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Alamo DSEB-D16 manual

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Table of contents for the manual

  • Page 1

    © 2003 Alamo Group Inc. ALAMO INDUSTRIAL 1502 E. W alnut Seguin, T exas 78155 210-372-3551 Assembly Instruction Manual John Deere 6615 and 7615 Part No. 02980169 Tractors equipped with additional options, special equipment, tractor manufacturer modifications, new tractor models, or Customer alterations may prevent this Mount Kit from being properl[...]

  • Page 2

    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 c[...]

  • Page 3

    © 2003 Alamo Group Inc. Index -3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 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 [...]

  • Page 4

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Index -4 Page Safety Section Operation Safety............................................................................. 1 Section 1 Tools and Supplies Needed f/ Assembly.................................. 1-2 Pre-Dilivery Check List......................................[...]

  • Page 5

    © 2003 Alamo Group Inc. Index -5 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 INDEX - ASSEMBL Y INSTRUCTION Page Section 7 Cutter Motor Control Valve................................................................ 7-2 Boom Installation / Boom Hoses....................................................... 7-2 to 7-3 Pump / Tank Hose Installat[...]

  • Page 6

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Index -6 NOTES[...]

  • Page 7

    SAFETY SECTION Safety Section 1-1 © 2003 Alamo Group Inc.[...]

  • Page 8

    Safety Section - 2 SAFETY © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Read these assembly instructions through completely and understand them before proceeding with the assembly of the equipement. A safe and careful operator is the best operator . Safety is of primary importance to the manufac- turer and should be [...]

  • Page 9

    Safety Section - 3 SAFETY © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. (SG-3) PELIGRO! !LEA EL INSTRUCTIVO! READ , UNDERST AND , and FOLLOW the following Safety Messages. Serious injury or death may occur unless care [...]

  • Page 10

    Safety Section - 4 SAFETY © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Many of the parts are heavy and require lifting assistance. Do not try to lift the heavy parts by yourself. Get help from another employee or from an overhead crane. WARNING! The operator and all support personnel should wear hard hats, safety sh[...]

  • Page 11

    Safety Section - 5 SAFETY © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Before starting the mower make sure the area is clear and the floor has been swept. The mower blade can throw objects several hundred feet. Thrown objects could damge property or cause severe bodily injuries even death. WARNING! Make certain that[...]

  • Page 12

    Safety Section - 6 SAFETY © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 DANGER! NEVER use drugs or alcohol immediately before or while operating the Tractor and Implement. Drugs and alcohol will affect an operator’s alertness and coordination and therefore affect the operator’s ability t o operate the equipment s[...]

  • Page 13

    © 2003 Alamo Group Inc. Section1 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM T OOL REQUIREMENTS AND PRE-DELIVER Y INSPECTION CHECKLIST Section 1[...]

  • Page 14

    A-Boom (JD 6615/ 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 1 - 2 Assembly T ools, Supplies and Equipment Needed Tools that are recommended to complete this assembly. There are number of different ways to do things, some items are recommended to make assembly easier but may not be required. 1. An over Head Hoist, the hoist [...]

  • Page 15

    © 2003 Alamo Group Inc. Section1 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM PRE-DELIVER Y INSPECTION CHECKLIST Pre-Operation Inspection: After Assembly is complete. Check the following items before operating the unit to assure that they are properly assembled. (See following page 1-4 for component location) Saf tey Equipment: [...]

  • Page 16

    A-Boom (JD 6615/ 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 1 - 4 A-BOOM PRE-DELIVER Y INSPECTION CHECKLIST Pre-Operation Inspection: Check the following items before operating the unit to assure that they are properly assembled. (See following page 1-4 for component location) Flail Mower Head: ___ Skid Shoe Bolts are torqu[...]

  • Page 17

    © 2003 Alamo Group Inc. Section1 - 5 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 T ractor - Mower Component Location For Check List 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 2[...]

  • Page 18

    © 2003 Alamo Group Inc. Section 2 - 1 A- Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Wheel W eight Inst allation Section 2[...]

