.

6. Install Sub-Frame Weldment. The Sub frame weldment bolts the frame at the mid way

point (Item 3 Figure 1), There are four bolts, lockwashers and nuts used to install the sub frame. The mounting holes are designed so sub-frame will only attach one way (See Figure 1). NOTE: Sub-frame has a cylinder lug welded to it, this lug will be at the bottom and to the rear as shown in Figure 1. Torque the four sub-frame mounting bolts

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

Section 4 - 3

(Page Rev 01-23-06)

Page 36

Frame Installation

7. Cutter Head Assembly. The Cutter head

Assembly is shipped completely assembled with the Skid Shoe, Actuator Pre-Assembly, Carriage Arm, Hydraulic Cylinders, Hydraulic Motor, Drive Assembly, Motor Cover and Cutter Bar Assembly attached (See Figure 4). To mount this the carriage Arm (See Figure 5) which has the Carriage Arm Mounting pin installed in it when shipped will have to have the pin removed (See Figure 4 pin is removed).

8. Install Cutter Bar Head Assembly Using

an over head hoist lift and slide the cutter bar assembly into place until the carriage arm is in alignment with the sub-frame (See Figure 1 ) mounting holes. Insert the carriage arm mounting pin (See Figure 5, 6 & 7) and the two retaining bolts and nuts that were in the retaining pin when it was removed from the carriage arm.

Figure 4

Carriage Arm Pin

9. Install The Hydraulic Tank Assembly . The

hydraulic tank is shipped as an assembly with the filter and directional solenoid valve attached to it. The Hydraulic tank will bolt to the frame (See Item 4 Figure 1) with 4 bolts, lockwashers and Nuts (See Figure 1 & 7)

10. Make Certain Bolts are Tightened. Make

certain that the mounting bolts so far are tight.

Figure 6

Figure 5

Carriage Arm Pivot Pin

Figure 7

Carriage Arm Asy

Tank Mounting Bolts

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

Section 4 - 4

Page 37

Mount Kit Component Identification

11. Install Operators Manual Cannister. The

operator manual cannister bolts to the hydraulic tank on the side toward operator, this cannister should have the operators manual inside of it when shipped from the factory (See Figure 8). Note: The hydraulic tank has the return filter and directional control valve (Solenoid) already connected to it when shipped from the factory.

12. Install V alve Control Handle Mounting Brack-

ets. The valve control stand weldment (P/N 107352) will bolt to the flat operators platform on the RH side. Install the mount stand where it will be convenient for the operator to use. The control stand weldment is adjustable for height, this is done by selecting the mounting hole you want to use. The stand can be cut for height adjustment if wanted. The valve control bracket (P/N 02977335) bolts the stand weldment using the holes that best fir the operators needs (See Figure 9 & 10). Once the right distance is decided to fit operator the valve control mount will bolt to the floor of the operators plat form with 4 bolts. The holes will need to drilled through the floor, check the under side of the floor before drilling any holes to make certain drill bit will not hit and damage anything (See Figure 1 1).

Motor Directional

Control V alve

Return Filter

Assembly

Operators Manual

Cannister

Figure 8

P/N 107352

Control Stand

Weldment

P/N 02977335

Valve Mount Brkt

Hydraulic T ank

Weldment

Figure 9

Figure 10

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

Section 4 - 5

Figure 11

Page 38

NOTES

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

Section 4 - 6

Page 39

Section 5

Switchblade

John Deere

JD-5225, JD-5325

JD-5425 & JD-5525

CAB / ROPS 2 WD & 4 WD

Hyd. Valve Control Handles

Hyd. Hose Connections

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

Section 5 - 1

Page 40

Control Valve & Valve Controls Installation

Item Part No. Qty. Description

02982077 -- Valve Asy. W/ Fittings 02974306 -- Valve Asy. W/O Fittings

1. 02976934 2 Unload Plunger

2. 02966645 2 Poppet Asy.

3. 02966646 1 Spacer

4. 02976933 2 Spool

5. 02966648 4 Seat Asy.

6. 02966649 2 Plug Asy.

7. 02966650 2 Plug Asy.

8. 02966651 2 Bushing

9. 02966652 2 Lockout Spring

10. 02966653 1 Cap Asy.

11. 02966654 1 Plug Asy.

12. 02976932 1 Body

13. 02976931 1 Poppet

14. 02976930 1 Seat

15. 02966657 4 O-Ring

16. 02966658 2 Retaining Ring

17. 02966659 A/R Washer

18. 02966660 A/R Washer

19. 02966661 A/R Washer

20. 02966662 1 Washer

Item Part No. Qty. Description

21. 02976946 1 Cap Asy.

22. 02976945 4 Spring

23. 02966669 1 Spring

24. 02976944 2 Plug Asy.

25. 02976943 1 Washer

26. 02976942 1 Washer

27. 02976941 3 Ball

28. 02976940 1 Spring

29. 02976939 1 Spring

30. 02976938 1 Cone

31. 02976937 1 Spacer

32. 02976936 1 Adapter Cap

33. 02976935 A/R Washer

34. 02966671 2 Wiper Seal

35. 02976957 2 Handle Kit

36. 02968850 2 Adapter,Straight 8MB - 6MJ

37. 03200284 2 Adapter,Straight 6MB - 4MJ

38. 02965166 2 Adapter,Tee 6FJX - 6MJ - 6MJ

39. 02982479 2 Adapter, Straight 4MB - 6FJX

Two Spool Control Valve:

The two spool valve assembly shown (See Figure 13) shows the components that are

replaceable in the two spool control valve. Study the drawings, the torque specification if any are listed for figure 12. The fittings are shown in figure 1 & 2. When working on valve always clean the exterior of the valve and hoses before disconnecting them. After disconnecting the hoses cap them with clean caps to keep contamination out of hydraulic system. When disassembling the valve make certain the OD of it and all work areas are clean, do not use dirty tools or rags that will leave lint. Only lint free towels (paper or suitable type) can be used to wipe down the hydraulic system. If any components need to be held in the valve body during assembly petroleum jelly can be used. DO NOT Exceed the recommended torque setting listed in figure 12. When removing plug item 11 watch the qty of washers that are removed, this amount is what should be started with when reassembling plug.

Figure 1

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Section 5 - 2

Page 41

HydraulicControl Valve & Hoses - ROPS

Control Valve & Hoses: (ROPS)

1. The two spool valve assembly shown (See

Figure 2 ) shows the fittings that are used on the two spool control valve. Study the drawing. When working on valve always clean the exterior of the valve and hoses before disconnecting them. After disconnecting the hoses cap them with clean caps to keep contamination out of hydraulic system. When disassembling the valve make certain the OD of it and all work areas are clean, do not use dirty tools or rags that will leave lint. Only lint free towels (paper or suitable type) can be used to wipe down the hydraulic system. If any components need to be held in the valve body during assembly petroleum jelly can be used.

2. When Connecting the hoses to the control

valve follow the directions as shown in the hydraulic diagram (See Figure 6). Do not connect hoses backward as this could damage the components.

3. The control handle will connect direct to the

valve (See Figure 3 & 4 ), the electric switch and components also connect to the valve mount bracket as shown (See Figure 3 & 4).

Figure 2

ItemPart No. Qty. Description

1. 02968850 2 Adapter,Straight 8MB - 6MJ

2. 03200284 2 Adapter,Straight 6MB - 4MJ

3. 02965166 2 Adapter,Tee 6FJX - 6MJ - 6MJ

4. 02982479 2 Adapter, Straight 4MB - 6FJX

4. RH side of front bolster (See Figure 5). Looking at the side of the tractor you will see 8 threaded holes, bolt hose holder in the lower hole in second set back from front (16 mm Hole) (See Figure 5). All hoses will be run through sleeving material, this must be done before they are connected.

Install The Hose Holder. This will bolt on the

Figure 4

Figure 3

Tractor Bolster RH Side

20 mm Threaded

holes, Frame Rail

Bolts here

Figure 5

16 mm

Threaded

hole

P/N 02978281

Hose Ring Weldment

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Section 5 - 3

Page 42

HydraulicControl Valve & Hoses - CAB

1. Install Control Valve Mount Bracket, Cab Model The cab model uses a bracket that will bolt

inside the cab to the fender wall (See Figure 6, 7 & 8). NOTE: For exact instructions on the removal of any upholstery panels consult the tractor manufactures service / repair manual. The inside upholstery panel on the RH side of the cab will need to be removed to find the two threaded mounting holes for the control stand will bolt onto (See Figure 6) to the side piller of the cab on the right hand side. Install the control Stand P/N 02979374 to the side panel of the RH cab support post (See Figure 6)

2. Cut Hole in Floor Mat for Cables and Electrical Harness to pass through. Cut a hole in the floor

mat of cab as shown (See Figure 9). Check under floor to make certain that there is noting under the floor that can be hit when cutting hole or that will obstruct the cables and wire harnes after they are inserted.

3. Install Control valve for Cab Model. The control

valve for the cab model bolts onto the tractor frame (Casting) after the mower frame is installed. The valve must be mounted to the valve mount plate before it is bolted onto the tractor. There are two different valve mount plates (See Figure 8 & 9A). Insert the cables down through the hole in the floor (See Figure 9). The cables and wire harness will have screw down cable boot over it (See Figure 1 1). Make certain to run the cables through this cover before connecting them at the ends as once the cables are connected they cannot be run through the boot. The wire harness can be run through later if wanted.

P/N 02983284

Offset Valve Mount Plate

(JD-5425 & 5525 Cab Tractors only)

P/N 02979374

Control Mount Stand

(All CAB Tractors)

Figure 6

P/N 02980073

Valve Mount Plate

(All CAB Tractors)

Use on Cab (Remote

Cable Control) Models

Figure 7

P/N 02983228

Valve Mount Plate

(JD-5225 & JD-5325 Tractors only)

Figure 9

Figure 8

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Section 5 - 4

Page 43

HydraulicControl Valve & Hoses - CAB

NOTE: This as shown (P/N 02983284) is used on the JD-5425 & JD-5525 Cab Tractor only. Item 1 is a flat plate (P/N 02983228) when used on JD-5225 & JD-5325 Cab Tractors.

, (Front part of Switch

Blade Frame Shown for reference only)

4, 5

Front of Tractor

3, 6

Item Part No. Qty Description 1 02983284 1 Offset Valve Mount Plate (JD-5425 & 5525 Cab Only)

02983228 1 Flat Valve Mount Plate (JD-5225 & JD-5325 Cab Only) 2 02980073 1 Plate, Valve Mount 3 00010300 2 Lockwasher, 5/8" 4 02959924 1 Locknut, Toplock 1/4"-NC PLB 5 0461600 2 Bolt, Hex Head 1/4"-20NC X 2-1/4" PL GR5 6 02972846 2 Bolt, Hex Head M20-P2.0 X 40MM PL GR10.9

Figure 9A

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

Section 5 - 5

Page 44

Control Valve & Valve Controls Installation - CAB

Run Cables and Wire

Figure 10

Figure 11

harness through boot

Figure 12

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Section 5 - 6

Page 45

Control Valve & Valve Controls Installation - Remote Cables

Control Cable Connection to Control Stick Assemblies:

1. First remove the Cross- Screw from the

bottom of the Control Stick Assembly. DO NOT remove the screws that fasten the two housings halves together (See Figure 13).

2. Next holding the housing, fully shift the

Handle in the Control Stick Assembly to expose the female-threaded end of the Plunger Rod (See Figure 14).

