Tiger Electronics JD 62-6420 User Manual
BENGAL BRUTE
Current as of 02/22/2010
ASSEMBLIES
JD 62-6420
CAB
P A RTS LISTING WITH
MOUNTING AND OPERATING
INSTRUCTIONS
Tiger Corporation
3301 N. Louise Ave.
Sioux Falls, SD 57107
1-800-843-6849
1-605-336-7900
www.tiger-mowers.com
06011000
TO THE OWNER / OPERATOR / DEALER
All implements with moving parts are potentially hazardous. There is no substitute for a cautious,
safe-minded operator who recognizes the potential hazards and follows reasonable safety practices.
The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents.
BEFORE YOU START!! Read the safety messages on the implement and shown in this manual.
Observe the rules of safety and use common sense!
READ AND UNDERSTAND THIS MANUAL! Non–English speaking operators will need to GET
THE MANUAL TRANSLATED as needed!
W arranty Information: Read and understand the complete W arranty Statement found in this manual. Fill out the
W arranty Registration form in full and return it within 90 days. Make certain the Serial Number of the machine is
recorded on the W arranty Card, and form that you retain.
FORWARD
This manual contains information about many features of the T iger mowing
and roadside maintenance equipment. Some of these include: Safety precautions,
Assembly instructions, Operations, Maintenance and Parts. This manual will also
assist you in the proper break-in, daily care, andtroubleshooting of your new
mower .
We recommend that you read carefully the entire manual before operating the
unit. Also, time spent in becoming fully acquainted with its performance features,
adjustments, and maintenance schedules will be repaid in a long and satisfactory
life of the equipment.
T roubleshooting - Please, before you call, help us to help you!
Please look at the equipment to observe what is happening, then:
• Classify the problem
• Hydraulic, electrical or mechanical - Read the trouble shooting section
• Tractor or T ruck chassis - Contact vehicle dealer
• If unable to correct the problem yourself, contact your local Tiger Dealer af ter
gathering:
• Machine model _______________________
• Serial number ________________________
• Dealer name _________________________
• Detailed information about the problem including results of troubleshooting
Attention Owner / Operator / Dealer: It is your obligation to read, and understand,
the warranty information section located at the back of this manual denoting that the
purchaser understands the safety issues relating to this machine and has received
and will read a copy of this manual.
If at any time, you have a service problem with your Tiger mower , Contact
your local dealer for service and parts needed.
MANUF ACTURED BY: DISTRIBUTED BY :
Tiger Corporation _____________________
3301 N. Louise Ave. _____________________
Sioux Falls, SD 57107 1-_____-_____-________
1-800-843-6849 1-_____-_____-________
1-605-336-7900
www .tiger-mowers.com
T ABLE OF CONTENTS
SAFETY_____________________________________________ 1-1
Safety Information__________________________________ 1-2
ASSEMBLY / MOUNTING SECTION_______________________2-1
OPERATION SECTION_________________________________ 3-1
MAINTENANCE SECTION______________________________ 4-1
PARTS SECTION_____________________________________ 5-1
Parts Ordering Guide_______________________________ 5-2
Parts Table of Contents______________________________ 5-3
Common Parts Section____________________________ 6-1
WARRANTY INFORMATION_____________________________ 7-1
This symbol means:
CAUTION – YOUR SAFETY IS AT RISK!
When you see this symbol, read and
follow the associated instructions carefully
or personal injury or damage may result.
Tiger is a registered trademark.
ASSEMBLY
SECTION
Assembly Section 2-1
ASSEMBLY
Before attempting to mount your Tiger mower, it is
important to read an understand all of the Safety Messages
in the Safety section of this manual.
Check complete shipment list against the packing list to make sure there are no
shortages. Make certain the tractor model is the appropriate one for the mower received!
Always use a floor jack, hoist or fork lift to lift and raise heavy parts.
Read and understand the entire assembly section instructions before attempting to
mount your Tiger mower . Refer to the part s section of this manual for detailed illustrations
to locate all parts.
