Assembly Instruction Manual John Deere 6615 and
ALAMO INDUSTRIAL
A-BOOM
TO THE OWNER/OPERATOR/DEALER
INTRODUCTION
HOW YOU CAN HELP
CONTACT ALAMO INDUSTRIAL
2003 Alamo Group Inc
INDEX - ASSEMBLY INSTRUCTION
Safety Section
Operation Safety
Section
INDEX - ASSEMBLY INSTRUCTION
Section
Section
Section
2003 Alamo Group Inc
Index
SAFETY SECTION
2003 Alamo Group Inc Safety Section
SAFETY
SAFETY
Safety Section
2003Alamo Group Inc
LEA EL INSTRUCTIVO
SAFETY
DANGER
SG-23
SAFETY
DANGER
been swept. The mower blade can throw objects several hundred feet
DANGER
SAFETY
Battery posts, terminals and related accessories contain lead
Engine Exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the state of
Section
A-BOOM
TOOL REQUIREMENTS AND PRE-DELIVERY INSPECTION CHECKLIST
2003 Alamo Group Inc
Assembly Tools, Supplies and Equipment Needed
2003 Alamo Group Inc
Assortment of Screwdrivers, Short ones and Long ones. Required
Paint Scraper to remove Paint before welding. Recommended
A-BOOM PRE-DELIVERY INSPECTION CHECKLIST
Saftey Equipment
Frame and Boom
Hydraulic System
Flail Mower Head
Tractor Mower Operation Inspection
Post-Operation Inspection
A-BOOM PRE-DELIVERY INSPECTION CHECKLIST
Tractor - Mower Component Location
For Check List
2003 Alamo Group Inc
Wheel Weight Installation
Section
A-BOOM
2003 Alamo Group Inc
Rear Wheel Counter Weight
Fill Left Rear Wheel with Liquid
2003 Alamo Group Inc
Description
Installing Wheel Weight
Rear Wheel Counter Weight
Wheel Weight Mntg
Wheel Weight
2003 Alamo Group Inc
A-Boom JD 6615 / 7615 Asy Instruction Manual 07/03
Section 2
Front Pump Drive Shaft Installation
A-Boom
Section
2003 Alamo Group Inc
Pump / Drive Assembly Instructions
Installing Pump, Pump Drive Components and Hydraulic Tank
Installing Pump Drive Components
2003 Alamo Group Inc
Pump / Drive Assembly Instructions
Installing Pump Drive Components
Drive Shaft Assembly
Alamo Group Inc
Installing Pump Drive Components continued
Installing Pump Mount Plate & Tube End of Driveshaft
Pump / Drive Assembly Instructions
Shaft 1/2 Assembly
Installing Pump Mount Plate & Tube End of Driveshaft continued
Installing Pump
Pump / Drive Assembly Instructions
Alamo Group Inc
Installing Pump continued
Pump / Drive Assembly Instructions
2003 Alamo Group Inc
See Figure
Install Front frame Rail Supports
Pump / Drive Assembly Instructions
Alamo Group Inc
2003 Alamo Group Inc
A-Boom JD 6615 / 7615 Asy Instruction Manual 07/03
Section
Frame Rail / High Frame Setup / Pre- Assembly Installation
Section
A-Boom
2003 Alamo Group Inc
Frame Rail Set Up
Frame Rail Pre-Assembly
2003 Alamo Group Inc
Frame Rail Installation
Frame Rail Pre-Assembly continued
Alamo Group Inc
Description
Frame Stiiffener Kit
Frame Rail Installation
Frame Rail Pre-Assembly continued
2003 Alamo Group Inc
High Frame Mounting Tube Componnets
Frame Rail Installation
Frame Rail Pre-Assembly continued
Alamo Group Inc
High Frame Installation
Frame Rail Pre-Assembly continued
2003 Alamo Group Inc
High Frame & King Post Asy
High Frame Installation
Pre-Installing Frame Rails
Frame Rail Installation
Frame Rail
Support Brackets
Pre-Installing Frame Rails continued
Frame Rail Installation
Alamo Group Inc
Front Frame Rail Mount Pad Front Frame Rail Support Mount
Frame Rail Installation
Pre-Installing Frame Rails continued
Rear Axle
2003 Alamo Group Inc