3. Then while holding the Handle to expose

the Plunger Rod, thread the Threaded Bead of the Cable into the end of the Plunger Rod and tighten securely. Release the Handle, allowing the Cable to pull into the Control Stick Assembly (See Figure 15)

4. Once Cable is attached to Plunger Rod,

move the handle to pull conduit sleeve up and into the control stick assembly (See Figure 16) The Conduit Sleeve has a groove in it that should align with the cross screw (See Figure 16)

Figure 13

Control Stick

Assembly

Cross-Screw

Female Threaded

Plunger Rod

5. Reinstall the Cross Screw making certain

that the cross screw and conduit sleeve groove are in alignment. Tighten the cross screw securely (See Figure 17)

Threaded Bead

Figure 15

Figure 14

Figure 16

Cross-

Screw Hole

Conduit Sleeve

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Section 5 - 7

Page 46

Control Valve & Valve Controls Installation - Remote Cables

6. There are three holes in the handle

assembly that are used to stack the handles on the control handle mount. Install the bolts through the first handle, then the second handle and then through the switch mount plate. Next the three bolts are inserted through the handle mount. (See Figure 17) This is for the cab model (or with remote cable control. The Rops model the valve is mounted to the valve stand and the control handles are connected directly to the valve (See Figure 18). NOTE: Cab models the control handles are installed with the three mounting bolt heads toward operator and the nuts toward the RH Door away from operator (See Figure 20)

7. Install the Operation instruction decal to the

valve controls as shown (See Figure 18 & 19)

Figure 17

Push / Pull & Reversing Toggle Switch:

1. The push pull switch mount to the valve

stand on non cab tractors (See Figure 19) and to the remote valve control cable handle mount on a cab model (See Figure 18) . On Cab models the switch can be mounted some where else if that is what the customer wanted, however it is recommended that the switch be mounted as shown (See Figure 18 & 19)

ROPS Model Shown Here

Cab Model Shown Here

Figure 18

Figure 19

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

Section 5 - 8

Figure 20

Page 47

HydraulicControl Valve & Hoses

Control Valve & Hoses:

1. The two spool valve assembly shown (See

Figure 21) shows the fittings that are used on the two spool control valve. Study the drawing. When working on valve always clean the exterior of the valve and hoses before disconnecting them. After disconnecting the hoses cap them with clean caps to keep contamination out of hydraulic system. When disassembling the valve make certain the OD of it and all work areas are clean, do not use dirty tools or rags that will leave lint. Only lint free towels (paper or suitable type) can be used to wipe down the hydraulic system. If any components need to be held in the valve body during assembly petroleum jelly can be used.

2. When Connecting the hoses to the control

valve follow the directions as shown in the hydraulic diagram (See Figure 26). Do not connect hoses backward as this could damage the components.

Figure 21

Item Part No. Qty. Description

1. 02968850 2 Adapter,Straight 8MB - 6MJ

2. 03200284 2 Adapter,Straight 6MB - 4MJ

3. 02965166 2 Adapter,Tee 6FJX - 6MJ - 6MJ

4. 02982479 2 Adapter, Straight 4MB - 6FJX

3. The control handle will connect direct to the

valve on ROPS Trctor (See Figure 23), the electric reversing switch and components also connect to the valve mount bracket as shown (See Figure 22).

4. Install The Hose Holder. This will bolt on the RH

side of front bolster (See Figure 23). Looking at the side of the tractor you will see 8 threaded holes, bolt hose holder in the lower hole in second set back from front (16 mm Hole) (See Figure 23). All hoses will be run through sleeving material, this must be done before they are connected.

5. Install Electrical Switches. The electric neu-

tral safety switch and the head reversing switch both mount into the valve mounting bracket (See Figure 22, and Electrical section in this assembly manual)., Make certain that the battery cables are disconnected before connecting any electrical connections, this is to prevent the shorting of any components. Check the tractors manufactures service /repair manual for any restrictions or special instructions about connecting electric components to the tractor.

Figure 22

P/N 02978281

Hose Ring

Weldment

Figure 23

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Section 5 - 9

Page 48

Hydraulic Connections / Hose Routing

Single RH Wing Shown

Figure 24

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Section 5 - 10

Page 49

HydraulicPump Hose Connection

6. Pump Hose Connections. When connec-

tion the hoses to the pump keep all fittings closed and capped until you are ready to connect the hoses, this is to keep contamination out of the system (See Figure 25). When connection the hoses connect the pressure hoses first (See Figure 6). when the pressure hoses are connected to the pump and to the cylinder control valve & the directional control solenoid valve on the tank (See Figure 24, 25 & 26). Connect the Suction hose to the hose bib fitting on the pump (See Figure 26). Use clean hydraulic oil (recommended type and brand only) pour clean oil into the suction hose from the tank end, this will fill the pump with oil and help when pump is started for the first time to not start dry of oil. After filling hose with oil connect the hose to bottom side of the tank (See Figure 27) The motor pressure hose from pump connects to the directional control valve on the tank (See Figure 28).

Motor Pressure Port

Cylinder Valve

Pressure Port

Figure 25

Motor Pressure

Hose

Suction Port

Figure 27

Pump Suction Hose From Tank

Cylinder Valve Pressure Hose

Figure 26

Motor Pressure

Hose From Pump

Figure 28

Pump Suction Hose From Tank

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Section 5 - 11

Page 50

Fill Hydraulic Tank

Fill Hydraulic Tank with Oil:

1. DO NOT START TRACTOR until you have filled

Hydraulic Oil Tank to a level as shown in Sight Glass gauge and fill the Suction Hose to Pump with Oil.

2. Remove Filler Cap. Remove Filler cap only when

ready to fill hydraulic Tank with Oil. Do Not leave the Cap off and the system Open, always keep system closed when possible. Avoid any oil contamination. (See Figure

29)

3. Avoid Hydraulic Contamination by filtering the

Hydraulic Oil while filling the Hydraulic Tank. Filter buggies or carts are commercially available for Hydraulic system cleanup and Oil transfer. These consist of high capacity filter, a Circulating Pump, a Drive Motor and hoses for connecting to the units hydraulic system. When adding Oil always use Clean new Oil from a sealed container, If you suspect the Oil of being contaminated don't use it. (See Figure 30 & 31). It is best to always use a filter system when adding even new oil.

Figure 29

4. When adding Oil in the field keeping it clean is

critical, do not use dirty funnels or hoses. Do Not open Hydraulic tank or any containers unless the openings have been cleaned first. The outside of the containers must be clean. If a windy dusty day do not fill and allow dirt to blow into oil. Always add Oil using a pump system with at least a 10 Micron filter system. (See Figure 32)

Figure 30

Figure 31

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

Section 5 - 12

Figure 32

Page 51

Fill Hydraulic Tank

Fill Hydraulic Tank with Oil:

5. Fill Tank. Fill the Hydraulic Tank (See Figure 35) Fill tank till the Oil is visible in the sight Gauge

(See Figure 33 & 34). This will fill tank for the start but it will have to filled again later. Read Step 6 a must.

6. Fill Suction Hose with Oil. This is an important step that must be done. Remove the Suction Hose at the Tank (See

Figure 6) and fill the hose with clean oil, THIS IS A MUST DO. The Suction Hose must be filled with Oil to prevent Dry start up of Pump. Dry start up of PUMP can damage the Pump. After filling suction Hose reinstall it and tighten down Hose Clamp.

Pressure

Gauge

Sight Gauge

Figure 33

Figure 34

Oil Level & Temperature Sight Gauge

Figure 35

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Section 5 - 13

Page 52

NOTES

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Section 5 - 14

Page 53

Section 6

Switchblade

John Deere

JD-5225, JD-5325

JD-5425 & JD-5525

CAB / ROPS 2 WD & 4 WD

Electrical Connections

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

Section 6 - 1

Page 54

MOTOR - PUMP ELECTRICAL CIRCUIT

Electrical Circuit: RH Wing Mower

The electrical circuit is a pre-assembled wire harness that will control the motor functions. The harness will be used with a push pull off/on switch that prevents the tractor from being started when motor is engaged. The wire harness uses a three position toggle switch that is used to reverse the knife bar direction of travel. These switches are not part of the wire harness assembly, These switches must be connected correctly to operate correctly (See Figure 1). There is a motor control valve mounted on top of the hydraulic tank that will have two electrical solenoids connected to it. The wire harness has two plugs on one end that connects to the solenoids, one plug will have longer wire (also has White Wire) than the other and will connect to the solenoid further most from the cutter bar mount. The other plug with the shorter wire (has Yellow Wire) will connect to the first solenoid closet to the operator.

IMPORTANT NOTICE, READ: The Starter solenoid wires and the 12V power supply

wire must be connected to tractor wiring, The power source wire must be connected to a power source that is only charged when the tractors key switch is in the on position. It is nessasary to connect power supply close to ignition switch, (with in 3" of switch). If power supply wire is connected direct to a power source that is charge when ignition switch is off, it will run the tractor battery down. The Solenoid wires (two Brown wires) must be connected close the tractor ignition switch, (within 3" of switch). This is required because some later tractor are using electronic monitoring of the tractor electrical system. If the solenoid wires are connected further down the line the monitoring system may detect this circuit as disconnected and cause the tractor to do different things, from engine shut down to jump out of gear. If you have electrical problems with the tractor doing strange things, check this connection.

When connecting wire harness to toggle switch the red wire MUST connect to the center post of switch, the yellow and the white wire must connect to the two outside post, it will not mater which outside post as long as one each of yellow or white wire is connect to the outer post (See Figure 1).

- Black #16 Wire

White #16 Wire

Yellow #16 Wire

- Black #16 Wire

NOTE: + Red # 16 Wire (12 Volt Supply) Connect to Key Switch Connection (within 3" of switch) that is positive only when ignition key is in “ON” Position. If connected to direct power supply and push pull switch is left on when tractor is stopped and parked it will run down the tractor battery.

pull switch to prevent it being connected wrong.

Brown # 12 Butt Connectors Wire to Starter Solenoid

Push Pull Switch, Wire Harness plug will only fit one way on push

Figure 1

Use Gaskets to Seal Both Plugs

- Black #16 Wire (Common Ground)

Front Solenoid Plug

+ Red #16 Wire

(12 Volt Supply)

Rear Solenoid Plug

This Wire Harness Used for RH Wing

123456

Red #16 Wire (Spade Connector)

Brown #12 Wire

Red #16 Wire

White #16 Wire (Spade Connector)

Yellow #16 Wire (Spade Connector)

Fuse Holder with 10 AMP Inline Fuse

4 Terminal Plug for Push Pull Switch

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Section 6 - 2

Page 55

Section 7

Switchblade

John Deere

JD-5225, JD-5325

JD-5425 & JD-5525

CAB / ROPS 2 WD & 4 WD

Mechanical Repairs

& Adjustment s

This Section is for the adjustment of the cutter bar / Knives if needed after assembly, the unit is assembled when shipped but because of dis assembly for shipping some adjustments may be required.

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

Section 7 - 1

Page 56

CUTTER BAR ADJUSTMENTS

Lead Adjustment:

The lead angle is how far the outer end of

the cutter bar runs forward of the inner end.

The lead angle of the cutter bar is preset at the factory at 3/6" per foot. The lead may be changed if desired. To reduce the lead, move the washers from the outside of the cutterbar support plate in between the rubber strike pad and plate (See Figure 3).