TRACTOR PREP ARA TION
A: Remove right hand steps.
B: Disconnect battery cables from both batteries.
C: Remove engine side panels, or raise hood to access front pulley.
D: Remove plugs from tractor casting where main frame and pump
mount will be attached.
E: Remove any front weights and weight supports.
F: Raise the tractor onto jack-stands and remove the right rear wheel.
CRANKSHAFT ADAPTER
If necessary remove the four capscrews from the crankshaft pulley . Then install the
crankshaft adapter to the pulley with capscrews and lockwashers as shown in the parts
section.
Assembly Section 2-2
ASSEMBLY
FRONT CRANKSHAFT PULLEY
John Deere has changed to a
the change, Tiger has found that the front crankshaft pulley used by JD will not allow for the
installation of a front drive system. With the change on the 6X15 and 6X20 series tractors,
you will need to order a different pulley, washer and bolt from John Deere to allow for a front
drive to be installed on your tractor .
Inspect the front pulley on your tractor to verify you have the correct pulley needed to
mount the spacer plate. If your pulley has the (4) four holes needed to mount the spacer,
your pulley is the correct one needed. If your pulley does not have the (4) four holes in the
pulley , you will need to order the correct pulley, washer and bolt from John Deere.
new tier two engine on all 6000 series tractors. With
PARTS REQUIRED TO PURCHASE FROM JOHN DEERE:
Pulley from JD – R516320
Washer from JD – R517237
Bolt from JD – R516648
Torque on the pulley bolt with locktite is 369 lb-ft.*
Solution:
1. Clean nose of crankshaft using TY16285 clean and cure primer.
2. Apply a light 2-3 mm bead of TY15969 retaining compound around the leading edge
of the crankshaft nose.
3. Dip damper mounting caps crew in clean SAE30 engine oil (Always use a new cap
screw)
4. Position damper/pulley on the crankshaft and thread cap screw up tight (do not rely
on the cap screw to pull the pulley straight onto the taper)
5. Tighten cap screw to specification 500Nm (369lb-ft) (the engine will most likely
have to be pinned)
6. Measure run-out on the pulley, spec is 0.003” or less
Assembly Section 2-3
ASSEMBLY
DRIVESHAFT & FRONT PUMP MOUNTING
Install spacer plate on tractor engine using bolts and lockwashers as shown in
parts section. Grease sleeve section of the driveshaft and install from the side of the
engine compartment. Once you have the sleeve section in place, bolt to spacer plate
using bolts and lockwashers as shown in parts section. Install shaft end of driveshaft
through opening and into driveshaft sleeve. Shaft and sleeve yokes should be aligned,
if shaft does not insert easily in sleeve, turn shaft 180°, and then install. Shaft end
must be installed in correct orientation, failure to do so may result in damage to
tractor and/or driveshaft. After installation of shaft end, install pump mount. Next,
install pump. After pump is secured, install driveshaft in to pump shaft. The end of
driveshaft should be no more than 1/2” away from contact with pump housing. Tighten
crimping bolt on driveshaft. Lube driveshaft & check all hoses, flanges, the pump,
pump mount, driveshaft and mounting plate to ensure all fasteners are tightened before
operation.
CAUTION: DO NOT START THE TRACTOR UNTIL ALL HOSES ARE
A TTACHED, TANK IS FILLED WITH PROPER OIL AND BALL VALVES ARE
OPEN! STARTING AT THIS TIME WILL CAUSE SERIOUS DAMAGE TO THE
PUMP.
ADJUSTING REAR WHEELS
Follow the instructions in the tractor owners manual for adjusting tires and
rims. The rear wheels MUST be adjusted to the widest setting. NOTE: This may
require switching the wheels to opposite sides of the tractor. Also take note of any width
restrictions when transporting by trailer. (For ease of inst allation, it is best to leave rear
wheels removed during installation of the mower).
Assembly Section 2-4
ASSEMBLY
WEATHER-PACK/METRI-PACK ASSEMBLY
These instructions apply to both Weather-Pack and Metri-pack connectors.