  • Page 19

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 2 - 2 Rear Wheel Counter Weight Item Part No. Qt y Description 1 02979603 3 Hex Head Bolt, 7/8" NC X 16" 2 02971569 3 Wheel Weight Washer, Special 3 02970758 1 Wheel Weight Casting, 1400 lbs. 4 5JRC1490 3 Locknut, Top Lock 7/8" NC Note: some Older U[...]

  • Page 20

    © 2003 Alamo Group Inc. Section 2 - 3 A- Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Rear Wheel Counter Weight Inst alling Wheel Weight 1. This Wheel Weight is 1400 lbs. Always use caution when working with it. 2. Locate the three Holes in LH Rear Wheel. Make sure these holes are 15/16" dia. if not, they must be reamed out. 3. Lift Lef[...]

  • Page 21

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 2 - 4 NOTES[...]

  • Page 22

    © 2003 Alamo Group Inc. Section 3 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-Boom Front Pump & Drive Shaf t Inst allation Section 3[...]

  • Page 23

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 3 - 2 Pump / Drive Assembly Instructions Inst alling Pump, Pump Drive Component s and Hydraulic T ank: This Section covers the installation of Pump Drive Components, Pump Assembly and the Hydraulic Tank. Some precautions must be followed during the Assembly Proces[...]

  • Page 24

    © 2003 Alamo Group Inc. Section 3 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Pump / Drive Assembly Instructions Inst alling Pump Drive Component s: 2. Access to Crankshaft Pulley. The Factory Crankshaft Pulley will not need to be removed. The Pulley Adapter will be bolted to the Factory Crank- shaft Pulley. 3. Install Pulley Adapter.[...]

  • Page 25

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 3 - 4 Pump / Drive Assembly Instructions 6. Install Shaft End of Driveline / Engine end. Install the Shaft 1/2 Assembly w/ Flanged Yoke into the Engine compartment of Tractor, install it from the LH front Side down and under radiator. (See Figure 6) . This needs t[...]

  • Page 26

    © 2003 Alamo Group Inc. Section 3 - 5 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Pump / Drive Assembly Instructions 4. Loosen Splined Clamp Yoke. Insert a bar through the Yoke to hold Driveshaft up and to help loosen the Bolts in the clamp Yoke (See Figure 10) . This can be loosened with a hand Wrench or a Socket whichever is easier for [...]

  • Page 27

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 3 - 6 Pump / Drive Assembly Instructions Figure 14 Gap ? Check, this must have a gap between Pump & drivesahft Figure 15 Pump Retaining Bolts (2) Inst alling Pump: (continued) 5 . Mount Pump to Pump Plate. Remove the Bar that is slid through the Driveshaft Yok[...]

  • Page 28

    © 2003 Alamo Group Inc. Section 3 - 7 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Inst all Front frame Rail Support s: 1 . Remove Bolts from Tractor Frame Rails. Find the front most 4 Bolts in the Tractor Frame Rail, There are 4 on the RH side and 4 on the LH Side. DO NOT REMOVE THE BOLTS FROM BOTH SIDES AT THE SAME TIME, ONLY do one side[...]

  • Page 29

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 3 - 8 NOTES[...]

  • Page 30

    © 2003 Alamo Group Inc. Section 4 - 1 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 A-Boom Frame Rail / High Frame Setup / Pre- Assembly Inst allation Section 4[...]

  • Page 31

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 2 Frame Rail Set Up The Frame Rail Set UP. The Frame Rails for the Machete will be set up on the tractor, positioned, measured but not welded. The Machete High frame is set on to Frame Rails, positioned and leveled. After all is set up and positioned it will b[...]

  • Page 32

    © 2003 Alamo Group Inc. Section 4 - 3 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation RH & LH Frame Rails. Shown below are example of Frame rails, There is a Right and Left Frame Rail, They will not interchange from side to side. LH must be mounted on the Left and Right on the Right. To ID which is which, the easies[...]