Pitch Adjustment:

The Pitch angle is the level of the cutter bar front to rear or what angle the blade is to level front to rear. Different cutting conditions allow you to change the pitch of the knife by + 15° to - 15° or level.

The pitch is set by loosening the three mounting bolts that connects the skid shoe / Break-A--Way assembly to the carriage arm assembly (See Figure 4 & 4A). The two lower bolts holes are slotted, this will allow the cutter bat to be tipped up +15° or down -15° in front. Set Pitch at what works best for your application.

Figure 3

Non-Slotted

Hole

Cutter Bar Alignment:

All cutting is done by the knife passing over ledger plate in the guard. It is vital that these sections are parallel with the plates and in contact with them, (See Figure 5 & 6).

The knife should move smoothly in the cutterbar guides and every knife section should rest on the ledger plate to make a shear cut. This means the guards, ledger plate, wear plates, clip and knife head caps must be in good condition and correctly set. If these parts become loose or worn, the knife will flop around in the cutter bar, chewing and tearing instead of cutting.

Guard Adjustment:

1. To align the guards, the only method pro-

vided to accomplish this very important adjustment is to bend the guards into alignment with a hammer. No easier method has been found to adjust heavy duty guards which will stand up in rocky conditions.

Continued Next Page

Figure 4

Figure 4A

Slotted Holes

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Section 7 - 2

Page 57

CUTTER BAR ADJUSTMENTS

Note: Guards are cast from alloy steel. If they are worked to much, they will harden and cannot be bent. In this case remove the guard from the bar and remove the ledger plate. Heat the guard to a cherry red and cool. This process will anneal the guard enough that it can be bent.

2. Raise the bar to about 45°. Make certain the knife

is at the full retracted position of the stroke so the flywheel doesn't suddenly turn and catch your fingers in the knife. A pair of Vise Grip Pliers gripped tightly to the knife on the upper side of the rock guard will allow extra protection against cutter bar from turning. Make certain the Tractor is secured so it cannot be started until you are the one who decides to start it when the job is finished, all tools removed and cleaned up and it is safe to do so. Make certain tractor parking brake is set.

3. Sight down the bar and look for a knife section in

close contact with a guard ledger. If the section to the right and left are both 1/8" of the ledger do not bend the two sides up until they contact the knife. This is wrong (see Figure 5), the high guard should be knocked down until all three contact. The higher up a guard gets bent, the more the knife section will tend to contact only the tip (See Figure 5 & 6).

4. Bolt the guards tight and strike them in the thick

part, just in front of the ledger plates (see Figure 6). Do not pound down the guard lips as the knife might bind. Retighten the bolts as each guard is aligned. Disregard the position of the guard points. It is the ledger plate which must be kept in line. Blunt points should be filed sharp.

5. Start from the inner shoe, adjust each guard so that the knife section and ledger are parallel and

reasonably close to each other. Find the high guard and knock them down. Usually, the only time it is necessary to knock a guard up is when new guards are first installed on the bar.

6. Make certain that the first knife section is contacting the inner shoe ledger plate. If it doesn't

contact, check the first or second guard which may be holding the knife up or the inner shoe ledger plate may be worn out.

7. Finally, align the industrial outer shoe in the same way as the guards. (See Figure 5 & 6 and step

1 through 6)

Figure 5

Figure 6

Wear Plates::

The wear plates must line up with each other to give the knife back straight bearing along its entire length. Wear plates should project approximately 1/16" in front of the leading edge of the cutterbar after adjustment. Alamo Industrial wear plates are hardened on both edges. After the first edge has worn back, simply turn over the plate to obtain a new wearing surface.

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Section 7 - 3

Page 58

CUTTER BAR ADJUSTMENTS

Clips:

After all guards are adjusted, it is necessary to see that the knife clips are bent down to within 1/ 64" of the section. The easiest way to check this is to hold the knife down on the ledger plate and use a feeler gauge or the cover of a paper match book to measure the clearance. Do not attempt to hold the tightly against the ledger plate with the clips. Knock the clips down with a hammer. A light blow with hammer is all that is required. If the clips drag on the knife, pry them up. Drag will bind the knife and wear the clip very rapidly (See Figure 7 & 8).

Knife Repair:

ALWAYS USE A SHARP KNIFE. A dull knife cuts poorly, may plug and doesn't do a clean job. Keep the knife straight with the sections firmly riveted to the knife back. When sharpening knife, be careful to restore the original shear angle and bevel of 23 °. Properly and improperly ground knife sections are shown (See Figure 9). A knife section that has been ground several times may have the proper angle and bevel and still be unserviceable because the hard cutting edge has been ground away and the section is to short to cut everything encountered.

Clips

Figure 7

Match Book Cover

Knife Replacement:

Replace worn or broken knife sections. Alamo Industrial knife sections are heavy duty sections made of special steel and will stay sharp for many more hours than conventional sections.

New Sections proper bevel and angle for good work.

Improperly ground sections - narrow bevel and wrong angle which changes the angle of shear.

Figure 8

properly ground sections even after repeated griding, proper bevel and angle are retained.

Figure 9

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Clips

Sections ground off center, destroying the register of blade in guard.

Section 7 - 4

Page 59

CUTTER BAR REPLACEMENT

Cutter Bar Assembly Replacement:

Replacement of the complete cutter bar assembly will require the cutter bar assembly to be unbolted from skid shoe / break-a-way assembly. Wear gloves as the knives on the cutter bar can be very sharp and can cut you. (See Figure 10)

It will not be require to remove any of the hydraulic hoses or even take them loose. Looking down at the planetary drive (and Hydraulic Motor Assembly) there are four nuts in the plate that is attached to the drive assembly. Remove these four nuts, if you want to remove the four carriage bolts the skid shoe will have to be unbolted and removed. When lifting the drive assembly up and away from the cutter bar take notice of the four tube spacers under the drive assembly, there are two different length of the spacers. The short ones go to the rear and the long ones go to the front. Once the drive assembly has been lifted off you will see a nylon bearing in the knife bar head clamp, it should have stayed in the clamp.

There will be two more bolts connecting cutter bar to break-a-way assembly once these nuts are removed the cutter bar should lift up over the bolts if they were left in. There will be a square plate under the cutter bar that has 4 holes in it, make certain to note this for reassembly

When reinstalling cutter bar reverse the disassembly procedures. Make certain the nylon bearing is in good condition or replaced, sometimes the clamp will have to be loosened to get the nylon bushing installed into clamp and the drive stud that is attached to the drive assembly with two socket head bolts, DO NOT tighten clamp bolt now. This drive stud can be unbolted from drive assembly, inserted into nylon bearing and re-bolted to drive assembly later.

The nuts on the carriage bolts (4 short and 2 long 3/4" carriage bolts) that retain the drive assembly and the cutter bar to the break-a-way assembly must be torqued to 85 ft. lbs.

After the assembly is finished the guards, clips and ledger must be checked, see the previous section in this manual for setting cutter bar components.

Tighten the clamp bolt around the drive stud, use a good thread lock compound on clamp bolt and tighten the clamp bolt until the up & and down movement of clamp on drive stud is removed. DO OVER TIGHTEN the clamp bolt as the drive stud has a bearing inside that will be damaged.

Short Tube

Spacers

Motor

Planetary Drive

Assembly

Long Tube

Spacers

Knife Drive Stud Assembly

Nylon Bearing

Clamp & Clamp Bolt

Figure 10

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Section 7 - 5

Knife Head Weldment

Blade Sections

Knife Backing Strip

Page 60

KNIFE BAR REPLACEMENT

Knife Bar Replacement:

Replace the Knife Bar assembly will require the cutter bar assembly to be unbolted from skid shoe / break-a-way assembly. Wear gloves as the knives on the cutter bar can be very sharp and can cut you. (See Figure 10 & 11)

It will not be require to remove any of the hydraulic hoses or even take them loose. Looking down at the planetary drive (and Hydraulic Pump Assembly) there are four nuts in the plate that is attached to the drive assembly. Remove these four nuts, if you want to remove the four carriage bolts the skid shoe will have to unbolted and removed. When lifting the drive assembly up and away from the cutter bar take notice of the four tube spacers under the drive assembly, there are two different length of the spacers. The short ones go to the rear and the long ones go to the front. Once the drive assembly has been lifted off you will see a nylon bearing in the knife bar head clamp, it should have stayed in the clamp.

There will be two more bolts connecting cutter bar to break-a-way assembly once these nuts are removed the cutter bar should lift up over the bolts if they were left in. There will be a square plate under the cutter bar that has 6 holes in it, make certain to note this for reassembly.

Use caution the knife bar can be very sharp, it is recommended that you wear gloves to protect your hands. The Knife Bar will slide out at the drive end, if it will not slide out then something is wrong. Check the rock guards, clips and other components to see where it is to tight. The easiest way if any of these make it to tight is to unbolt them and remove them for now. The new or repaired knife bar will install the same way, it will slide in from the drive end under clips and between rock guards. DO NOT use hammer or force to install knife bar, if it will not slide in find out why because if the bar is forced in it will be damaged or other component will be damages. The Knife bar and cutter bar can not operate fitting tightly together they will bind causing damage..

When reinstalling cutter bar reverse the disassembly procedures. Make certain the nylon bearing is in good condition or replaced, sometimes the clamp will have to be loosened to get the nylon bushing installed into clamp and the drive stud that is attached to the drive assembly with two socket head bolts, DO NOT tighten the clamp bolt at this time. This drive stud can be unbolted from drive assembly, inserted into nylon bearing and re-bolted to drive assembly later (See Figure 10 & 11). if the drive stud is removed from the drive assembly when you reinstall it the two socket head bolts will need to be torqued to 35 ft. lbs.

The nuts on the carriage bolts (4 short and 2 long 3/4" carriage bolts) that retain the drive assembly and the cutter bar to the break-away assembly must be torqued to 85 ft. lbs.

After the assembly is finished the guards, clips and ledger must be checked for clearance, see the previous section in this manual for setting knife bar to cutter bar components (See Figure 10 & 11).

The skid shoe will be the last item reinstalled. Make certain the rod deflector which bolts to the front of the skid shoe is pointed correctly.

Knife Backing Strip

Figure 11

Drive Stud

Nylon Bearing

Clamp & Clamp Bolt

Knife Head Weldment

Blade Section

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Section 7 - 6

Page 61

KNIFE REPLACEMENT

Knife Replacement:

The Knives are very sharp, use gloves and

caution when working with these knives. Secure tractor so that it cannot be started until you are ready for it to. Set the parking brake on the tractor. Make certain cutter bar is completely on the down stroke, this will prevent the cutter bar from moving down ward. Also the Knives can be locked with a clamp so it cannot move unless you want it to. If cutter bar needs to move the best way is by using a punch in one of the holes on the flywheel, remove clamp the replace it after you have moved the cutterbar.

To remove the old knife the Knife retaining bolt will have to be removed, usually these bolts cannot be used again and it is recommended that new one be used when changing knives. When lock nut is removed the bolt should not fall out as the shoulder of the bolted is ridged to make a drive in fit. Drive the bolt out from the top, there are two bolts per knife. There are two different length of these bolts, the majority is 5/8" long. The first 7 bolts which also bolt the knife section, knife backing strip and the knife head weldment together is longer, 1-1/64" long. Remove the locknut, if the lock nut cannot be removed these bolts can be cut with a chisel under the lock nut and the bolt driven out from the top, use caution and not drive a punch or anything through the hole that is larger than the bolt as it will damage the hole in the knife backing plate.