NOTE: Use the specific tool for the type of connector you are assembling.
1. Apply seal to cable, before stripping
insulation.
3. Put terminal in crimping tool, then
position wire and seal in place.
2. Align seal with cable insulation.
4. Crimp and visually inspect for a good
crimp before installing in connector body .
INSTALLING O-RING FITTINGS
Installing straight, 45° and 90° O-rings requires that the O-ring and washer be up
against the swivel body. Insert the swivel and turn in until the swivel is pointed in the
desired direction and O-ring contact is made. Hold swivel in set direction with a wrench
and turn the O-ring nut away from the swivel body and carefully tighten.
Assembly Section 2-5
ASSEMBLY
POLYCARBONATE SAFETY WINDOW
NOTE: Installing a boom mower requires that all of the right side windows be
replaced, or protected with a polycarbonate window. This should be done before
mounting the main frame.
1. Disconnect gas shock at door. Remove the right side cab door/window glass
from tractor cab by removing hinge pins. Also, remove rear right side window.
2. Remove the existing hardware and discard factory glass door and window.
3. Place small beed of adhesive seal in the botom of the trim lock bubble beed.
4. Install trim lock bubble seal on polycarbonate starting at the center bottom
horizontal portion.
5. Install existing hardware removed from glass door and window on the
polycarbonate.
6. Install the polycarbonate assembly in the cab with existing and supplied
hardware.
7. Place the retaining brackets on the upper front and lower front of the cab
door/window with the 8mm capscrews.
8. Place the third bracket at the bottom of the door by the fender as shown in the
illustration below. Hold the bracket in place and mark the door jam.
9. Drill 21/64” hole in the door jam for the 5/16” capscrew and mount the bracket.
10. Install the right rear poly window into place where factory window was removed.
Assembly Section 2-6
ASSEMBLY
MAIN FRAME INSTALLATION
With an overhead hoist and / or jack-stands, raise one side of the frame up to the
correctly matching mounting holes. Install capscrews and all other hardware as shown
in main frame parts section to secure the sides of the main frame to the tractor casting,
DO NOT tighten at this time. Remove the capscrews one at a time and apply a thread
locking agent. Reinsert the capscrews and tighten / torque to values noted in the torque
chart located in the maintenance section of this manual.
VALVE MOUNTING PLATE
Align the mounting bracket to the existing holes on top of the tractor remote valve at
the rear of the tractor. Secure the bracket to the tractor with the hardware shown in the
parts section of the manual. Attach the valve mounting plate to the valve mounting
bracket on the rear of the tractor as shown below. Then place and secure the lift valve
on top of the valve plate, in the position shown in the parts section. Install the control
cables to the valve and route the hydraulic lines from the lift valve to the hydraulic cylinders
as noted on the lift valve page of the parts section.
HUSCO
VALVE
DANFOSS
VALVE
Assembly Section 2-7
ASSEMBLY
CABLE CONTROL LEVER STAND
On the corner cab post, mark a point at 1-3/8” from the windshield and 22 ½” from
thefloor; then cut a ¾” diameter hole through the outer plastic shell. This will expose a threaded
steel boss to attach the control box support bracket.
The rear corner of the cable control stand is
placed approximately 5 ¾” from the edge of the mat.
The front edge of the stand is up against the corner
cab post and the door sill lip of the mat. Before you
mark or drill any holes, check for support plates or
wires under the mat & the cab floor. NOTE: Cutting
into plates or wires makes more work for everyone
and could be dangerous. When you know where the
wires/plates lie, mark one of the mounting holes. Drill
a 3/8” hole through the mat and through the floor of
the cab. Next, lift the mat up and mark the other two
holes on the cab floor. Drill the holes through the
floor. Mark the mat and drill the other two 3/8” holes.
Use a 1” hole saw and cut a 1” hole through the mat
over each 3/8” hole. Secure the stand to the floor with the spacers, capscrews and nylock
nuts provided.