  • Page 33

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 4 Frame Rail Inst allation Frame Rail Stiffener Kit (Crossmember). Shown below is the Frame Rail Stiffener Kit. This mounts under the Tractor and will be added to the Frame Rails during Assembly. Item 5 Rail Support Gussets are shipped loose and are not part o[...]

  • Page 34

    © 2003 Alamo Group Inc. Section 4 - 5 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation Frame Rail Pre-Assembly: (continued) High Frame Mounting Tube Components. (See Figure 3 & 4) These Components are to be laid out and will be tack welded to frame Rails and High frame during Pre-Assembly Process. Locate and ID these[...]

  • Page 35

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 6 High Frame Inst allation Frame Rail Pre-Assembly: (continued) High Frame Mounting Tube Components. (See Figure 4) These Components are Sitting in approx. position of assembly to illustrate where they are to be when tack welding them. Space is left between th[...]

  • Page 36

    © 2003 Alamo Group Inc. Section 4 - 7 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 High Frame Inst allation NOTE: 2 Wheel Drive High Frame and 4 Wheel Drive Frame looks the same ex- cept King Post and Bracing is higher up. The 2 Wheel Drive and the 4 Wheel Drive High Frames will not inter- change. High Frame & King Post Asy Figure 5 High[...]

  • Page 37

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 8 Frame Rail Inst allation 1. Lay Out Components in Display. It is helpful to lay out the component in as neat a display as possible. Lay out the Bolts accord- ing to size and length. Lay out the Nuts and washer by size. This will allow you to see how many of [...]

  • Page 38

    © 2003 Alamo Group Inc. Section 4 - 9 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation Pre-Installing Frame Rails: (continued) 4. Front Rail Mounting Pad. There are two of these Pads; one is used on the left and one on the right. These Pads are the same so it will not matter which goes on which side. (See Figure 9). Set [...]

  • Page 39

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 10 Frame Rail Inst allation Pre-Installing Frame Rails: (continued) 7. Installing Frame Rails. Using a Hoist, lift the frame rail and slide it into place under the right rear Axle. Hold the frame rails as shown to prevent it from moving (See Figure 13). Using [...]

  • Page 40

    © 2003 Alamo Group Inc. Section 4 - 11 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation Pre-Installing Frame Rails: (continued) 11. Raising Frame Stabilizer Kit Up Under Tractor. Using a Floor Jack slide Stabilizer Kit under Tractor right behind the front wheels. (See Figure 17). Note the Floor Jack used here has had cha[...]

  • Page 41

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 12 Frame Rail Inst allation Pre-Installing High Frame: 1. High Frame Shipping Pallet. The High frame is shipped bolted to a Pallet, Do not unbolt this from the Pallet untill the Hoist has been connected to the High frame. The Hoist must be supporting the weigh[...]

  • Page 42

    © 2003 Alamo Group Inc. Section 4 - 13 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation Pre-Installing High Frame: (continued) 4. Lower High frame down over Tractor. This is a two man job in order to keep control of High Frame on both sides of tractor (See Figure 25) . Lower the High Frame down over the Frame rails (See [...]

  • Page 43

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 14 Frame Rail Inst allation Figure 29 Pre-Installing High Frame: (continued) 7. Align High frame to Frame Rails. The High Frame Vertical Tube should be as directly above the Vertical tube of the frame rails as possible (See Figure 30) . The illustrations in fi[...]

  • Page 44

    © 2003 Alamo Group Inc. Section 4 - 15 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation 9. Install Mounting Tubes . Loosely bolt the Front Angle Mount end of Mounting Tube (See Figure 32). Slide 1 Mounting Tube in on top of the Frame Rail on each side, the end that has the Angle Mount bolted to it goes to the Front away [...]

  • Page 45

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 16 Frame Rail Inst allation 10. Install Front Angle Mount. Loosely bolt the Front Angle Mount on the other end (front) of each Mounting Tube (See Figure 33). Notice the washer that is installed be- tween the Angle Mount and Mount Tube, This is there because ab[...]