Special Cone

knife

Ridged

Shoulder

Figure 12

Figure 13

Locknut

123

1234

knife

Ridged

Shoulder

123

Backing

Special

Knife Bolt

knife

Knife

Strip

Replace a Knife or a group of knives. The knife can be changed without disassembly of the cutter bar. The Knife retaining bolt is a special ridged shouldered bolt, this makes the bolt have a wedged fit into the knife backing strip. The special bolt will need to be driven into the knife backing strip from the bottom until the head of bolt bottoms out on the knife backing strip. Install the new cone locknut and snugly secure the bolt, do not over tighten these bolts as they are 1/4" gr. 5 and will twist off. Torque 9 to 10 ft. lbs max. If all the rock guards and clips were adjusted right to begin with they should not have changed, but check them for alignment to make certain. If the rock guards and clips need to be

Figure 14

adjusted go back to the guard ajustment section earlier in the manual. (See Figure 11, 12, 13 & 14)

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Section 7 - 7

Page 62

OUTER SHOE ASSEMBLY REPLACEMENT

Outer Shoe Assembly Replacement:

The outer shoe assembly bolts to the last two holes in the cutterbar. There are two different length

bolts used here because the last bolt will also mount the outer shoe sole to the outer shoe assembly.

These are 7/16" grade 5 carriage bolts and will torque 45 to 50 ft. lbs. The outer shoe sole is a replaceable wear item and be replaced as needed without disassembly of the cutterbar (See Figure 15 & 16).

Inner Shoe Replacement:

The inner shoe bolts to the Break-a-way

assembly using two bolts in the rear and the rod deflector in the front. There is also a motor cover weldment that bolts over the motor and drive assembly that is bolted on with three bolts (See Figure 17 &

18).

Rock Guard, Clip & Wear Plate Replacement:

The rock guards, clip and wearplates can be

replaced without removing that cutterbar or knife bar assembly. They are bolt on items that can be bolted one at a time for repair or they can all be replaced all at the same time. Anytime the guards, clips or wearplates are replaced they will have to be checked to make certain they are fitting correctly. See the guard, clip and wearplate adjustment section on previous pages. The bolts mounting rock guards are 7/16" grade 5 plow bolts and will torque 45 to 50 ft. lbs (See Figure 16)

Cutter Bar

Outer Shoe Asy

Outer Shoe Sole

Figure 15

Figure 16

Figure 17

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Section 7 - 8

Figure 18

Page 63

INNER SHOE WELDMENT REPLACEMENT

Inner Shoe Weldment Replacement:

The Inner Shoe Weldment replacement will require other components to be removed in order

to replace the weldment. Removal or disconnection of hydraulic line will not be required. DO NOT Start tractor after this repair has began, secure tractor from starting and set parking brake on tractor.

1. Inner Skid Shoe Plate will have to be removed, See inner shoe replacement on previous page

(See Figure 17 & 18).

2. Drive Assembly will need to be removed,

See cutter bar assembly replacement on previous pages (See Figure 10).

3. Cutter Bar Assembly will need to be removed,

See cutter bar assembly replacement (See Figure 10).

4. The Rotor Actuator is a hydraulic operated

break-a-way unit. Before starting repair put a drain pan under rotor actuator. The hoses at the actuator should be loosen slowly, but NOT Removed to relieve pressure in lines and actuator. Make certain that it is the hose at the actuator and not the control or the relief valve block. After the pressure if any has been relieved the hoses can be retightened. This is important DO NOT try to unbolt Actuator Pin or any other frame component until the hoses have had the pressure relieved. (See Figure 19, 20 & 21)

5. The Skid Shoe weldment

can be removed with the Rotor Actuator attached to skid shoe weldment and then removed or it can be left bolted to Back Pivot Plate. The rotor actuator is not part of the skid shoe weldment. To remove the actuator from skid shoe remove the 8 bolts that retain break-a-way rotor actuator pin. The rotor Actuator pin goes all the way through the shoe weldment and can be removed by pushing up on pin from bottom (See Figure 19, 20 & 21) is retained by 3 bolts which mount it to the Carriage Arm, It is not required to remove the Back Pivot Plate to remove skid show weldment. It must removed, remove the three retaining bolts to drop the back plate.

6. The Back Plate

Short Tube Spacer

Break-A-Way Rotor Actuator Pin

Back Pivot Plate

Rotor Actuator

Figure 20

Figure 19

Motor

Drive Assembly

Long Tube Spacer

Inner Skid Shoe Weldment

Motor Drive Asy Cover

Inner Skid Shoe

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Section 7 - 9

Page 64

INNER SHOE WELDMENT REPLACEMENT

6. If the Back Plate has been removed from the carriage arm, it will have to be reset after the reassembly is done. See the Pitch adjustment in previous instruction (See Figure 4). The adjustment to the cutter bar should be check and reset if required after reassembly.

7. Before beginning the reassembly read this section as well as the section that pertains to the component listed below. This is important that these components be assembled correctly as well as adjusted properly. The assembly of the skid shoe weldment, replacement of the Rotor Actuator, Drive Assembly, Cutter Bar, Skid Shoe and Drive Assembly Cover will be reinstalled by reversing the disassembly instructions. (See Figure 10 thru 21)

Rubber Bumper

Pad

Back Pivot

Plate

Rotor Actuator

Figure 21

3/8" Bolts

3/8" Lockwashers

Rotor Actuator

Retaining Pin

Shoe

Weldment

Rotor Actuator

Mounting Bolts

Knife Backing Strip

Figure 22

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Section 7 - 10

Figure 23

Drive Stud Bearing Asy

Nylon Bearing

Clamp & Clamp Bolt

Knife Head Weldment

Blade Section

Page 65

CARRIAGE ARM ASSEMBL Y REPLACEMENT

Carriage Arm Assembly Replacement:

The carriage arm replacement will require

the Back Pivot Plate to be unbolted with the skid shoe / break-a-way assembly to be removed with Back Pivot but not disassembled. The skid shoe / break-a-way assembly can be removed by unbolting the back pivot plate from the carriage arm (See Figure 17 thru 25). The hydraulic hoses to the motor will not have to be disconnected but the hose brackets may have to be disconnected to allow the assembly to be moved outward far enough to clear carriage arm assembly. If the complete cutterbar / break-a-way assembly needs to be moved it is sometimes easier and cleaner to unbolt the motor and the complete assembly can be removed an the motor can be moved out of the way with the hoses attached to it. DO NOT pull assembly with the hoses attached and damage them.

To remove the carriage arm the lift and tilt cylinder will need to be disconnected, the hoses will not require disconnecting, the cylinders can be set aside with the hoses connected. Remove the roll pins from the carriage pin. The carriage arm is pinned to the back pivot plate and the tractor mainframe. The mounting frame to attach to the tractor will vary from tractor model, but the way the carriage arm is pinned to will not. Drive the carriage pins out and carriage arm will lift out (See Figure 24, 25 & 26).

Carriage Arm

Assembly

Figure 24

Back Pivot

Plate

Carriage Arm

Figure 25

Carriage Pin

Back Pivot

Plate

Inner Shoe

Wledment

Carriage Arm

Assembly

Carriage Pin

To reassemble the carriage arm reverse the disassembly instruction, insert carriage arm, insert carriage arm pins, install roll pin in to carriage arm pin. Install the lift and tilt cylinders, make certain hoses connecting to the cylinders is not twisted or routed wrong as they could be damaged. Attach the back pivot plate with the carriage pin. Bolt the cutterbar / skid shoe assembly to the back pivot plate, note the two lower holes in back pivot plate are slotted on a curve. Flatwashers will have to be used on these two lower bolts (See Figure 25). The pitch of the cutter bar will have to be readjusted, see pitch adjustment instructions in earlier pages (See Figure 4 & 26)

Curb Lift Cyl.

Bar Tilt

Cyl

Rear View

Figure 26

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Section 7 - 11

Carriage Arm

Front View

Page 66

KNIFE DRIVE REPAIR / REPLACEMENT

Knife Drive Assembly Repair / Replacement:

1. The knife drive assembly will be limited to the parts that can be replaced. The Actual knife drive

subassembly is not a repairable part and will not have replacement parts available, components on the knife drive assembly can be replaced only.

2. It will not be require to remove any of

the hydraulic hoses or even take them loose. The Motor can be unbolted from the drive assembly and laid aside with the hoses still connected. The motor has a splined shaft that mates to the hub adapter.

3. Looking down at the planetary drive

(and Hydraulic Motor Assembly) there are four nuts in the plate that is attached to the drive assembly. Remove these four nuts, if you want to remove the four carriage bolts the skid shoe will have to unbolted and removed. When lifting the drive assembly up and away from the cutter bar take notice of the four tube spacers under the drive assembly, there are two different length of the spacers. The short ones go to the rear and the long ones go to the front (See Figure

22)

4. There are two ways to remove

Support the knife drive assembly from the cutter bar knife head weldment.

5. 1 st. is to remove the two knife drive

Support Mnt

Bolts bolt that retain the knife drive stud to the drive assembly support bracket, this allows the drive stud bearing assembly to stay with the

Figure 27

cutterbar (See Figure 27) .

6. Or 2 nd. there is a clamp bolt on the Knife Head Weldment, loosen the clamp bolt, this will allow

the Knife drive stud bearing to pull out of the knife head weldment clamp or off the knife drive stud bearing assembly. (See Figure 23 & 24) Once the drive assembly has been lifted off you will see a nylon bearing in the knife bar head clamp, it should have stayed in the clamp or it could have stayed on the knife drive stud bearing assembly (See Figure 23 & 27)

7. The Hub Adapter is bolted to the Flywheel with four bolts, the flywheel is pressed down over the

top shaft of the drive subassembly. The Knife stud bearing support bolts to the bottom of the drive subassembly with two bolts. The Knife drive stud bearing bolts to the support bracket (See Figure 27). If you unbolted the stud drive and left it in the cutter bar it should be removed and inspected. This stud drive is a sealed bearing drive assembly, there are no replaceable parts in it so it can only be replace as an assembly. To check the stud drive bearing assembly hold the top where the two bolts mount it to the support bracket. Grab the OD of the stud drive and the outer cover should spin freely while the top for the two bolts will not, it should not be rough or out of round. To work properly it must be free and smooth turning. Check the nylon bearing in the knife head weldment, it has to be in good condition also. This nylon bearing does not turn when installed, it acts solely as a bushing between the clamp and stud drive bearing assembly and prevent the clamp from crushing the drive stud bearing. (See Figure 22, 23 & 27)

Hub Adapter

Flywheel

Knife Drive

Sub-Asy

Knife Drive

Stud Bearing

123

Knife Drive

Stud Brg Mnt

Bolts

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Section 7 - 12

Page 67

KNIFE DRIVE REPAIR / REPLACEMENT

8. To reassemble the Knife Drive Assembly reverse the disassembly steps but first the cutter bar

must be made ready. If the drive stud assembly was not removed from cutterbar knife head weldment (See Figure 22, 23 & 27) and you do not plan to loosen the clamp around the nylon nearing on knife drive stud, you will not need to do this. IF the drive stud is removed the cutter bar head clamp will need to be prepared. Loosen the clamp bolt to where the nylon bearing (bushing) can be installed into the clamp, reinstall the clamp bolt into clamp BUT DO NOT tighten clamp bolt. Insert the drive stud bearing into the nylon bearing of clamp, still DO NOT tighten the clamp bolt.

9. Install the support bracket to the lower side OD the knife drive assembly, these e are two 8 mm

bolts that screw into the knife drive assembly bottom side. Torque the 8 mm bolts to 20 ft. lbs.