Cut a 1 ¾” hole in the floor to route the cables and wires through. It needs to have a
¼” clearance for the trim lock. Before you mark or drill any holes, check for support plates
or wires under the cab floor.
NOTE: Cutting into plates or wires makes more work
for everyone and could be dangerous. Look under the
floor for cables and plates that you need to avoid. The
hole should be approximately 4 ½” from the door sill
and 4 ¾” from the lip of the mat under the console.
Install the trim lock around the metal edges of the hole,
then route the control cables and wires through the
hole.
Next, wrap the cables with the 6” split hose at
the point they pass through the hole, and secure the zip-ties. Apply RTV sealer in and
around individual cables and split hose, inside and outside of the cab for a water tight seal.
Install upper support bracket from cab post to the control lever stand.
Assembly Section 2-8
ASSEMBLY
WIRE ACCESS FOR SWITCH BOX (CABLE)
Refer to the parts section for wiring diagrams. Remove right side cowl panel,
tach panel, and hour meter panel for access to the wires.
Route the red wire from the switch box to the bare electrical plug in the fuse box,
or other un-used “keyed” hot wire. NOTE: +12 VOLTS ELECTRICAL POWER
MUST BE TAKEN FROM A SOURCE LOCATION WHERE IT IS LIVE ONLY
WHEN THE IGNITION SWITCH IS IN THE “ON” POSITION.
Drill a ½” hole in the 9” X 5” right side panel to route the green & blue safety
switch wires.
The switch box is to be secured to the operators side of the control handles, or
valve stand.
The green & blue wires will connect to the neutral safety switch blue wires,
located on the back of the ignition switch, under the cowl panel.
SWITCH BOX WIRING (CABLE)
Refer to the parts section for wiring diagram to hook up the switch box. Cover all
the wires from the switch box with plastic wire wrap provided. Route the wires from
the switch box to the front console panel as shown on previous page. Remove the
console panel under the steering wheel to access tractor wires. Locate the brown
colored wire. Using a test light or meter to verify this wire is the neutral safety
wire. Cut the brown wire and connect the green wires from the switch box as shown
in the wiring diagram.
To run the white wire to the solenoid valve, you will need to drill a hole in the front
edge of the cab floor on the right side of the front console. Insert a rubber grommet
into the hole to protect the wire, and route the wire out of the cab.
The red wire is to be hooked to the tractor ignition switch or an available slot in the
fuse box. NOTE: Be certain that the power taken for the switch box is “HOT”
only when the tractor ignition is “ON”. Also double check that the line is
fused.
The travel lock red wire from the switch box should also run with the white wire
through the rubber grommet and be covered with wire wrap. This wire will be
connected to the electronic travel lock located on the main boom cylinder. The wires
from the switch box are longer than needed and should carefully cut and spliced as
required. Zip ties should be used to secure the wires to the tractor framework and
boom hoses to eliminate vibation and rubbing.
Assembly Section 2-9
ASSEMBLY
HUSCO CONTROL VAL VES IDENTIFICATION
Manual, cable controlled (Husco control valve) boom mowers require check valves
with integral restricting orifice (#06502036) installed in the control valve work ports that
are connected to the gland ends of the main and secondary boom cylinders. This
check valve allows oil to free flow into the gland end of the main and secondary boom
cylinders, but restricts flow out of the cylinder, thereby providing proper boom control.
This check valve, #06502036(Vendor #1968R-.063) is similar in appearance to hose
adapter #33271 and Adapter #34396, with.06 orifice. These components can be
identified as follows, and are to be installed per parts section for the lift valve.
Assembly Section 2-10
ASSEMBLY
SWITCH BOX WIRING (JOYSTICK)
Refer to the parts section for wiring diagram to hook up the switch box. Cover
the four wires (1-white / 2-green & blue / 1-red) from the on / off terminal of the switch
box with plastic wire wrap provided. Run these wires through the drilled hole in the
right side panel of the steering column on next page.
With the panel under the steering wheel removed to access the wires, locate the
brown wire. Using a test light or meter to verify this wire is the neutral safety wire.