  • Page 46

    © 2003 Alamo Group Inc. Section 4 - 17 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation T ack W elding Frame Rails: 1. Tack Weld Frame Rails to Front Mount- ing Pads. Check to make sure that the Frame rail is still aligned on front rail Mounting Pad, Frame Rail should not interfere with the Mount- ing Pad bolt heads Chec[...]

  • Page 47

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 18 Frame Rail Inst allation T ack W elding Frame Rails: (continued) 4. Frame Stiffener Assembly. The frame stiffener is an assembly designed to run under the Tractor to tie the two Frame Rails together and support each other. The Gusset Rail Support is designe[...]

  • Page 48

    © 2003 Alamo Group Inc. Section 4 - 19 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation T ack W elding Frame Rails: (continued) 6. Tack Weld Front and Rear Angle Mounts. The Angle Mounts should be tack Welded to the Frame Rails in 4 places each. This works best by weld a tack Weld in each corner of Angle Mount. (See Figu[...]

  • Page 49

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 20 Frame Rail Inst allation T ack W elding Frame Rails: (continued) 8. Weld Bar Mounting Straps. The RH Front bar Mounting Straps will have to be cut (See Figure 31) and welded to the top of the Mounting Tube (See Figure 43) . Another one cut off and welded to[...]

  • Page 50

    © 2003 Alamo Group Inc. Section 4 - 21 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation Remove High Frame for Final W elding.: 1. Remove and Weld High Frame. Lift the High frame back up off of frame rails (See Figure 46). Finish Weld Mount Tubes. The Mounting Tubes are to be welded completely all the way around. This is [...]

  • Page 51

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 22 Frame Rail Inst allation Remove High Frame for W elding.: 1. Remove Frame Rails. It is best to remove the Frame Rails to weld them. Frame Rails will need to be welded in five places. Note: The RH Frame Rail and the LH Frame Rail will have the same Welding d[...]

  • Page 52

    © 2003 Alamo Group Inc. Section 4 - 23 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation 6. The Side Rails. These Frame rails will be welded to the Rail Support Plates, so it will be necessary to scrape the paint off approxi- mately 5/8" of the base before attaching. Clamp Side Rails to Front Mount Supports. (See Fig[...]

  • Page 53

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 24 NOTES[...]

  • Page 54

    © 2003 Alamo Group Inc. Section 5- 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-Boom Frame Rail & High Frame Final Inst allation Section 5[...]

  • Page 55

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 5 - 2 Frame Rail Inst allation Re-Install Frame Rails to T ractor: 1. Re-Install Frame Rails. With the Welding done touch up or re-paint frame rails before re- installing them. The RH and the LH Rail will install to the Tractor the same except for the Boom rest th[...]

  • Page 56

    © 2003 Alamo Group Inc. Section 5- 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation Re-Install Frame Rails to T ractor: (continued) 5. Install Axle Mounted Boom Rest. This will require two people, one to align the Boom rest with the Hoist and one to align the Bolt holes on the bottom to start them into the Axle Housi[...]

  • Page 57

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 5 - 4 Frame Rail Inst allation 4 WD Figure 9 Re-Install Frame Rails to T ractor: (continued) 6. Install Stabilizer Crossmember. This will con- sist of a Tube cross member and four Bolts and Nuts (See Figure 11). Install the Bolts with the Nuts on Top and bolts com[...]

  • Page 58

    © 2003 Alamo Group Inc. Section 5- 5 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation 4 WD Re-Install High Frame to T ractor: 1. High Frame Paint. Re-Paint or Touch up Paint on High Frame now before lowering it on to Tractor. Keep in mind there will be one more Place to Weld on High frame that will need touch up Paint [...]

  • Page 59

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 5 - 6 Frame Rail Inst allation 4 WD Re-Install High Frame to T ractor: (continued) 5. Install Mounting Tube Bolts. The High frame must still be hung on the Hoist for safety and support, but sitting down on the frame rails. There are 8 Bolts and Nuts that go throug[...]

  • Page 60

    © 2003 Alamo Group Inc. Section 5- 7 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Frame Rail Inst allation 4 WD Re-Install High Frame to T ractor: (continued) 8. Tighten All Frame Mounting Bolts. Tighten all the Frame Mounting bolts that have only be snugged till now. Go through and make sure none are missed. A. Front Mounting Pad Bolts. T[...]