10. Install the Tube spacers over the carriage bolts, remember the long ones go in the front and the

short ones go in the rear. Set the drive assembly down over the four bolts where it is setting on the four tube spacers. Install the motor adapter down over the same four bolts (See Figure 28), The Drive assembly can be tightened down now, these are 1/2" grade 8 plow bolts and should be torqued to 100 to 110 ft. lbs.

11. From the bottom of the drive assembly turn the drive assembly, (there are holes in the outer

diameter of the flywheel that can be used to turn it by inserting a bar into the hole). Align the drive assembly support bracket with the two bolt holes for the drive stud bearing, KEEP YOUR HAND away from the cutting blades they are sharp. After the two 10 mm bolts are installed into the drive stud bearing torque them to 35 ft. lbs. The drive assembly can be checked prior to bolting on the motor. Use a punch or rod that can be inserted into the hole on the OD of the flywheel (KEEP YOUR HANDS OUT OF THE KNIVES). This will check to make certain the cutter bar is not binding and also check to make certain the drive stud bearing is rotating freely.

12. With the drive assembly bolted down to the skid shoe weldment and the knife drive stud bolted

to the support bracket at the bottom of the knife drive assembly. The Clamp Bolt on the knife head weldment will need to be tighten down, CAUTION MUST BE USED when tightening the clamp bolt to prevent the knife drive stud beading from being damaged. Before tighten you should be able to slide the knife head weldment with the nylon bearing in it to slide the bearing and knife head weldment up and down slightly on the knife drive stud bearing. Slowly tighten the clamp bolt checking this up and down movement. When you have tighten the clamp bolt and all the up and down movement between the knife head weldment (Nylon Bearing) is removed the clamp bolt will be tight enough. Do not over tight clamp bolt as damage to the knife drive stud bearing can be damaged. The Knife head weldment clamp has to be in the right position up and down on the knife drive stud bearing so the cutter bar in center for height to match the cutter bar.

13. Install the Motor onto the hub adapter by

aligning the Key on the motor shaft with the key slot in the adapter hub. Install and tighten the two 1/2"NC X 1-1/4" GR 5 bolts that retain the motor to the drive assembly (See Figure 28 ). the hoses should all ready be connected, but if they are not you will need to consult the hydraulic schematic (See Figure

1) showing the hose routing for the motor.

14. Recheck all the installation to make certain

that the bolts have all been installed and are tightened to the required torque. Make certain all guards and shield have been reinstalled before starting tractor or mower.

Figure 28

Motor

Knife Drive

Asy

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Section 7 - 13

Page 68

NOTE

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Section 7 - 14

Page 69

Section 8

SWITCHBLADE

John Deere

JD-5105, JD-5205 JD-5225, JD-5325

JD-5425 & JD-5525

CAB / ROPS 2 WD & 4 WD

Mount Kit Components

Identification

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Section 8 - 1

Page 70

Mount Kit Component Identification

John Deere

5425/5525 CAB & ROPS/2&4wd w/Flat Platform

As Of: 03-25-05

Front Tires:

11.2-24 (R-1) Max front tire

Rear Tires:

16.9-30 (R-1) Max rear tire

Mount Kit: ROPS Flat (IOOS) Platform Only

Subframe Kit ………………………………………………….....02982523

Hydraulic Kit ………………………………………………......... 02982524

Mount Kit: Cab Only

Sub-frame Kit ……………………………………..................... 02982523

Hydraulic Kit …………………………………………………......02983229

Important Note:

1. The ROPS mount kit has been designed to fit tractors equipped with an “isolated open operator station (IOOS)” (ie: flat platform). The dealer/customer is responsible for any required modifications for mounting tractors equipped with a “straddle mount operator station” instead.

2. The right hand step must be removed for lift carriage clearance. Ingress/egress on the right is otherwise blocked by the control stand.

3. If the tractor is equipped with a mid-mount valve, it may also need to be moved for clearance reasons. Mid - Mount Valve Is a Tractor Mounted Option where aux vlave is mounted on the RH side of tractor behind RH step. Cab models should clear butmodification may be required by installer at customer or dealer exspense.

4. First cut from tractor center line for a right hand cutterbar is 54".

Flat Operators

Platform

(1) isolated open operator station (flat platform).

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.)05/05

Section 8 - 2

(2) The right hand step must be removed .

The right hand step has been

removed

Page 71

Mount Kit - Bill of Material - 5425 & 5525 CAB / ROPS

Notice: Mounting restrictions may change as designs of tractor model changes and/or design of the Switchblade is updated or changed. Listing in this assembly manual is current as of the print date.

2 WD & 4WD ROPS W/ Flat Platform

IMPORTANT NOTICE: The following Part / Assembly Numbers are for reference and should

not be ordered as replacement parts, unless all the components in that assembly are wanted. These will break down to bills of material of the components. Some of numbers listed are NOT individual Parts but complete assemblies and/or box of assemblies. Check before ordering.

Sub-Frame Kit : 02982523 Consist of the Following Items.

Used On: John Deere 5425/5525 CAB & ROPS / 2&4wd w/Flat Platform

Item Part No. Qty Description

1 00695100 4 LOCKNUT, TOPLOCK 5/8"-NC 2 00756077 4 WASHER, 5/8" HARDENED 3 02971158 4 LOCKWASHER, 20MM 4 02975692 4 BOLT, HEX HEAD M20-P2.5 X 50MM - PL - GR10.9 5 02976342 4 BOLT, HEX HEAD M16-P2.0 X 55MM - PL - GR10.9 6 02982525 1 SWITCHBLADE FRAME WELDMENT 7 0665400 1 SUBFRAME, WELDMENT 8 0112400 1 PIN, STOP PIN 9 01 14600 1 PIN, HAIR PIN 10 00010300 4 LOCKWASHER, 5/8" 11 00753753 4 BOLT, HEX HEAD 5/8"-NC X 2" - PL - GR8

Above items are included in Switchblade Sub-Frame Kit P/N 02982523

Hydraulic Kit : 02982524 Consist of the Following Items.

Used On: John Deere 5425/5525 ROPS ONLY / 2&4wd w/Flat Platform

Item Part No. Qty Description

1 000849 2 STREET ELBOW, 45 DEG. 2 000859 12 PLASTIC TIE 3 0022400 1 ELBOW, STREET ELL 3/4" NPT

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Section 8 - 3

(continued Next page)

Page 72

Mount Kit - Bill of Material - 5425 & 5525 CAB / ROPS

Hydraulic Kit : 02982524 Consist of the Following Items.

Used On: John Deere 5425/5525

Item Part No. Qty Description (continued from previous page)

4 0022800 1 BUSHING,REDUCING 5 0148600 1 KEY 6 01501075 5 BULK HYD HOSE #16 SAE100R4 7 0222100 2 FITTING, HOSE BIB #16HOSE-12MP 8 02702900 1 HUB 9 02962749 3 ADAPTER, HYD ELBOW 8MJ-8FJX45 10 02968850 1 ADAPTER, HYD STRAIGHT 8MB-6MJ 11 02971158 4 LOCKWASHER, 20MM 12 02973992 1 PULLEY ADAPTER, MACHINED 13 02974303A 1 PUMP ASY, TANDEM GEAR 0.98/0.37 CID 14 02975186 1 ADAPTER, HYD STRAIGHT 16MB - 12FP 15 02975187 1 ADAPTER, HYD ELBOW 12MB - 8MJ45 16 02975188 1 FLEX COUPLER ASY 17 02975692 4 BOLT, HEX HEAD M20-P2.5 X 50MM PL GR10.9 18 02977335 1 VALVE MOUNT BRACKET WELDMENT 19 02979318 1 PLATE, BELT COVER 20 02979436 1 PUMP MOUNT PLATE, MACHINED 21 02982530 1 D/L 7/8-13 X 3/4-3/16 KEY 26.5 22 0741300 2 HOSE CLAMP,STEEL,HEXSCREW 23 107352 1 WLDMT, CONTROL STAND 24 001580 1 HOSE, #6 - 6FJX - 6FJX - 45" LG 25 0075681 1 1 HOSE, #4 - 4FJX - 4FJX - 70" LG 26 00761200 2 HOSE, #8 - 8FJX - 8FJX - 74" LG 27 02966175 1 HOSE, #8 - 8FJX - 8FJX90 - 69.5" LG 28 02976531 3 ADAPTER, HYD ELBOW 6MJ - 6FJX45 29 02976532 2 ADAPTER, HYD ELBOW 4MJ - 4FJX45 30 02839000 1 HOSE, #4 - 4FJX - 4FJX - 64"LG 31 02982565 1 HOSE, #6 - 6FJX - 6FJX - 103" LG 32 02982566 1 MANUAL, INST SWB JD5425 ROPS 33 00010300 1 LOCKWASHER, 5/8" 34 00756077 1 WASHER, 5/8" HARDENED 35 02976342 1 BOLT, HEX HEAD M16-P2.0 X 55MM PL GR10.9 36 00013900 1 BOLT, HEX HEAD 3/8"-NC X 2-1/2" PL GR5 37 00015800 12 LOCKNUT, TOPLOCK 3/8" 38 00023100 9 BOLT, HEX HEAD 3/8"-16UNC X 1-1/2" PL GR5 39 001636 2 BOLT, HEX HEAD 1/4"-NC X 2" 40 00900913 18 CORDURA SLEEVING , 2.54 ID BLACK 41 02959924 2 LOCKNUT, TOPLOCK 1/4"-NC PLB 42 02970595 2 BOLT, HEX HEAD 3/8"-NC X 2-3/4" PL GR8 43 02978281 1 HOSE RING WELDMENT 44 02976344 4 BOLT, HEX HEAD 7/16"-NC X 1-1/4" PL GR8 45 00022200 4 LOCKWASHER, 7/16" PL 46 00012101 2 LOCKWASHER, 3/8" PL 47 00011100 6 FLATW ASHER, STD 3/8"

Above items are included in Hydraulic Kit P/N 02982524.

ROPS ONLY / 2&4wd w/Flat Platform

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Section 8 - 4

Page 73

Mount Kit - Bill of Material - 5425 & 5525 CAB / ROPS

Hydraulic Kit : 02983229 Consist of the Following Items.

