A-BOOM
Assembly Instruction Manual
John Deere 6615 and 7615
Tractors equipped with additional options, special equipment, tractor manufacturer modifications,
new tractor models, or Customer alterations may prevent this Mount Kit from being properly
mounted to the tractor. Alamo Group is not responsible for modifications to the MountKit to
accommodate these differences.
Part No. 02980169
ALAMO INDUSTRIAL
1502 E. Walnut
Seguin, Texas 78155
210-372-3551
© 2003 Alamo Group Inc.
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INTRODUCTION
ABOUT THIS MANUAL:
Theintentofthispublicationtoprovidethecompetenttechnicianwiththeinformationnecessary
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 neces-
sary.
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
hasnevergoneouttolookattheequipmentandmerelycallsinquiringoftheproblemsdescribedtohim
by the operator or customer.
Most calls received by Alamo Industrial Service can be classified into approx. 6 general categories.
1.
2.
3.
4.
5.
6.
Hydraulic or Mechanical Trouble Shooting.
Request for Technical Information or Specifications.
Mounting or Fitting Problem.
Special Service Problem.
Equipment Application Problems.
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
ManualorServiceManual,manyoftheseareavailableviatheAlamoIndustrialInternetsite(www.Alamo-
Industrial.Com). Attempt to diagnose or repair problem before calling.
2.
IfacalltoAlamoIndustrialisneeded,CertainInformationshouldbeavailableandready
fortheAlamoIndustrialServiceStaff.Suchinformationas, MachineModel,SerialNumber,YourDealer
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
databaseofproblemsandrelatedsolutions,whichwillexpediteasolutiontofutureproblemsofasimilar
nature.
3.
The technician may be asked to provide detailed information about the problem
includingtheresultsofanyrequiredtroubleshootingtechniques. Iftheinformationisnotavailable, The
technician may be asked to get the information and call back. Most recommendations for repairs will
be based on the procedures listed in the Service Manual / Trouble Shooting Guide and Information
provided by customer.
CONTACT ALAMO INDUSTRIAL:
Alamo Industrial, 1502 E. Walnut St. Seguin TX. 78155, Technical Service Dept. PH: 830-372-2708
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
Index-3
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INDEX - ASSEMBLY INSTRUCTION
Page
Safety Section
OperationSafety............................................................................. 1
Section 1
Tools and Supplies Needed f/ Assembly.................................. 1-2
Pre-DiliveryCheckList...................................................................... 1-3 to 1-5
Section 2
Fill Left rear Wheel w/ calcium Cloride............................................. 2-2
Wheel Counter Weight Parts.............................................................2-2
Wheel Counter Weight Installation.................................................... 2-3
Section 3
Front Pump Drive Parts.....................................................................3-2
CrankshaftPulleyPreparation........................................................... 3-3
Pump Driveshaft Assembly............................................................... 3-3
Pump Driveshaft Half, Shaft End.......................................................3-4
PumpMountPlate..............................................................................3-4 to 3-5
Pump Drive Shaft, Tube End.............................................................3-5
PumpInstallation................................................................................3-5 to 3-6
FrameRailSupportInstallation......................................................... 3-7
Section 4
Frame Rail Pre- Assembly................................................................ 4-2 to 4-6
HighFrameParts...............................................................................4-7
FrameRailPre-Installation................................................................ 4-8 to 4-11
HighFramePre-Installation............................................................... 4-12 to 4-16
Tack Welding Frame Assembly........................................................ 4-17 to 4-21
Remove Frame for Final Welding......................................................4-21 to 4-23
Section 5
FrameRailsFinalInstallation.............................................................5-2
BoomRestInstallation.......................................................................5-3
AxleStrapInstallation.........................................................................5-4
StabilizerKitInstallation..................................................................... 5-4
HighFrameInstallation...................................................................... 5-5 to 5-8
Tie Up Hoses to Tractor Frame (Stack valve Hoses)....................... 5-8
Section 6
HydraulicTankInstallation................................................................. 6-2
Hydraulic Tank Counter Weight Installation...................................... 6-2
Hydraulic Tank Oil Level Sight Gauge............................................... 6-3
HydraulicTankDecalInstallation.......................................................6-3
CabDecalInstallation........................................................................ 6-4