  • Page 61

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 5 - 8 Frame Rail Inst allation 4 WD Frame Rail Bar Mounting Strap Wleded to Frame Approx 1/2" from end of frame rail Frame Rail Machete High Frame Front Support Mount Mounting Angle / Mounting Tube Bolts & Nuts Mounting Tube Bar Mounting Straps with Bolts[...]

  • Page 62

    © 2003 Alamo Group Inc. Section 6 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-Boom Hyd. T ank, CWT & Decal Final Inst allation Section 6[...]

  • Page 63

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 6 - 2 Hyd. T ank - CWT Inst allation Hydraulic T ank Installation: 1. Caution. Care must be taken to keep Hydrau- lic System clean. Do not leave any openings in Tank while installing it, they must remain sealed untill ready to install a component and then sealed b[...]

  • Page 64

    © 2003 Alamo Group Inc. Section 6 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Decal Inst allation T ank Oil Level Sight Gauge: 1. Oil Level Sight Gauge is mounted on the side of the tank facing the rear of the tractor. The Tank may have to have the Paint touched up, or repainted completly. Use caution not to paint over this or damage [...]

  • Page 65

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 6 - 4 Decal Inst allation Cab Decal Installation: 1. Install Decals on Windows inside Cab There are 8 decals that need to be installed on Windows and inside Cab of Tractor. Clean all surfaces before installing Decals. Do Not Install any Decals that will interfer w[...]

  • Page 66

    © 2003 Alamo Group Inc. Section 7 - 1 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Boom Inst allation Section 7[...]

  • Page 67

    A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 7 - 2 Boom Inst allation Cutter Motor Control V alve Asy: 1. Cutter Motor Control Valve Asy. Install the Cutter Motor Control Valve Asy to the LH side of High Frame, it will not have the Hoses attached as shown, the Hoses will be connected later (See Figure 1) Boom[...]

  • Page 68

    © 2003 Alamo Group Inc. Section 7 - 3 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 Boom Inst allation 4. Attach the Rod end of the Lift Cylinder (7) to the Lift Section with Pin (8), Bolt (9) and Nut (10) (also see Parts Section on the Boom Assembly) (See Figure 3). 5. Attach the Swing Cylinder . The Swing Cylinder attaches to the King Post[...]

  • Page 69

    A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 7 - 4 Hose Inst allation Pump / T ank Hose Installation: 1. Suction Hose, Tank to Pump. The Suction hose connects to the front RH side of Tank (See Figure 8) and runs through a Hose Ring that is welded to the frame Rail (See Figure 9). The Suction Hose connects to [...]

  • Page 70

    © 2003 Alamo Group Inc. Section 7 - 5 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 Hose Inst allation Pump / T ank Hose Installation: (continued) 3. Connect hose from Pump to Cylinder Control Valve. This will be the small hose connec- tion on thr RH side of the pump (See Figure 10) for this hose, this hose cannot be connected to Cyl. Contro[...]

  • Page 71

    A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 7 - 6 NOTES[...]

  • Page 72

    © 2003 Alamo Group Inc. Section 8 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM S t andard Cylinder Control V alve Inst allation Section 8[...]

  • Page 73

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 8 - 2 Cylinder Control V alve Inst allation 1. The controller assemblies will be bolted together using a tie rod bolt. The control handles are the same and the cables are the same, it is where they are connected to the control valve that makes a difference. (See F[...]

  • Page 74

    © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Section 8 - 3 Start Off Ign Acc Acc T ractor Ignition Switch Push/ Pull Switch T ractor S tarter Red & White or White Wire Red Wire Y ellow or Orange Wire 10Amp S pade Fuse Quick S plice Acc Service Wire Line Connector Billet T erminal Solenoid Cutter V alve Blue Blac[...]