Cut the brown wire and connect the green & blue wires from the switch box as
shown in the wiring diagram.
To run the white wire to the solenoid valve, you will need to drill a hole in the front
edge of the cab behind the front council. Insert a rubber grommet into the hole to
protect the wire, and route the wire out of the cab to the solenoid valve.
The red wire from the on / off terminal is to be hooked to the tractor ignition switch or
an available slot in the fuse box. NOTE: +12 VOLTS ELECTRICAL POWER
MUST BE TAKEN FROM A SOURCE LOCATION WHERE IT IS LIVE ONLY
WHEN THE IGNITION SWITCH IS IN THE “ON” POSITION. THIS WIRE MUST
BE FUSED AT THE SOURCE LOCATION
The travel lock red wire from the switch box should also be covered with wire
wrap and should run with the white wire through the grommet. This wire will be
connected to the electronic travel lock located on the main boom cylinder. The wires
from the switch box are longer than needed and should be carefully cut and spliced
as required. Zip ties should be used to secure the wires to the tractor framework
and boom hoses to eliminate vibation and rubbing.
The black ground wire from the switch box can be attached to the switch box
mounting bracket.
A 2-1/8” hole must be drilled in the floor of the cab on the right side of the steering
wheel. The center of the hole is located 12” from the front window and 4-1/2” from
the right cab door. Shown on the next p age.
Wrap the valve cables in hose wrap and route the cables through the hole in the
floor of the cab. The hose wrap will stick out above and below the hole in the cab
floor. Use zip ties to secure the hose wrap to the cables. Seal the edge of the hole
with silicon sealant or strip caulk.
Assembly Section 2-11
ASSEMBLY
SWITCH BOX MOUNTING (JOYSTICK)
Locate the 2 holes in the right front corner of the cab frame. These will be the
mounting holes for the 2 mounting bolts of the switch box bracket. See picture on
the last page. Mount the bracket using the hardware supplied, as noted in the parts
section.
Cut slot in right side panel of steering column to run wires from switch box.
NOTE: When cutting or drilling hole, be sure not to damage existing wires running
behind panels.
Assembly Section 2-12
ASSEMBLY
JOYSTICK MOUNTING
The joystick control will require that the right armrest be modified and an additional
bracket attached that will accommodate the joystick. In doing this, the armrest must be
removed by sliding off the plastic cover and removing the capscrew from the lower right
side of the seat. After the capscrew is removed the armrest should be loose from the
seat and able to be removed at this point. Once the armrest is removed, then place the
joystick holder under the armrest, so that the indentation on the outside of the armrest is
lined up with the hole in the armrest bracket for the capscrew to pass through. Once
the correct placement is achieved, then mark on the armrest where the hole passes
through the armrest bracket. At this point a 1/2” hole must be drill through the armrest
so that the bracket can be secured to the armrest. Af ter the hole is drilled, then on the
inside of the armrest the 1/2” hole must be cut to a larger diameter up to the metal plate
in the armrest so that a spacer and hex nut can be fastened to the capscrew that
secures the armrest bracket. Install the armrest bracket on the armrest with the
hardware as shown in the parts section.
Once the bracket is installed on the armrest then reattach the armrest back onto the
seat using the existing hardware previously removed. Then install the joystick in the
bracket with the machine screws as shown in the parts section.
Assembly Section 2-13
ASSEMBLY
PRESSURE LINE INSTALLATION
The hydraulic pressure line will be plumbed into the side of the tractor rear
remotes. Locate the pressure port on the spacer and remove the plug (refer to the
illustration below and the Parts Section pages for position of the pressure port). After
the plug is removed then install 22mm adapter or elbow . Next connect a 1/2” hose
from the tractor remote valve to the Tiger valve.
RETURN LINE INSTALLATION
The return line will be plumed next to the pressure line on the side of the tractor
rear remotes. Locate the return port and remove the plug (refer to the illustration
below and the Parts Section for the position of the return port). Af ter the plug is
removed then install 22mm adapter or elbow . Next connect a 1/2” hose from the
tractor remote valve to the Tiger valve.