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INDEX - ASSEMBLY INSTRUCTION
Page
Section 7
CutterMotorControlValve................................................................ 7-2
Boom Installation / Boom Hoses....................................................... 7-2 to 7-3
Pump / Tank Hose Installation........................................................... 7-4 to 7-5
Section 8
ControlHandleAsyInstallation(MechanicalValve).......................... 8-2
"ON" "OFF" Switch Schematic (Standard Mechanical).................... 8-3
"ON" "OFF" Switch Installation (Standard Mechanical).................... 8-4
Control Valve Operation (Standard Mechanical)............................... 8-5
Hydraulic Hose Schematic (Standard Mechanical)...........................8-6
Hydraulic Hose Control Circuit (Standard Mechanical)..................... 8-7 to 8-8
Remote Control Cable Installation (Standard Mechanical)............... 8-8 to 8-11
Section 9
JoystickMountParts......................................................................... 9-2
InstallJoystickMounttoSeat............................................................ 9-3
Install Joystick Controler to Seat Bracket.......................................... 9-4
TractorFloorMatRemoval................................................................ 9-4
Wire Harness to Tractor Connections...............................................9-5 to 9-6
Tractor Ignition Wire Connection....................................................... 9-6
Connect Wire Harness to Joystick.................................................... 9-6
TractorFloorMatre-Install.................................................................9-6
Tractor Cab Decal Installation........................................................... 9-7
Connect Wire Harness to Control Valve........................................... 9-8 to 9-13
Section 10
AttachingFlailAxeHead.................................................................... 10-2 to 10-3
AttachingDitcherHead...................................................................... 10-4
AttachingTimbercatHead................................................................. 10-5
AttachingX-FrameSquareHead...................................................... 10-6
Section 11
FillingHydraulicTankw/Oil................................................................11-2 to 11-3
Section 12
HydraulicStartUpInstructions.......................................................... 12-2
Post Assembly Check List................................................................ 12-3
Section 13
BoomRestPlateInstallation............................................................ 13-2 to 13-3
BoomSwingStopInstallation........................................................... 13-4
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NOTES
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Index-6
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SAFETY
SECTION
© 2003 Alamo Group Inc.
Safety Section 1-1
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SAFETY
Read these assembly instructions through completely and understand them
before proceeding with the assembly of the equipement.
Asafe and careful operator is the best operator. Safety is of primary importance to the manufac-
turer and should be to the owner/operator. Most accidents can be avoided by being aware of
your equipment, your surroundings, and observing certain precautions. The first section of this
manual includes a list of Safety Messages that, if followed, will help protect the operator and
bystanders from injury or death. Read and understand these Safety Messages before assem-
bling, operating or servicing this Implement. This equipment should only be operated by those
persons who have read the Manual, who are responsible and trained, and who know how to do
so safely and responsibly.
The Safety Alert Symbol combined with a Signal Word, as seen below, is used throughout this
manual and on decals which are attached to the equipment. The Safety Alert Symbol means:
“ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!” The Symbol and Signal
Word are intended to warn the owner/operator of impending hazards and the degree of possible
injury faced when operating this equipment..
Practice all usual and customary safe working precautions and
above all---remember safety is up to YOU. Only YOU can prevent
serious injury or death from unsafe practices.
CAUTION!
The lowest level of Safety Message; warns of possible injury. Decals
located on the Equipment with this Signal Word are Black and Yellow.
WARNING!
DANGER!
Serious injury or possible death! Decals are Black and Orange.
Imminent death/critical injury. Decals are Red and White.
(SG-1)
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Safety Section - 2
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SAFETY
Si no lee Ingles, pida ayuda a alguien que si lo lea para que le
PELIGRO!
traduzca las medidas de seguridad. (SG-3)
!LEA EL INSTRUCTIVO!
READ, UNDERSTAND, and FOLLOW the following Safety
Messages. Serious injury or death may occur unless care is
taken to follow the warnings and instructions stated in the Safety
Messages. Always use good common sense to avoid hazards.
(SG-2)
!
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!