Frame Rail Installation
Pre-Installing Frame Rails continued
Alamo Group Inc
Stabilizer up against Gusset C-Clamps
Pre-Installing High Frame
Frame Rail Installation
2003 Alamo Group Inc
Front of
Pre-Installing High Frame continued
Frame Rail Installation
2003 Alamo Group Inc
24-1/2 Min height frame to Hood
Frame Rail Installation
Pre-Installing High Frame continued
2003 Alamo Group Inc
Pre-Install Mounting Tubes for High Frame continued
Frame Rail Installation
Alamo Group Inc
Item Part No
Frame Rail Installation
Pre-Install Mounting Tubes for High Frame continued
Frame
Rail
Tack Welding Frame Rails
places on
each side
Frame Rail Installation
Tack Welding Frame Rails continued
Frame Rail Installation
2003 Alamo Group Inc
Figure 31 - Item
Frame Rail Installation
Tack Welding Frame Rails continued
Alamo Group Inc
Corners of Angle
Frame Rail Installation
Tack Welding Frame Rails continued
2003 Alamo Group Inc
Tack Weld Here in 3 places on top and 3 places on bottom
Remove High Frame for Final Welding
Frame Rail Installation
Alamo Group Inc
Left Side of High Frame Mounting Tube Weld Solid all the way around
Remove High Frame for Welding
Frame Rail Installation
2003 Alamo Group Inc
Do Not Weld next to Bolt Holes, it will interfere Hex Heads of Bolts
Remove High Frame for Welding. Continued
Frame Rail Installation
Alamo Group Inc
Weld here on
2003 Alamo Group Inc
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Section 4
Frame Rail & High Frame Final Installation
Section
A-Boom
2003 Alamo Group Inc
Re-Install Frame Rails to Tractor
Front Mounting Pads
Frame Rail Mounting
Rear Axle Strap
Re-Install Frame Rails to Tractor continued
Frame Rail Installation
2003 Alamo Group Inc
Figure 5, 6
Frame Rail Installation 4 WD
Re-Install Frame Rails to Tractor continued
are installed
Install with Nuts on top and Bolt Heads on the bottom
Re-Install High Frame to Tractor
Frame Rail Installation 4 WD
2003 Alamo Group Inc
Aligning on the RH side between the front and rear angle mount
Re-Install High Frame to Tractor continued
Frame Rail Installation 4 WD
2003 Alamo Group Inc
See figure 20
Tighten LH & RH Side
Frame Rail Installation 4 WD
Re-Install High Frame to Tractor continued
Tighten LH & RH Side
Frame Rail Installation 4 WD
Re-Install High Frame to Tractor continued
2003 Alamo Group Inc
Hyd. Tank, CWT & Decal Final Installation
Section
A-Boom
2003 Alamo Group Inc
Hyd. Tank - CWT Installation
Hydraulic Tank Installation
Counter Weight Installation
LH Frame
Decal Installation
Tank Decal Installation
Tank Oil Level Sight Gauge
2003 Alamo Group Inc
Cab Decal Installation
Decal Installation
OFF Switch See Figure
2003 Alamo Group Inc
Boom Installation
Section
A-BOOM
2003 Alamo Group Inc
Boom Installation
Boom Installation / Boom Hoses
Cutter Motor Control Valve Asy
2003 Alamo Group Inc
Boom Installation
Boom Installation / Boom Hoses
Attach Swing
Cylinder to King
Hose Installation
Pump / Tank Hose Installation
Front of Tank Front of Tractor
2003 Alamo Group Inc
Pump / Tank Hose Installation continued
Hose Installation
Alamo Group Inc
See Figure
2003 Alamo Group Inc
A-Boom JD6615 / 7615 Asy Instruction Manual 07/03
Section 7
Cylinder Control Valve Installation
Section
A-BOOM
Standard
Cylinder Control Valve Installation
Handle Assembly Installation
Control
2003 Alamo Group Inc
ON - OFF Switch Installation