  • Page 75

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 8 - 4 Wire Harness : (Standard Mechanical Valve) 1. Starter Safety Switch Schematic, Mechanical Cable Operated Valve Type, NOT correct for Optional Joystick (Electronic) Controls. 2. Figure 4 illustrates a common wire harness connection for A-Boom mowers with mech[...]

  • Page 76

    © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Section 8 - 5 Cylinder Control V alve Inst allation Figure 6 5 Spool Valve Shown Pressure Return One Way Restrictors "B' Side Ports End Cap "A" Side Ports Tilt Dipper Lift Swing Handle Inlet Cover Figure 5 S tandard Control V alve Operation: (continued[...]

  • Page 77

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 8 - 6 Cylinder Control V alve Inst allation System Schematic (T ypical 17' through 23' with 4 S pool V alve) Filter Hyd. Tank Motor Control Valve Motor Return Motor Pressure M 1 M 2 Control Valve Tilt Cyl. Dipper Cyl. Hyd. Pump Swing Cyl. Lift Cyl. Figur[...]

  • Page 78

    © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Section 8 - 7 Cylinder Control V alve Inst allation A Cylinder Hydraulic Control Circuit: (See Figure 2 & 3) 1. Hydraulic power for the cylinder control circuit is taken from the second (smaller) stage of the hydraulic pump. Oil is supplied through hose 2 to the four [...]

  • Page 79

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 8 - 8 REMOTE CABLE OPERA TION AND INST ALLA TION: 1. Remote operation of the boom movement control valve can be achieved with the use of cables and remote actuator handles. The remote operation system is standard equipment on cab tractor units and can be installed[...]

  • Page 80

    © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Section 8 - 9 Cylinder Control V alve Inst allation 3. Turn the Jam Nut and the Flange/ Sleeve Assembly onto the threaded cable end to the entire length of the threads. Cables are not included in Valve connec- tion Kit. (See Figure 5). Figure 5 Flange Sleeve Flange Flange[...]

  • Page 81

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 8 - 10 4. Turn the cable eye Jam nut on the threaded cable end until it bottoms. Thread the Cable Eye onto the cable end until it bottoms on the cable. Turn the eye to align with the spool end and secure the jam nut against the cable eye. (See Figure 6). 5. Slide [...]

  • Page 82

    © 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Section 8 - 11 Cylinder Control V alve Inst allation 10. Each cable is controlled by the operator with the use of single axis control handle assemblies. A single control handle assembly is required to oper- ate each individual valve section. The control handle assemblies [...]

  • Page 83

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 8 - 12 NOTES[...]

  • Page 84

    © 2003 Alamo Group Inc. Section 9 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Optional Joystick - Wire Harness & V alve Inst allation Section 9[...]

  • Page 85

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 2 Optional Joystick Mounting Item Part No. Qty Description 1 00011100 2 Flatwasher, 3/8" 2 00012101 2 Lockwasher, 3/8" 3 00011400 2 Bolt, 3/8" NC X 1" 4 00750940 3 Locknut, 5/16" Toplock 5 00023500 3 Flatwasher, 5/16" 6 10119000 3[...]

  • Page 86

    © 2003 Alamo Group Inc. Section 9 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Option Joystick Mounting Inst alling Joystick Mount to T rac- tor Seat: 1. Remove Tractor Seat Cushion . Remove Lower Seat Cushion from Tractor Seat. The Seat Cushion should have three phillips head screws across the front edge (See Figure 2). Once these scr[...]

  • Page 87

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 4 Inst allingJoystick to Bracket: 1. Bolt Joystick to Mounting Bracket. Set Joystick Assembly on Mounting Bracket. Make sure Joystick is mounted as shown, the Push Pull Switch in rear and Toggle Switch to the front. (See Figure 6) 2. Installing Joystick Mounti[...]

  • Page 88

    © 2003 Alamo Group Inc. Section 9 - 5 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Joystick Mounting 2 WD & 4 WD Inst alling Wiring Harness for Joystick: (Continued) 4. Wires to be Connected. You will need to find the wire from the switch that activates the Starter Solenoid for the Tractor This wire will need to be cut to form 2 ends. [...]