Used On: John Deere 5425/5525 CAB ONLY / 2&4wd

Item Part No. Qty Description

1 000849 2 ELBOW, STREET ELL12MP-12FP45 2 000859 12 PLASTIC TIE 3 0022400 1 ADAPTER, HYD ELBOW 12MP - 12FP90 4 0022800 1 BUSHING, REDUCING 5 0148600 1 KEY 6 01501075 5 BULK HYD HOSE, #16 SAE100R4 8 0222100 2 FITTING, HOSE BIB #16HOSE - 12MP 9 02962749 3 ADAPTER, HYD ELBOW 8MJ - 8FJX45 10 02968850 1 ADAPTER, HYD STRAIGHT 8MB - 6MJ 11 02971158 4 LOCKWASHER, 20MM 12 02974303A 1 PUMP ASY, TANDEM GEAR 0.98/0.37 CID 13 02975186 1 ADAPTER, HYD STRAIGHT 16MB - 12FP 14 02975187 1 ADAPTER, HYD ELBOW 12MB - 8MJ45 15 02975188 1 FLEX COUPLER ASY 16 02975692 4 BOLT, HEX HEAD M20-P2.5 X 50MM PL GR10.9 17 02979318 1 PLATE, BELT COVER 18 02979436 1 PUMP MOUNT PLATE, MACHINED 19 0741300 2 HOSE CLAMP,STEEL W/ HEXSCREW 20 00015800 6 LOCKNUT, TOPLOCK 3/8" 21 00023100 6 BOLT, HEX HEAD 3/8"-16UNC X 1-1/2" PL GR5 22 00761200 2 HOSE, #8 - 8FJX - 8FJX - 74" LG 23 00900913 18 CORDURA SLEEVING, 2.54" ID BLACK 24 02959924 2 LOCKNUT, TOPLOCK 1/4"-NC PLB 25 02966175 1 HOSE, #8 - 8FJX - 8FJX90 - 69.5" LG 26 02976531 2 ADAPTER, HYD ELBOW 6MJ - 6FJX45 27 02978281 1 WLDMT, HOSE RING 28 02982566 1 MANUAL, INST SWB JD5425 ROPS 29 00010300 3 LOCKWASHER, 5/8" 30 00756077 1 WASHER, 5/8" HARDENED 31 02976342 1 BOLT, HEX HEAD M16-P2.0 X 55MM PL GR10.9 32 00012101 2 LOCKWASHER, 3/8" PL 33 00011100 6 FLATWASHER, STD 3/8" 34 00755954 2 LOCKWASHER, M10 SPRING 35 02979374 1 CONTROL MOUNT STAND 36 00751688 2 BOLT, HEX HEAD M10-P1.5 X 25MM PL GR8.8 37 02974296 1 SWITCH MOUNT WELDMENT 38 02971202 2 CABLE REMOTE CONTROL 72" RVC-BLKHD 39 02980073 1 PLATE VALVE MOUNT 40 02966874 1 BOOT,CABLE 41 00750940 3 LOCKNUT, TOPLOCK 5/16"-NC PLB 42 02975200 1 DRAWING INSTRUCTION, REMOTE CONTROL ASY 43 02974323 2 ANGLED SINGLE AXIS CONTROL ASY 44 02966687 2 YOKE, ADJ 45 02966688 2 CLEVIS PIN 3/16" X 7/8" (Continued Next Page) Above items are included in Hydraulic Kit P/N 02983229.

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 5

Page 74

Mount Kit - Bill of Material - 5425 & 5525 CAB / ROPS

Hydraulic Kit : 02983229 Consist of the Following Items.

Used On: John Deere 5425/5525 CAB ONLY / 2&4wd

Item Part No. Qty Description (Continued From Previous Page)

46 02968698 2 COTTER PIN 3/32" X 3/4" 47 02733700 3 BOLT, HEX HEAD 5/16"-NC X 4-1/2" PL GR5 48 00023500 6 FLATWASHER, 5/16" PL 49 0461600 2 BOLT, HEX HEAD 1/4"-20 NC X 2-1/4" PL GR5 50 02972846 2 BOLT, HEX HEAD M16-P2.0 X 40MM PL GR10.9 51 02962022 2 ADAPTER, HYD ELBOW 4MJ - 4FJX90 52 001921 1 ADAPTER, HYD ELBOW 6MJ - 6FJX90 22 00761200 2 HOSE, #8 - 8FJX - 8FJX - 74" LG 56 00019700 2 FLATWASHER, STD 7/16" PL 57 02976344 4 BOLT, HEX HEAD 7/16"-NC X 1-1/4" PL GR8 58 00022200 4 LOCKWASHER, 7/16" PL 59 02973992 1 PULLEY ADAPTER, MACHINED 60 02702900 1 HUB 61 02982530 1 DRIVELINE 7/8"-13 SPL X 3/4" W/ 3/16 KEY X 26.5" LG 62 02983284 1 OFFSET VALVE MOUNT PLATE (USED ON 5425 & 5525

CAB TRACTOR ONLY) 63 02983285 1 OFFSET VALVE MOUNT INSTALLATION DRAWING Above items are included in Hydraulic Kit P/N 02983229.

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 6

Page 75

Mount Kit Component Identification

John Deere As Of 08-04-05

5225/5325 Cab & ROPS/2&4wd w/S traddle or Flat Platform

9.5-16 (Turf) Max front tire

21.5-16 (Turf) Min / 16.9-30 (R-1) Max rear tire

Cab Only:

Subframe Kit ………………………………………………...............02983098

Hydraulic Kit ………………………………………………...............02983101

Cab Options:

Virginia DOT Option Kit (Oct. 2003 Bid Spec.) …………….............. 02983446

Pump Guard Kit ……………………………………………….......... 02983480

Cab Mirror Kit................................................................................. 02983482

Knife Bracket Kit.............................................................................02983490

Hydraulic Break-Away Hose Kit.......................................................02983493

ROPS Straddle or Flat (IOOS) Platform:

Subframe Kit …………………………………………………............02983098

Hydraulic Kit …………………………………………………............02983099

ROPS Options:

Aluminum Canopy (Straddle Platform Only) …………………............02983053

Virginia DOT Option Kit (Oct. 2003 Bid Spec.)..................................02983447

Pump Guard Kit............................................................................... 02983480

Knife Bracket Kit.............................................................................02983490

Hydraulic Break-Away Hose Kit.......................................................02982718

Important notes:

1. The right hand steps must be removed for lift carriage clearance. Ingress/egress on the right is otherwise blocked by the control stand.

2. If the tractor is equipped with a mid-mount valve, it may also need to be removed for clearance reasons.

3. First cut from tractor center line for a right hand cutterbar is 54".

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 7

Page 76

Mount Kit - Bill of Material - 5225 & 5325 CAB / ROPS

IMPORTANT NOTICE: The following Part / Assembly Numbers are for reference and should

Sub-Frame Kit : 02983098 Consist of the Following Items.

Used On: John Deere 5225/5325

Item Part No. Qty Description

1 00695100 4 LOCKNUT, TOPLOCK 5/8"-NC 2 00756077 4 WASHER, 5/8" HARDENED 3 02971158 4 LOCKWASHER, 20MM 4 02975692 4 BOLT, HEX HEAD M20-P2.5 X 50MM PL GR10.9 5 02976342 4 BOLT, HEX HEAD M16-P2.0 X 55MM PL GR10.9 6 0665400 1 SUBFRAME 7 0112400 1 PIN, STOP 8 0114600 1 HAIR PIN 9 00010300 4 LOCKWASHER, 5/8" 10 00753753 4 BOLT, HEX HEAD 5/8"-NC X 2" PL GR8 11 02983050 1 FRAME WELDMENT

Above items are included in Switchblade Sub-Frame Kit P/N 02983098

CAB & ROPS / 2&4wd w/Flat Platform

Hydraulic Kit : 02983101 Consist of the Following Items.

Used On: John Deere 5225/5325 CAB ONLY / 2&4wd

Item Part No. Qty Description

(Continued Next Page)

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.)05/05

Section 8 - 8

Page 77

Mount Kit - Bill of Material - 5225 & 5325 CAB / ROPS

Hydraulic Kit : 02983101 Consist of the Following Items.

Used On: John Deere 5225/5325

Item Part No. Qty Description (Continued From Previous Page)

24 02966175 1 HOSE, #8 - 8FJX - 8FJX90 - 69.5" LG 25 02976531 2 ADAPTER, HYD ELBOW 6MJ - 6FJX45 26 02978281 1 HOSE RING WELDMENT 27 02982566 1 ASSEMBLY INSTRUCTION MANUAL 28 00010300 3 LOCKWASHER, 5/8" 29 00756077 1 WASHER, 5/8" HARDENED 30 02976342 1 BOLT, HEX HEAD M16-P2.0 X 55MM PL GR10.9 31 00012101 2 LOCKWASHER, 3/8" PL 32 00011100 6 FLATWASHER, STD 3/8" 33 02983085 1 DRIVELINE, 7/8"-13 SPL X 3/4" KEY X 26.25" LG 34 02982837 1 PULLEY ADAPTER, MACHINED 35 02983100 4 BOLT, HEX HEAD M10-P1.5 X 90MM PL GR10.9 36 00755954 6 LOCKWASHER, M10 SPRING 37 02979374 1 CONTROL MOUNT STAND 38 00751688 2 BOLT, HEX HEAD M10-P1.5 X 25MM PL GR8.8 39 02974296 1 SWITCH MOUNT WELDMENT 40 02971202 2 CABLE REMOTE CONTROL, 72" RVC-BLKHD 41 02980073 1 VALVE MOUNT PLATE 42 02966874 1 CABLE BOOT 43 00750940 3 LOCKNUT, TOPLOCK 5/16"-NC PLB 44 02975200 1 DRAWING, INSTRUCTION REMOTE CONTROL ASY 45 02974323 2 ANGLED SINGLE AXIS CONTROL ASY 46 02966687 2 YOKE, ADJ 47 02966688 2 CLEVIS PIN 3/16" X 7/8" 48 02968698 2 COTTER PIN 3/32" X 3/4" 49 02733700 3 BOLT, HEX HEAD 5/16"-NC X 4-1/2" PL GR5 50 00023500 6 FLATWASHER, 5/16" PL 51 02983228 1 VALVE MOUNT PLATE 52 0461600 2 BOLT, HEX HEAD 1/4"-20NC X 2-1/4" PL GR5 53 02972846 2 BOLT, HEX HEAD M16-P2.0 X 40MM PL GR10.9 54 02962022 2 ADAPTER, HYD ELBOW 4MJ - 4FJX90 55 001921 1 ADAPTER, HYD ELBOW 6MJ - 6FJX90 56 02968156 1 HOSE, #6 - 6FJX - 6FJX - 35" LG 57 001979 1 HOSE, #4 - 4FJX90 - 4FJX - 72" LG 58 03200288 1 HOSE, #6 - 6FJX - 6FJX90 - 58" LG 59 00019700 1 FLATWASHER, STD 7/16" PL

Above items are included in Hydraulic Kit P/N 02983101

CAB ONLY / 2&4wd

Virginia DOT Option Kit (Oct. 2003 Bid Spec.), P/N 02983446 Consist of the Following Items

Used On: John Deere 5225/5325 CAB ONLY / 2&4wd

Item Part No. Qty Description

1 02983458 1 ENGINE PRIM FILTER JD#AT171854 2 02983459 1 ENGINE SECND FILTER JD#KV16429 (ContinuedNext Page)

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 9

Page 78

Mount Kit - Bill of Material - 5225 & 5325 CAB / ROPS

Virginia DOT Option Kit (Oct. 2003 Bid Spec.), P/N 02983446: Consist of the Following Items (Continued From Previous Page)

Used On: John Deere 5225/5325 CAB ONLY / 2&4wd

Item Part No. Qty Description

3 02983460 2 CAB AIR FILTER JD#RE195491 4 02983461 2 CAB AIR FILTER JD#RE198488 5 02983462 1 FUEL FILTER JD#RE508202 6 02983463 1 HYDRAULIC FILTER JD#RE197065 7 02983464 1 ENGINE OIL FILTER JD#RE519626 8 B82-0230B 1 S353 BUSHING 1/BG 9 B82-0290B 2 B8221 LIFT ARM BUSHI 10 651312 4 COUPLER HALF, MALE

Above items are included in Virginia DOT Option Kit (Oct. 2003 Bid Spec.), P/N 02983446