Perform service, repairs and lubrication according to the maintenance section. Ensure the unit
is properly lubricated as specified in the lubrication schedule and all bolts and nuts are properly
torqued. Failure to properly service, repair and maintain this Implement in good operating
condition could cause component failure and possible serious injury or even death. (SG-35)
WARNING!
WARNING!
Operate this Equipment only with a Tractor equipped with an
approved roll-over-protective system (ROPS). Always wear seat
belts. Serious injury or even death could result from falling off the
tractor--particularly during a turnover when the operator could be
pinned under the ROPS. (SG-7)
DANGER!
Never work under the Implement, the framework, or any lifted compo-
nent unless the Implement is securely supported or blocked up to
prevent sudden or inadvertent falling which could cause serious injury
or even death. (SG-14)
Use caution and wear protective gloves when handling sharp objects such as blades, knives,
andothercuttingedges. Bealerttoworncomponentsurfaceswhichhavesharpedges. Sharp
surfaces can inflict severe laceration injuries if proper hand protection is not worn. (SG-37)
WARNING!
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Safety Section - 3
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© 2003Alamo Group Inc.
SAFETY
WARNING!
Many of the parts are heavy and require lifting assistance. Do not try to
lift the heavy parts by yourself. Get help from another employee or from
an overhead crane.
WARNING!
The operator and all support personnel should wear hard hats,
safety shoes, safety glasses, and proper hearing protection at all
times for protection from injury including injury from items thrown by
the equipment. (SG-16)
WARNING!
Always wear safety shoes with steel toes when working on this equipment.
It is recommended that the safety shoes have metatarsal guards.
WARNING!
When welding use Welding hood with the appropriate OSHA required
protective lens, welding apron, and welding gloves.
DANGER!
DANGER!
Always disconnect the wire leads from the mower valve solenoid before
performing service on the Tractor or Mower. Use caution when working
on the Tractor or Mower. Tractor engine must be stopped before
working on Mower or Tractor. The Mower Blades could inadvertently be
turned on without warning and cause immediate dismemberment, injury
or death. (SBM-12)
Never run the tractor engine in a closed building or without adequate
ventilation. The exhaust fumes can be hazardous to your health.
(SG-23)
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Safety Section - 4
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SAFETY
DANGER!
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 the “Slow Moving Vehicle” (SMV) sign is installed in
such a way as to be clearly visible and legible. When transporting the
EquipmentusetheTractorflashingwarninglightsandfollowalllocaltraffic
regulations. (SG-6)
DANGER!
Start tractor only when properly seated in the Tractor seat. Starting a
tractor in gear can result in injury or death. Read the Tractor operators
manual for proper starting instructions. (SG-13)
Do not operate this Equipment with hydraulic oil leaking. Oil is
expensive and its presence could present a hazard. Do not check for
leaks with your hand! Use a piece of heavy paper or cardboard. High-
pressure oil streams from breaks in the line could penetrate the skin
andcausetissuedamageincludinggangrene. Ifoildoespenetratethe
skin, have the injury treated immediately by a physician knowledge-
able and skilled in this procedure. (SG-15)
DANGER!
WARNING!
DANGER!
Always read carefully and comply fully with the manufacturers instruc-
tions when handling oil, solvents, cleansers, and any other chemical
agent. (SG-22)
All Safety Shields, Guards and Safety devices including
(but not limited to) - the Deflectors, Chain Guards, Steel
Guards, Gearbox Shields, PTO integral shields , and
Retractable Door Shields should be used and main-
tained in good working condition. All safety devices
should be inspected carefully at least daily for missing
or broken components. Missing, broken, or worn items
must be replaced at once to reduce the possibility of
injury or death from thrown objects, entanglement, or
blade contact. (SGM-3)
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Safety Section - 5
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© 2003Alamo Group Inc.
SAFETY
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 to
operate the equipment safely. Before operating the Tractor or Imple-
ment, an operator on prescription or over-the-counter medication must
consult a medical professional regarding any side effects of the medi-
cation that would hinder their ability to operate the Equipment safely.
NEVER knowingly allow anyone to operate this equipment when their
alertness or coordination is impaired. Serious injury or death to the
operator or others could result if the operator is under the influence of
drugs or alcohol. (SG-27)
DANGER!