HUSCO VA LVE
PRESSURE
RETURN
LOAD
SENSE
Assembly Section 2-14
ASSEMBLY
DANFOSS LOAD SENSE LINE INSTALLATION
The load sense line will be plumbed into the side of the tractor remote valve (shown
in the picture on the last page). Locate the plug on the spacer for the load sense, and
remove the plug. Install a 14mm elbow and then connect the 1/4” hose from the
spacer to the T iger valve. Refer to the Parts Section p ages for an exploded diagram of
the tractor remote valve hookup.
HUSCO LOAD SENSE LINE INSTALLATION
To install the load sense line from a Husco valve to the tractor remote valve, first
locate the load sense port located on the bottom of the spacer. Remove the plug and
install 14mm elbow , then attach the 1/4” hose to the end cap and to the top front port on
the Husco valve.
For more information refer to the Parts Section pages for a complete diagram of the
tractor valve hookup.
ACCUMULATOR INSTALLATION / PLUMBING
Install the accumulator bracket on top of the main frame mast with the capscrews
and lockwashers shown. Install the accumulator in the bracket and secure with the
hardware shown. Install the tee on the accumulator and the hose from the accumulator
to the gland on the main boom cylinder. Install hose from accumulator to the control
valve.
SELECTOR VALVE INSTALLATION
NOTE: Refer to the parts section and illustration below for hardware and position.
The selector valve is attached to the boom rest. The 1/4” hoses from the swivel
section of the lift valve are plumbed to the “A” and “B” ports on the selector valve. A
run tee is added to the return section of the lift valve. Attach the 1/2” hose from the
“T” port of the selector valve to the run tee. 1/4” hoses are attached to the “A1”, ”A2”,
“B1” & “B2” ports on the selector valve to the knuckle cylinder and swivel cylider .
Assembly Section 2-15
03-01-05
ASSEMBLY
FILLING HYDRAULIC RESERVOIR
Refer to the maintenance section for filling specifications and hydraulic oil
requirements.
NOTE: Starting or running your Tiger mower before filling reservoir will cause
serious damage to hydraulic pump.
HYDRAULIC T ANK INSTALLA TION
Install all fittings and tubes into tank and tank filter as shown in the parts section
illustration. Insert tank sight glass into front side of tank. Install the temperature sensor
(optional), or pipe plug into side of the tank.
Place the tank in the mounting bracket on the main frame as shown in the parts
section. Secure the tank in the mounting bracket with the tank strap and nylock nuts.
Install the filter gauge into the filter housing so that it points to the rear of the tractor
and is clearly visible to the operator. Locate the tank breather and reducer bushing
(bushing may be already installed in the tank along with many of the for-mentioned
parts). These will be installed after tank is filled.
TEMPERATURE GAUGE MOUNTING
(OPTIONAL)
Mount the temperature gauge where it is clearly visible to the operator. Attach the
green (-) wire from the negative post on the gauge to a grounded bolt on the tractor
frame. Remove paint if needed to make a good ground. Remove the pipe plug from the
side of the hydraulic reservoir, and inst all the temperature sensor using thread sealing
tape. Run the white wire from the (s) sensor post of the gauge to the temperature
sensor on the hydraulic reservoir tank.
GENERAL HOSE INSTALLATION
Refer to the parts section for detailed information about hoses and fittings for this
application.
Assembly Section 2-16
ASSEMBLY
BENGAL BRUTE HOSE ROUTING
WARNING NOTE: The sudden release of hydraulic pressure could cause the
sudden movement of very heavy parts. Anyone in the way of these parts could be
severely hurt or killed. DO NOT ALLOW these hydraulic hoses to BREAK or BURST
in order to prevent hydraulic failure Make sure the hoses do not pinch or stretch as
boom moves. Measure TWICE, check TWICE then proceed with caution.