  • Page 89

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 6 Joystick Mounting 2 WD & 4 WD Inst alling Wiring Harness to Joystick: (Continued) 8. Ground Wire. The Black wire at the harness (See Figure 11 and 13) can be connected inside the cab floor, or it can be run down through the floor and connected to the fra[...]

  • Page 90

    © 2003 Alamo Group Inc. Section 9 - 7 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Joystick Mounting 2 WD & 4 WD Installing W arning and Instruction Decals: 1. Always clean windows before installing decals. Windows must be dry and free of any oil, after cleaning do not touch windows before decals are installed. Take precaution to make [...]

  • Page 91

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 8 Ph Wire Harness / V alve Mounting 2 WD & 4 WD Inst alling Wire Harness T o V alve: 1. Wire Harness From Cab to Front. The wire harness runs out the bottom of the Cab on the right hand side. Run Harness along RH Frame rail of Tractor to the front of the T[...]

  • Page 92

    © 2003 Alamo Group Inc. Section 9 - 9 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 PhPhoPht Wire Harness / V alve Mounting 2 WD & 4 WD Inst alling Wire Harness T o V alve: (Continued) 5. Wire Harness Terminal Identification. The Wire Harness Terminal Plugs are marked in writ- ing on the plug. Swing, Lift, Dipper, Tilt and Door terminal[...]

  • Page 93

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 10 Wire Harness / V alve Mounting 2 WD & 4 WD Inst alling Wire Harness T o V alve: (Continued) 8. Solenoid Lock Valve Connection. Sole- noid Lock valve is mounted on the Valve Tilt Port on the RH Side (See Figure 27). Find the two wires in harness that has[...]

  • Page 94

    © 2003 Alamo Group Inc. Section 9 - 11 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Joystick Plug (Bottom of Joystick Console) A J C K L F M H X B D E G N P R S T U V W X X 1 2 3 4 5 7 6 Master Switch Motor Relay X Red Motor Push / Pull Switch With Momentary Start Grn Yel Red Wht/Violet Violet Rocker Switch Dbl Trigger Switches 1 2 3 4 5 6[...]

  • Page 95

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 12 Wire Harness (Joystick Console Plug to V alve) Wire Harness Plug (New S tyle) E G SWING LIFT DIPPER T I LT DOOR/ EXTEND Piston Pump Solenoid Soleniod Lock Valve Start Solenoid Loop T H 1 2 3 Grnd X N A 1 2 3 Grnd 1 2 3 Grnd 1 2 3 Grnd 1 2 3 Grnd P S H R R W[...]

  • Page 96

    © 2003 Alamo Group Inc. Section 9 - 13 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Control V alve - Electric / Hydraulic CONTROL VALVES: (See Figure 32) The Alamo A-Boom Optional Hydraulic Control Valve is an Electro-Hydraulic (Electric over Hydraulic) Valve. The Valve is designed to utilize Oil from the Tractors Hydraulic System. This is[...]

  • Page 97

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 14 NOTES[...]

  • Page 98

    © 2003 Alamo Group Inc. Section 10 - 1 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Head Inst allation (Optional Heads) Section 10[...]

  • Page 99

    A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 10 - 2 Optional Mower Head Inst allation Att aching Flail-Axe Head: 1. With a Forklift or Hoist, lower the boom Weldment on the Flail Axe Head. Align the boom Weldment with the Flail Axe Head Hitch Post. In- sert special bolts (item 1 p/n 02956972 and item 2 p/n 00[...]

  • Page 100

    © 2003 Alamo Group Inc. Section 10 - 3 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 Att aching Flail Head: 1. W ith a Forklif t or Hoist, lower the boom Weldment on the Flail Head. Align the boom Weldment with the Mower Head Hitch Post. Insert special bolts (item 1 p/n 02956972 and item 2 p/n 00752405) into Boom Weldment and Hitch Post. Att[...]

  • Page 101

    A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 10 - 4 Optional Mower Head Inst allation Att aching Ditcher Head: W ARNING Escaping fluid under pressure can penetrate the skin causing serious injury . Relieve pressure before unhooking hydraulic or other lines. T ighten all connec- tions before applying pressure.[...]