OperatetheTractorand/orImplementcontrolsonlywhileproperlyseated
in the Tractor seat with the seat belt securely fastened around you.
Inadvertent movement of the Tractor or Implement may cause serious
injury or death. (SG-29)
WARNING!
WARNING!
WARNING!
WARNING!
Engine Exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the state of
California to cause cancer and birth defects or other
reproductive harm. (SG-30)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the state of Califor-
nia to cause cancer and birth defects or other reproductive
harm. Wash Hands after handling. (SG-31)
Use extreme caution when getting onto the Implement to perform repairs, maintenance and
whenremovingaccumulatedmaterial. Onlystandonsolidflatsurfacestoensuregoodfooting.
Use a ladder or raised stand to access high spots which cannot be reached from gound level.
Slipping and falling can cause serious injury or death. (SG-33)
Avoid contact with hot surfaces including hydraulic oil tanks, pumps, motors, valves and hose
connections. Relieve hydraulic pressure before performing maintenance or repairs. Use
gloves and eye protection when servicing hot components. Contact with a hot surface or fluid
can cause serious injury from burns or scalding. (SG-34)
Avoid contact with hot surfaces of the engine or muffler. Use gloves and eye protection when
servicing hot components. Contact with a hot surface or fluid can cause serious injury from
burns or scalding. (SG-38)
WARNING!
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Safety Section - 6
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Section 1
A-BOOM
TOOL REQUIREMENTS
AND
PRE-DELIVERY INSPECTION
CHECKLIST
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
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Section1 - 1
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Assembly
Tools, Supplies and Equipment Needed
Tools that are recommended to complete this assembly. There are number of different ways
to do things, some items are recommended to make assembly easier but may not be
required.
1.
2.
An over Head Hoist, the hoist (or Lift) should be a 2-1/2 ton capacity minimum. Hoist should
be able to move and stop within fractions of an inch. Hoist should also have a 12 foot lift
(Required).
Compressed Air, Air must be filtered and dry. A Safety air nozzle for blowing out Hoses and
Fitting prior to assembly. (Required).
3.
4.
5.
6.
7.
8.
Complete Air Impact Sockets, 1/2" Drive and 3/4” drive (Recommended).
Torque Wrench, 400-ft lb. rating, can use a Torque Amplifier Wrench. (Required)
Complete Set of Hand Wrenches from 7/16" to 2" (Recommended).
Assortment of Screwdrivers, (Short ones and Long ones). (Required)
Electric Grinder or Air Grinder, Size according to needs (Required).
Burr Grinder, Electric or Air optional, for resizing Holes and removing Burrs from stamped
metal or stamped holes. (Required)
9.
Welder,capableofweldingupto3/8"material,UseexperiencedWelderPersonel.(Required)
10.
Flame Proof or flame retardant Material to Cover and protect Tractor finish and components
during assembly. (Required)
11.
A good fire Extinguisher on hand before any welding or grinding begins. (Required)
Clean dust free work area, clean Lint Free towels or wipes. Do not do any welding, use
compressed Air or lay out any component unless area is clean. Material the size of a human
hair can contaminate the Hydraulic System (Required).
12.
13.
14.
15.
16.
17.
A place to keep all Components separate and clean untill ready for them (Recommended)
Electrical Butt connectors and Electrical Pliers. (Required)
Paint Scraper to remove Paint before welding. (Recommended)
Floor Jack, 2-1/2 Ton capacity (Required)
An asortment of large C-Clamps (Required)
A-Boom (JD 6615/ 7615 Asy Instruction Manual) 07/03
Section 1 - 2
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A-BOOM PRE-DELIVERY INSPECTION CHECKLIST
Pre-Operation Inspection: After Assembly is complete. Check the following items
before operating the unit to assure that they are properly assembled. (See following page 1-4
for component location)
Saftey Equipment:
-----
-----
-----
-----
-----
-----
Operators Manual is with Unit.
The Safety Decals are installed as listed in the Assembly Manual.
Valve operation plate is installed.