Pump Guard Kit, P/N 02983480: Consist of the Following Items

Used On: John Deere 5225/5325 CAB & ROPS / 2&4wd w/ Flat Platform

Item Part No. Qty Description

1 02983481 1 PUMP GUARD FORMED 2 002508 1 DECAL,ALAMO LOGO (SQUARE) 3 02957276 4 HEXB METRIC 16 P2.0-45MMPL10.9 4 02970079 4 LOCKWASHER, 16MM

Above items are included in Pump Guard Kit, P/N 02983480

Cab Mirror Kit, P/N 02983482: Consist of the Following Items

Used On: John Deere 5225/5325 CAB ONLY / 2&4wd

Item Part No. Qty Description

1 02982758 2 MIRROR,8 1/2" CONVEX-BLK STEEL 2 02983483 2 BRACKET L&R MIRRORS 3 00753723 4 HHCS, M8-P1.25 x 25mm PL10.9 4 02970065 4 LOCKWASHER, 8MM

Above items are included in Cab Mirror Kit, P/N 02983482

Knife Bracket Kit, P/N 02983490: Consist of the Following Items

Used On: John Deere 5225/5325 CAB & ROPS / 2&4wd w/ Flat Platform

Item Part No. Qty Description

1 0487100 1 KNIFE BRACKET ASSY 2 02983491 1 WLDMT EXTRA KNIFE BRACKET 3 02976463 1 HHCS M20-P2.5 X 40MM PL10.9 4 02971158 1 LOCKWASHER, 20MM

Above items are included in Knife Bracket Kit, P/N 02983490

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 10

Page 79

Mount Kit - Bill of Material - 5225 & 5325 CAB / ROPS

Hydraulic Break-Away Hose Kit, P/N 02983493: Consist of the Following Items

Used On: John Deere 5225/5325 CAB ONLY / 2&4wd

Item Part No. Qty Description

1 02962022 5 ADP HYD ELBOW 4MJ-4FJX 90° 2 03200800 1 HOSE #4 - 4FJX - 4FJX90 52LG 3 00900913 3.5 CORDURA SLEEVING 2.54 ID BLACK 4 02983535 1 HOSE #4-4FJX-4FJX90-36LG 4 02983536 1 HOSE #4-4FJX-4FJX90-88LG

Above items are included in Hydraulic Break-Away Hose Kit, P/N 02983493

Hydraulic Kit : 02983099 Consist of the Following Items.

Used On: John Deere 5225/5325 ROPS ONLY / 2&4wd w/Flat Platform

Item Part No. Qty Description

1 000849 2 ELBOW, STREET ELL12MP - 12FP45 2 000859 12 PLASTIC TIE 3 0022400 1 ADAPTER, HYD ELBOW 12MP - 12FP90 4 0022800 1 BUSHING, REDUCING 5 0148600 1 KEY 6 01501075 5 BULK HYD HOSE, #16 SAE100R4 7 0222100 2 FITTING, HOSE BIB #16HOSE - 12MP 8 02962749 3 ADAPTER, HYD ELBOW 8MJ - 8FJX45 9 02968850 1 ADAPTER, HYD STRAIGHT 8MB - 6MJ 10 02971158 4 LOCKWASHER, 20MM 11 02974303A 1 PUMP ASY, TANDEM GEAR 0.98/0.37 CID 12 02975186 1 ADAPTER, HYD STRAIGHT 16MB - 12FP 13 02975187 1 ADAPTER, HYD ELBOW 12MB - 8MJ 45 14 02975188 1 FLEX COUPLER ASY 15 02975692 4 BOLT, HEX HEAD M20-P2.5 X 50MM PL GR10.9 16 02977335 1 VALVE MOUNT BRACKET WELDMENT 17 02979318 1 PLATE, BELT COVER 18 02979436 1 PUMP MOUNT PLATE, MACHINED 19 0741300 2 HOSE CLAMP,STEEL W/ HEXSCREW 20 107352 1 CONTROL STAND WELDMENT 21 00015800 12 LOCKNUT, TOPLOCK 3/8" 22 00023100 6 BOLT, HEX HEAD 3/8"-16UNC X 1-1/2" PL GR5 23 001580 1 HOSE, #6 - 6FJX - 6FJX - 45" LG 24 001636 2 BOLT, HEX HEAD 1/4"-NC X 2" 25 00756811 1 HOSE, #4 - 4FJX - 4FJX - 70" LG 26 00761200 2 HOSE, #8 - 8FJX - 8FJX - 74" LG 27 00900913 18 CORDURA SLEEVING 2.54" ID BLACK 28 02839000 1 HOSE, #4 - 4FJX - 4FJX - 64LG 29 02959924 2 LOCKNUT, TOPLOCK 1/4"-NC PLB 30 02966175 1 HOSE, #8 - 8FJX - 8FJX90 - 69.5" LG 31 02970595 2 BOLT, HEX HEAD 3/8"-NC X 2-3/4" PL GR8 32 02976531 3 ADAPTER, HYD ELBOW 6MJ - 6FJX45 Above items are included in Hydraulic Kit, P/N 02983099 (Continued Next Page)

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 11

Page 80

Mount Kit - Bill of Material - 5225 & 5325 CAB / ROPS

Hydraulic Kit : 02983099 Consist of the Following Items.

Used On: John Deere 5225/5325 ROPS ONLY / 2&4wd w/Flat Platform

Item Part No. Qty Description (Continued From Previous Page)

33 02976532 2 ADAPTER, HYD ELBOW 4MJ - 4FJX45 34 02978281 1 HOSE RING WELDMENT 35 02982565 1 HOSE, #6 - 6FJX - 6FJX -103" LG 36 02982566 1 ASSEMBLY INSTRUCTION MANUAL 37 00010300 1 LOCKWASHER, 5/8" 38 00756077 1 WASHER, 5/8" HARDENED 39 02976342 1 BOLT, HEX HEAD M16-P2.0 X 55MM PL GR10.9 40 00012101 2 LOCKWASHER, 3/8" PL 41 00011100 6 FLATWASHER, STD 3/8" 42 02983085 1 DRIVELINE, 7/8"-13 SPL X 3/4 W/ KEY X 26.25" LG 43 02982837 1 PULLEY ADAPTER MACHINED

Above items are included in Hydraulic Kit P/N 02983099

Aluminum Canopy (Straddle Platform Only), P/N 02983053: Consist of the Following Items

Used On: John Deere 5225/5325 ROPS / 2&4wd w/ Flat Platform

Item Part No. Qty Description

1 02983053 1 ALUMINUM CANOPY KIT

Above items are included in Hydraulic Kit P/N 02983053

Virginia DOT Option Kit (Oct. 2003 Bid Spec.), P/N 02983447: Consist of the Following Items.

Used On: John Deere 5225/5325 ROPS / 2&4wd w/ Flat Platform

Item Part No. Qty Description

1 02983458 1 ENGINE PRIM FILTER JD#AT171854 2 02983459 1 ENGINE SECND FILTER JD#KV16429 3 02983462 1 FUEL FILTER JD#RE508202 4 02983463 1 HYDRAULIC FILTER JD#RE197065 5 02983464 1 ENGINE OIL FILTER JD#RE519626 6 B82-0230B 1 S353 BUSHING 1/BG 7 B82-0290B 2 B8221 LIFT ARM BUSHI 8 651312 4 COUPLER HALF, MALE

Above items are included in Hydraulic Kit P/N 02983447

Hydraulic Break-Away Hose Kit, P/N 02982718: Consist of the Following Items

Used On: John Deere 5225/5325 ROPS / 2&4wd w/ Flat Platform

Item Part No. Qty Description

1 001846 1 HOSE #4 - 4FJX90 4FJX - 63LG 2 02980088 1 HOSE #4-4FJX - 4FJX90° - 80"LG 3 00762693 1 HOSE #4 4FJX - 4FJX 38LG

(Continued Next Page)

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.)05/05

Above items are included in Hydraulic Kit P/N 02983053

Section 8 - 12

Page 81

Mount Kit - Bill of Material - 5225 & 5325 CAB / ROPS

Hydraulic Break-Away Hose Kit, P/N 02982718: Consist of the Following Items

Used On: John Deere 5225/5325

Item Part No. Qty Description (Continued From Previous Page)

4 02962022 3 ADP HYD ELBOW 4MJ-4FJX 90° 5 02976532 2 ADP HYD ELBOW 4MJ - 4FJX 45DEG 6 00900913 7 CORDURA SLEEVING 2.54 ID BLACK 7 02976531 2 ADP HYD ELBOW 6MJ - 6FJX 45DEG

Above items are included in Hydraulic Break-Away Hose Kit P/N 02982718

ROPS / 2&4wd w/ Flat Platform

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 13

Page 82

Mount Kit Component Identification

John Deere

5105/5205 ROPS/2&4wd

Front Tires:

9.5-24 (R-1) Max front tire

Rear Tires:

14.9-28 (R-1) Max rear tire

Subframe Kit …………………………………………………............02983241

Hydraulic Kit …………………………………………………............02983239

Options:

Pump Guard Kit …………………................................................... 02983392

Important notes:

1. The right hand steps must be removed for lift carriage clearance. Ingress/egress on the right is otherwise blocked by the control stand.

2. If the tractor is equipped with a mid-mount valve, it may also need to be removed for clearance reasons.

3. First cut from tractor center line for a right hand cutterbar is 54".

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.)05/05

Section 8 - 14

Page 83

Mount Kit - Bill of Material - 5105 & 5205 ROPS

IMPORTANT NOTICE: The following Part / Assembly Numbers are for reference and should

Sub-Frame Kit, P/N 02983241: Consist of the Following Items.

Used On: John Deere 5105/5205

Item Part No. Qty Description

1 00695100 4 LOCKNUT, TOPLOCK 5/8"-NC 2 02983242 4 BOLT, HEX HEAD M16-P2.0 x 230mm PL10.9 3 02971158 4 LOCKWASHER, 20MM 4 02975692 4 BOLT, HEX HEAD M20-P2.5 X 50MM PL GR10.9 5 0696900 2 BOLT, HEX HEAD M16-P2.0 X 60MM PL10.9 6 0665400 1 SUBFRAME 7 0112400 1 PIN, STOP 8 0114600 1 HAIR PIN 9 00010300 4 LOCKWASHER, 5/8" 10 00753753 4 BOLT, HEX HEAD 5/8"-NC X 2" PL GR8 11 02983246 1 SUBFRAME WLD'MT, JD 5105/5205

Above items are included in Sub-Frame Kit P/N 02983241

ROPS / 2&4wd

Hydraulic Kit, P/N 02983239: Consist of the Following Items.

Used On: John Deere 5105/5205 ROPS / 2&4wd Item Part No. Qty Description

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 15

(continued Next Page)

Page 84

Mount Kit - Bill of Material - 5105 & 5205 ROPS

Hydraulic Kit, P/N 02983239: Consist of the Following Items.