Route the hoses through the space between the swivel and the boom mounting
bracket. Connect the hoses to the preformed tubes and move the boom arm to a few
feet from full forward. Assemble the swivel clamp and place the return hose for the
motor on top and the pressure line on the bottom. Place the ¼” hoses in the “C”
clamp and add it to the bottom screw of the swivel clamp. Next, make sure there is
enough slack for all hoses to pivot at the joint where the main boom arm bends in the
swivel, as shown in the next image, and tighten the hoses in the clamp.
Assembly Section 2-17
ASSEMBLY
Arrange the hoses in the clamp that attaches to the boom mounting bracket as
shown above, with the 1” motor hoses closest to the bracket and the return hose
closest to the boom arm. Pull the hoses snug from the swivel to the mounting bracket
clamps, when main boom is still forward, and tighten the hoses in the clamp.
Make sure the 1” motor hoses do not kink as the boom arm is moved into the
stowing position. If this happens the motor hoses will have to be shortened, because
there is too much hose between clamps.
Assembly Section 2-18
ASSEMBLY
Assembly Section 2-19
ASSEMBLY
GREASELESS BEARING INSTALLATION
It is recomended that grease is to be applied to the bore to aide in insertion of the
greaseless bearing.
Assembly Section 2-20
ASSEMBLY
AXLE BRACE MOUNTING
The axle braces are to be mounted under the rear axle of the tractor . The other
end of the axle brace mounts on the outside of the lower rear corners of the main
frame. Af ter att aching the boom rest, it should fit tightly and level under the tractor.
Attach the right axle brace to the main frame with hardware shown in the parts
section and tighten. Att ach the axle braces to the rear axle using the mounting
hardware shown in the parts section, but DO NOT tighten.
BOOM REST MOUNTING
Carefully raise the boom rest and align the holes with those of the axle brace.
Now install all attaching hardware as shown in the parts section loosely, to allow for
the alignment with the left and right axle brace. T ighten / torque all hardware on the
brace and the boom rest. If mounting the 60” rotary head, attach the additional stop
to the lower resting position as shown in the parts section. Finally, add the rest strips
to the boom rest as shown in the parts section.
Assembly Section 2-21
ASSEMBLY
BOOM MOUNTING BRACKET
Using a floor jack and / or a hoist, raise the boom mounting bracket up to level
and slide the bracket into position onto main frame as shown in parts section.
Install pin through main frame and bracket. Secure with cap-screw, lock-washer
and hex nut through boss on main frame as shown.
Secure mounting bracket to main frame with the cap-screws, lock-washers, flatwashers, cut flat-washers and hex nuts provided. Secure using the two slotted
holes on the bracket and main frame.
SWIVEL BRACKET MOUNTING
Install the boom swivel bracket onto the boom mounting bracket with the swivel
pin. Secure the pin in place using the capscrews, etc. through the hole in the boss
and pin. NOTE: The head of the capscrew must be toward the front of the tractor.
Install all new swivels and fittings on the swing cylinder with swivel openings
facing each other. Fittings will vary in type and direction depending on your
application, refer to your parts section for more details.
Install bearings in the main frame anchor for the swing cylinder . This may
already be done for you.
Install the swing cylinder between the boom mounting bracket cylinder anchor and
the boom swivel with the pins. Insert roll pins through the top and the bottom hole in
the pins.
Now the hoses can be attached from the control valve to the swing cylinder .
PREFORMED TUBE INSTALLATION
Lay booms on floor so the side with the nuts welded on is up. If mounting a
ditcher head, only the main boom tube installation is required. Locate all tube
clamps and install them loosely in the welded nuts on the left side of the booms.
Arrange the tubes and hoses as outlined in the parts section diagram. Install the
smaller tube closest to the boom arm, being careful not to pinch the tubes. Place
the large tubes outside of the small tubes. Snug all clamp bolts, but do not tighten.
Check all tubes for correct alignment and that none are pinched or bent. The clamp
bolts can now be tightened.
Assembly Section 2-22
ASSEMBLY
MAIN BOOM INSTALLATION
Install the boom swivel into the main frame as shown in the parts section using a
hoist. Line up holes in swivel and main frame for large swivel pin and insert pin. Secure
with hardware as shown.