Operators cage or Tractor Cab is in place. (Item 1 page 1-5)
Deflectors are installed on the Mower Head. (Item 2 page 1-5)
Tractor Rops or Cab with seatbels installed properly.
Frame and Boom:
-----
-----
-----
-----
-----
-----
-----
-----
Axle Plate Bolts are torqued to 240 ft. lbs. (Item 3 page 1-5)
Boom Rest Axle Plate Bolts are torqued to 240 ft. lbs.
Front Rail Bolts are torqued to 170 ft. lbs. (Item 17 page 1-5)
Front Support Bolts are torqued to 240 ft. lbs. (Item 4 page 1-5)
Hydraulic Tank mounting Pins / Bolts in place correctly.
Boom Main Pins are torqued to 170 ft. lbs.
King Pin Retaining Nut is properly locked in place.
All Welds inspected toinsure proper welds and locations.
Hydraulic System:
-----
-----
-----
-----
-----
Oil Level in Hydraulic Tank is within the sight gauge. (Item 5 page 1-5)
Hose connections are tightented according to specifications.
Hoses do not have any kinks or twist in them.
Front Pump Shaft adapter bolts are tight. (Item 6 page 1-5)
Front Pump Shaft Coupler / Drive Shaft is lubricated and has an anti-seize compound
on the Splines of Pump and Shafts. (Item 7 page 1-5)
The Pump Drive Shaft has correct alignment.
-----
-----
Suction Hose has no leaks or kinks.
Rotary Mower Head:
-----
-----
-----
-----
-----
-----
-----
Skid Shoe Bolts are torqued to 120 ft. lbs. (Item 8 page 1-5)
Spindle Housing Bolts are torqued to 400 ft. lbs. (Item 9 page 1-5)
The Spindle Housing is properly lubricated. (item 10 page 1-5)
Motor Bolts are torqued to 120 ft. lbs. (Item 11 page 1-5)
Blade Carrier (Bar) Bolts torque to 400 ft. lbs. (Item 12 page 1-5)
All Blade Bolts are torqued, the retainings Pins are in place. (item 13 page 1-5)
Blades Swing freely. (Item 14 page 1-5)
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
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Section1 - 3
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A-BOOM PRE-DELIVERY INSPECTION CHECKLIST
Pre-Operation Inspection: Check the following items before operating the unit to assure
that they are properly assembled. (See following page 1-4 for component location)
Flail Mower Head:
___ Skid Shoe Bolts are torqued to 120 ft-lbs (Item 15 page 5)
___ Motor Bolts are torqued to 120 ft-lbs
___ Belt Alignment& tension adjustment is correct
___ Cutter shaft bearings are properly lubricated
___ Roller bearings are properly lubricated (Item 16 Page 5)
___ Blades swing freely
Tractor Mower Operation Inspection:
___ Using all Safety precautions, operate the Tractor and Mower unit for 30 minutes and
while the unit is running check the following items: Note! Only make adjustments after
the mower has been turned off and all motion has stopped and all hydraulic pressure
has been relieved.
___ No Hydraulic oil leaks at the hose connections
___ Operate the boom and mower head throughout its full range of motion and check
for hose's rubbing, pinching, or kinking.
___ Make sure the Return Filter Gauge is reading in the Green after Oil is warm.
___ Check the function of the Mower Head On-Off Valve and switch for proper function
___ Make sure that the tractor will not start with the mower on-off switch in the on
position.
___ Check the Blade Rotation for the Rotary Mower Head to make sure it is turning
Clockwise looking from the top of the mower deck.
___ Make sure the control valve boom movements agree with the valve operation decal.
___ Make Sure Boom Movement operates as expected and is smooth and under control
(no air in the control system)
___ Look for any unusual or excessive noise or vibrations.
___ Make sure all Wheel Weights are installed, Tires are Filled with liquid and Counter
Weight is installed
___ Make sure the left rear wheel of the tractor stays on the ground when the boom is
fully extended horizontally with 200 lbs. placed on the outside of the mower head.
Post-Operation Inspection:
___ Check that the oil in the hydraulic tank has not turned milky in color or has foam on top.
___ Check that there are no loose fasteners or hardware.
A-Boom (JD 6615/ 7615 Asy Instruction Manual) 07/03
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