Used On: John Deere 5105/5205 ROPS / 2&4wd

Item Part No. Qty Description (Continued From Previous Page)

22 00023100 6 BOLT, HEX HEAD 3/8"-16UNC X 1-1/2" PL GR5 23 001580 1 HOSE, #6 - 6FJX - 6FJX - 45" LG 24 001636 2 BOLT, HEX HEAD 1/4"-NC X 2" 25 00756811 1 HOSE, #4 - 4FJX - 4FJX - 70" LG 26 00761200 2 HOSE, #8 - 8FJX - 8FJX - 74" LG 27 00900913 18 CORDURA SLEEVING 2.54" ID BLACK 28 02839000 1 HOSE, #4 - 4FJX - 4FJX - 64LG 29 02959924 2 LOCKNUT, TOPLOCK 1/4"-NC PLB 30 02966175 1 HOSE, #8 - 8FJX - 8FJX90 - 69.5" LG 31 02970595 2 BOLT, HEX HEAD 3/8"-NC X 2-3/4" PL GR8 32 02976531 3 ADAPTER, HYD ELBOW 6MJ - 6FJX45 33 02976532 2 ADAPTER, HYD ELBOW 4MJ - 4FJX45 34 02978281 1 HOSE RING WELDMENT 35 02982565 1 HOSE, #6 - 6FJX - 6FJX -103" LG 36 02982566 1 ASSEMBLY INSTRUCTION MANUAL 37 00010300 1 LOCKWASHER, 5/8" 38 00756077 1 WASHER, 5/8" HARDENED 39 02976342 1 BOLT, HEX HEAD M16-P2.0 X 55MM PL GR10.9 40 00012101 2 LOCKWASHER, 3/8 PL 41 00011100 6 FLATWASHER, STD 3/8 42 00753642 4 BOLT, HEX HEAD 3/8 NC X 1-1/4 PL5 42 02983411 1 DRIVELINE, 7/8-13 SPL X 3/4 W/ KEY X 21.25 LG 43 02983251 1 PULLEY ADAPTER, JD 5105/5205 44 00022200 4 LOCKWASHER, 7/16 PL 45 00003901 4 LOCKWASHER, 3/4 PL 46 02918600 4 BOLT, HEX HEAD 3/4-10UNC 2 PL8 48 02976387 1 BOLT, HEX HEAD 5/8 NC 1-1/2 PL8 49 02976344 4 BOLT, HEX HEAD 7/16 NC 1-1/4 PL8

Above items are included in Hydraulic Kit P/N 02983239

OPTIONS : Pump Guard Kit , P/N 02983392: Consist of the Following Items.

Used On: John Deere 5105/5205 ROPS / 2&4wd

Item Part No. Qty Description

1 02983393 1 PUMP GUARD FORMED 2 002508 1 DECAL, ALAMO LOGO (SQUARE) 3 02976387 4 BOLT, HEX HEAD 5/8 NC 1-1/2 PL8 4 00010300 4 LOCKWASHER, 5/8

Above items are included in Pump Guard Kit P/N 02983392

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.)05/05

Section 8 - 16

Page 85

Pump / Driveline Schematic - 5425 & 5525 CAB/ ROPS

Tractor Engine Pulley

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

12345

Setscrew, P/N 02957080

Flange Mounting Bolts & Locknuts (4 ea.)

( Included W/ Center Coupling )

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

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

Bolts, P/N 00023100

w/ 9 Spline )

Locknuts, P/N 00015800

P/N 02982530

12345

Pulley Adapter,

Use Existing Bolt & Lockwasher From Crankshaft Pulley

( 4 ea.)

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

12345678

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

Center Coupling, w/ Nut & Bolt Set

12345

P/N 02973992

1234

Hub, P/N 02702900

( Set Of 4 ea. )

Pump Assembly

12345

Pump Mount,

P/N 02979436

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

Pump Drive Schematic:

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 17

Page 86

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

12345

1234

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

12345

Crankshaft Pulley

Adapter Bolts (4 Req.)

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

1234567

12345

234567

Center Coupling, w/ Nut & Bolt Set

Pulley Adapter,

P/N 02982837

1234

234

1234

( Set Of 4 ea. )

12345

Pump Mount,

P/N 02979436

Pump Assembly

12345

123456

Bolts, P/N 02975692

Lockwasher, P/N 02971158

Pump Drive Schematic:

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.)05/05

Section 8 - 18

Page 87

Pump / Driveline Schematic - 5105 & 5205 CAB/ ROPS

Tractor Engine Pulley

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

Setscrew, P/N 02957080

12345

1234

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

12345

Pulley Adapter,

Crankshaft Pulley

Adapter Bolts (4 Req.)

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

Center Coupling, w/ Nut & Bolt Set

12345

P/N 02983251

1234

234

1234

( Set Of 4 ea. )

12345

Pump Mount Plate, P/N 02983152

Pump Assembly

12345

1234

123456

Bolts, P/N 02975692

Lockwasher, P/N 02971158

Pump Drive Schematic:

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 19

Page 88

Drive Shaft Installation - 5105 & 5205 (ONLY)

Drive Shaft Installation:

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

This hole

cut

w/1-1/2"

hole saw

for

driveshaft

access

crankshaft

pulley

Figure 1

This is the

area that

must be

ground

down for driveshaft clearance

JD-5105

JD-5205

ONLY

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 20

Page 89

Mount Kit Component Identification

P/N 02973992

Crankshaft Adapter

(JD-5425 & JD-5525

Tractor Only)

P/N 02702900

Splined Hub

(JD-5425 & JD-5525

Tractors Only)

P/N 107352

Control Stand

Weldment

(All ROPS Tractors)

P/N 02982837

Splined Pulley Adapter

(JD-5225 & JD-5325

Tractors Only)

7/8" x 13 Spline End

3/4" w/ 3/16" Keyway End

7/8" x 13 Spline End

26.50" LG

P/N 02983085 Drive Shaft

(JD-5225 & JD-5325

Tractors Only)

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

P/N 02982530 Drive Shaft

(JD-5425 & JD-5525

Section 8 - 21

26.25" LG

Tractors Only)

Page 90

Mount Kit Component Identification

P/N 02975188

Flex Coupler Asy.

(All Tractors)

P/N 02978281

Hose Ring

Weldment

(All Tractors)

P/N 02979436

Machined Pump

Mount Plate

(All Tractors)

P/N 029774296

Switch Mount Brkt

Weldment

(All CAB Tractors)

P/N 02977335

Valve Mount Brkt

Weldment

(All ROPS Tractors)

Control Mount Stand

(All CAB Tractors)

P/N 02983152

Plate Pump Mount

(JD-5105 & 5205

Tractors Only)

P/N 02979374

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 22

Page 91

Mount Kit Component Identification

P/N 02980073 Valve Mount Plate (All CAB Tractors)

P/N 02983284

Offset Valve Mount Plate

(JD-5425 & 5525 Cab Tractors)

P/N 02983228

Flat Valve Mount Plate

(JD-5225 & 5325 CAB Tractors)

P/N 02983411 Driveshaft

(JD-5105 & 5205 Tractors Only)

P/N 02983392

(JD-5105 & 5205 Tractors Only)

Pump Guard

(JD-5105 & 5205 Tractors Only)

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 23

P/N 02983251 Pulley Adapter

Page 92

Mount Kit Component Identification - 5425 & 5525

P/N 02975188

Flex CouplerAsy.

Mounting Bolt

P/N 02976342

Mounting Bolt

P/N 02975692

Lockwasher

P/N 02971158

P/N 02979436

MachinedPump

Mount Plate

Lockwasher

P/N 00010300

Pump Mounting (2 Bolts)

Bolt P/N 00023100

Lockwasher P/N 00012101

Locknut P/N 00015800

Hub Mounting (4 Bolts)

Bolt P/N 02976344

Lockwasher P/N 00022200

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

P/N 02702900

Splined Hub

ExistingBoltsFrom

Crankshaft Pulley

Valve Mount Brkt

Use

P/N 02977335

Weldment

P/N 02973992

Crankshaft

Adapter

Mounting Bolts

P/N 001636

Locknut

P/N 02959924

Section 8 - 24

Page 93

Mount Kit Component Identification - 5425 & 5525

Frame Weldment, Mount Bolt Location & Sizes

(JD-5425 & JD-5525 Model Tractor Only)

Item Part No. Qty Description 1 02982525 1 RH Frame Weldment

2 02976342 4 Bolt, Hex Head M16-P2.0 X 55MM - PL - GR10.9

00756077 4 Washer, 5/8"

3 0665400 1 Sub-Frame Weldment

00753753 4 Bolt, Hex Head 5/8"-NC X 2" - PL - GR8 00695100 4 Locknut, Toplock 5/8"

4 00023100 4 Bolt, Hex Head 3/8"- NC X 1-1/2"

00011100 4 Flatwasher, 3/8" 00015800 4 Locknut, Toplock 3/8"

5 02975692 4 Bolt, Hex Head M20-P2.5 X 50MM - PL - GR10.9

02971158 4 Lockwasher, 20MM

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 25

Page 94

Mount Kit Component Identification - 5225 & 5325

Frame Weldment, Mount Bolt Location & Sizes

(JD-5225 & JD-5325 Model Tractor Only)

Item Part No. Qty Description 1 02983050 1 RH Frame Weldment

2 02976342 4 Bolt, Hex Head M16-P2.0 X 55MM - PL - GR10.9

00756077 4 Washer, 5/8"

3 0665400 1 Sub-Frame Weldment

00753753 4 Bolt, Hex Head 5/8"-NC X 2" - PL - GR8 00695100 4 Locknut, Toplock 5/8"

4 00023100 4 Bolt, Hex Head 3/8"- NC X 1-1/2"

00011100 4 Flatwasher, 3/8" 00015800 4 Locknut, Toplock 3/8"

5 02975692 4 Bolt, Hex Head M20-P2.5 X 50MM - PL - GR10.9

02971158 4 Lockwasher, 20MM

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 26

Page 95

Mount Kit Component Identification - 5105 & 5205

Frame Weldment, Mount Bolt Location & Sizes

(JD-5105 & JD-5205 Model Tractor Only)

Item Part No. Qty Description 1 02983246 1 SubFrame Weldment

2 02983242 4 Bolt, Hex Head M16-P2.0 X 230MM - PL - GR10.9

00010300 4 Lockwasher, 5/8"

3 0665400 1 Sub-Frame Weldment

00753753 4 Bolt, Hex Head 5/8"-NC X 2" - PL - GR8 00695100 4 Locknut, Toplock 5/8"

4 00023100 4 Bolt, Hex Head 3/8"- NC X 1-1/2"

00011100 4 Flatwasher, 3/8" 00015800 4 Locknut, Toplock 3/8"

5 02975692 4 Bolt, Hex Head M20-P2.5 X 50MM - PL - GR10.9

02971158 4 Lockwasher, 20MM

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 27

Page 96

Common Component Identification - All Tractors

Skid Shoe & Actuator Pre-Asy

Motor Cover Weldment

Carriage Arm Asy

Skid Shoe & Breakaway Pre-Asy, w/ Cutterbar

Sight/Temperature Gauge

Canister Asy.

Tank Asy.

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 28

Page 97

Page 98

Mount Kit Component Identification

Hydraulic Schematic RH Wing Only

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 29

Page 99

Mount Kit Component Identification

Hydraulic Schematic Dual RH & LH Wing

T wo Spool Control Valve & Switches

LH Break-A-

Way Valve

Diverter Valve (Motor Control)

RH Break-AWay Valve

Port “D”

Port “B”

Return Out

C1 C4

Diverter Valve (Cyl. Control)

Pressure In

Filter

LH Actuater

LH Cylinders

LH Motor

Motor Pressure

T ank Asy

RH Cylinders

RH Motor

RH Actuater

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 30

Valve Pressure

Pump

Pump Suction

Page 100

Mount Kit Component Identification

HYDRAULIC HOSE ROUTING SCHEMATIC

P/N 02965475 This hose is included in the Carriage Arm Asy

(2)

Switchblade (JD-5105-5205-5225-5325-5425-5525 Asy. Man.) 05/05

Section 8 - 31

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

Specifications and Main Features

Frequently Asked Questions

User Manual