Attach the inner end of the main boom to the swivel bracket with the cylinder anchors
positioned upward, and at a right angle to the tractor. Secure it with the horizontal hinge
pin. Secure the hinge pin in the boss with capscrews, etc. (see parts section).
Attach the butt end of the main boom cylinder to the swivel bracket anchor with the
special “bracket head” cylinder pin and roll pin shown in parts section.
Install the travel lock on the butt end of the main boom cylinder. This should be
facing the butt end of the cylinder after installation.
Install the fittings and hoses to the main boom cylinder per parts section.
GREASELESS BEARINGS ARE DARK GRAY AND SHOULD NEVER BE
GREASED. THE MAIN BOOM CYLINDER AND THE SECONDAR Y CYLINDER ARE
NOT GREASELESS AND NEED TO BE GREASED.
SWITCHING SIDE MOUNT TO BOOM ARM
If you are changing over from a side mounted mower you must first close the ball
valves and remove the motor hoses from the motor to the solenoid valve. Also
remove and replace any fittings that do not match the ones shown in the parts
section diagram.
Next, disconnect all hoses from the control valve. Remove the pin that connects
the lift cylinder to the mast on the main frame. Remove the inner draft beam pin.
At this point the mower should be loose from the tractor.
Remove the two spool valve and mount the four spool valve for the boom
according the diagram in the parts section. Also refer to the parts section for the
new hoses that will need to be used.
DECK ATTACHMENT
The pivot assembly is used to attach the head to the secondary boom. Install the
deck pivot cylinder using the pins and hardware, which is illustrated in the common
section.
Connect the fittings and hoses from the pivot cylinder to the small preformed
tubes on the boom arm. Connect the fittings and hoses from the motor to the large
preformed tubes on the boom arm. Connect all remaining hoses from the control
valve to the cylinders and / or preformed tubes on the boom arm. Refer to common
section for diagrams.
SOLENOID BRAKE VALVE
Install a solenoid valve mounting bracket with the supplied hardware. While
installing fittings to the brake valve, the electrical coil on the spool must be removed to
make room. When reinstalling the coil, it is important to use no more than 5 ft. lbs. (or
60 in. lbs.) torque. Over torque to the coil will result in hydraulic failure of spool.
Assembly Section 2-23
ASSEMBLY
HOSE COVERING
Secure hoses together with zip ties wherever loose. Wrap the hoses with the
hose covers as illustrated in the parts book. Where hoses may contact the frame or
other edges, wrap with split hose and secure with hose clamps or zip ties. On non
cab units the pressure and return hoses from the control valve will also need to be
routed inside the protective clear hose wrap.
WHEEL WEIGHT MOUNTING
For the BoomKat mower, a wheel weight will be required for the lef t side rear wheel.
It will be necessary to mount the 1700 pound wheel weight in the wheel using the long
capscrews, lockwahers, flatwashers, and hex nuts per diagram in the parts section.
Installation is most easily done with a small fork lift, inserting a fork in the center slot
of the wheel weight. The head of the capscrews is to be toward the OUTSIDE of the
weight, with flatwashers on both inside and outside of the assembly.
The left rear tire must also be filled with a mixture of water and calcium chloride at
about five pound per gallon. Tire air pressure should be maint ained at approximately
30 P .S.I.
EXTENDING ZERK ON FLAIL HEAD
Due to the belt shield covering the cutter shaft bearing on the flail head a hose,
elbow, & grease zerk have been added to the bearing. Remove the existing grease
zerk from the bearing and discard. Att ach the elbow to the bearing. Next, the hose is
attached to the elbow and routed through the belt shield(shown below) and attached
to the outside of the shield. The additional zerk is connected to the end of the hose for
easier bearing maintenance.
ATTACH
HOSE HERE
After assembling all components, double check the complete
assembly from the main frame to the cutter head. Check the diagrams in
the parts sections for proper placement and assembly of all
components.
Assembly Section 2-24
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