  • Page 102

    © 2003 Alamo Group Inc. Section 10 - 5 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 Optional Mower Head Inst allation Att aching Timber Cat Head: 1. Attach the T imber Cat Head to the boom using the pins included with the head. Be careful not to damage the pivot bushings in the boom when inserting the pins. Attach the 90° elbow (Item 1) to[...]

  • Page 103

    A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 10 - 6 Optional Mower Head Inst allation X-Frame Square Head Att achment: 1. With a forklift or hoist, lower the Boom Weldment down on the X-Frame Square Head. Align the Boom Weldment with the X-Frame Square Head Hitch Post. Insert special bolts 1" x 9" ([...]

  • Page 104

    © 2003 Alamo Group Inc. Section 11 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Fill Hydraulic T ank Section 1 1[...]

  • Page 105

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 11 - 2 Fill Hydraulic T ank Fill Hydraulic T ank with Oil: 1 . DO NOT START TRACTOR untill you have filled Hydraulic Oil Tank to a level as shown in Sight Glass gauge and fill the Suc- tion Hose to Pump with Oil. 2. Remove Filler Cap . Remove Filler cap only when [...]

  • Page 106

    © 2003 Alamo Group Inc. Section 11 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Fill Hydraulic T ank Fill Hydraulic T ank with Oil: 5. Fill Tank . Fill the Hydraulic Tank (See Figure 4) Fill tank till the Oil is visable in the sight Gauge (See Figure 5 & 8). This will fill tank for the start but it will have to filled again later. [...]

  • Page 107

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 11 - 4 NOTES[...]

  • Page 108

    © 2003 Alamo Group Inc. Section 12 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Hydraulic S t art-Up Procedures Section 12[...]

  • Page 109

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 12 - 2 St art-up Instructions: 1. Read all safety instructions. Decals on the A-Boom warn you of particular and multiple Hazards. Many decals are attached close to p art of the A-Boom where there is a possible hazard. Read and make sure you understand the safety m[...]

  • Page 110

    © 2003 Alamo Group Inc. Section 12 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Post-Assembly Check List: 1. Is oil level in the tank even with the sight gauge on the tank? 2. Has the proper oil been used in the system? Proper oil is Universal T ractor Hydraulic. 3. Does Boom machine movement match operation decal - Swing, Lift, Dipper[...]

  • Page 111

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 12 - 4 NOTES[...]

  • Page 112

    © 2003 Alamo Group Inc. Section 13 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Boom Rest Plate and Boom Swing S top Inst allation Section 13[...]

  • Page 113

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 13 - 2 Boom Rest Plate & Hook Inst allation Boom Rest Plate inst allation: 1. Boom rest Mounted . Boom rest should already be mounted and tighten down to Tractor from earlier assembly section. At the top of the Boom rest there will be a Boom rest Plate bolted [...]

  • Page 114

    © 2003 Alamo Group Inc. Section 13 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Boom Rest Plate & Hook Inst allation Boom Rest Plate inst allation: 5. Marking Boom . Use a Black (or color de- sired) to mark the Boom, Make a Line on the Boom parrelel with the Bolt on Boom Rest across the Boom, (See Figure 5 & 6) . This line will[...]

  • Page 115

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 13 - 4 Boom Swing Stop Inst allation Boom Swing Stop inst allation: 1. Position Boom Swing Stop Lug . BoomSwing Stop Log is used to prevent Boom from swinging back to far and hitting Cab. With Boom folded and restin on Boom Hook in Boom Rest Plate. Position the Bo[...]

  • Page 116

    © 2003 Alamo Group Inc. Section 13 - 5 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 NOTES[...]

  • Page 117

    A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 13 - 6 NOTES[...]

  • Page 118

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  • Page 119

    A-Boom (JD 6615 Asy Instruction Manual) 05/03 © 2003 Alamo Group Inc. A-Boom (JD 6615 & JD7615) Assembly Manual 2003 Edition P/N 02980169[...]