Start
Common Problems
Standard Control Valve Operation
ON - OFF Switch Installation
Wire Harness Standard Mechanical Valve
Standard Control Valve Operationcontinued
Cylinder Control Valve Installation
System Schematic
Cylinder Hydraulic Control Circuit See Figures 2
Cylinder Control Valve Installation
2003 Alamo Group Inc
Cylinder Hydraulic Control Circuit See Figure 2
Cylinder Control Valve Installation
Tilt
Dipper
REMOTE CABLE OPERATION AND INSTALLATION
Cylinder Hydraulic Control Circuit continued
Cylinder Control Valve Installation
MECHANICAL VALVE MODELS
Cylinder Control Valve Installation
Flange
REMOTE CABLE OPERATION AND INSTALLATION continued
Cylinder Control Valve Installation
2003 Alamo Group Inc
Control Assembly - Controller End
Installation Procedure
Cylinder Control Valve Installation
REMOTE CABLE OPERATION AND INSTALLATION continued
2003 Alamo Group Inc
A-Boom JD 6615 / 7615 Asy Instruction Manual 07/03
Section 8
Optional Joystick - Wire Harness & Valve Installation
Section
A-BOOM
2003 Alamo Group Inc
Optional Joystick Mounting
Cushion Removed
Three Existing Holes
Tractor Seat with Seat
Installing Joystick Mount to Trac- tor Seat
Option Joystick Mounting
Alamo Group Inc
InstallingJoystick to Bracket
Installing Wiring Harness for Joystick
Joystick Mounting 2 WD & 4 WD
Wire Cover
Installing Wiring Harness for Joystick Continued
Starter Wires
5. Wire Harness Through Cab. There is a
Joystick Mounting 2 WD & 4 WD
Installing Wiring Harness to Joystick
Ground Wire. The Black
wire at the harness See Figure
Install Wiring Harness to
Installing Warning and Instruction Decals
Joystick Mounting 2 WD & 4 WD
Alamo Group Inc
02967827
Wire Harness / Valve Mounting 2 WD & 4 WD
Installing Wire Harness To Valve
Wire Harness
Wire Harness runs along Tractor Frame Rails
Installing Wire Harness
Wire Harness / Valve Mounting 2 WD & 4 WD
Alamo Group Inc
To Valve Continued
Wire Harness / Valve Mounting 2 WD & 4 WD
Installing Wire Harness
2003 Alamo Group Inc
To Valve Continued
Joystick Plug Bottom of Joystick Console
Wire Harness Joystick Console Plug to Valve
Actual Pin Location is Shown for Plug in this Illustration
Control Valve - Electric / Hydraulic
2003 Alamo Group Inc
Section 9
Head Installation Optional Heads
Section
A-BOOM
2003 Alamo Group Inc
Optional Mower Head Installation
Attaching Flail-Axe Head
2003 Alamo Group Inc
Hose #1 Hose #2
Attaching Flail Head
Optional Mower Head Installation
2003 Alamo Group Inc
Attaching Ditcher Head
Optional Mower Head Installation
2003 Alamo Group Inc
2003 Alamo Group Inc
Section 10
X-Frame Square Head Attachment
Optional Mower Head Installation
2003 Alamo Group Inc
1,3 2,4
Fill Hydraulic Tank
Section
A-BOOM
Alamo Group Inc
Fill Hydraulic Tank
Fill Hydraulic Tank with Oil
2003 Alamo Group Inc
See Figure
Sight Gauge
Return Pressure Gauge
Return Filter
Suction Line
2003 Alamo Group Inc
A-Boom JD 6615 / 7615 Asy Instruction Manual 07/03
Section 11
Hydraulic Start-Up Procedures
Section
A-BOOM
2003 Alamo Group Inc
Start-up Instructions
2003 Alamo Group Inc
Post-Assembly Check List
Alamo Group Inc
2003 Alamo Group Inc
A-Boom JD 6615 / 7615 Asy Instruction Manual 07/03
Section 12
Boom Rest Plate and Boom Swing Stop Installation
Section
A-BOOM
2003 Alamo Group Inc
Boom Rest Plate & Hook Installation
Boom Rest Plate installation
Boom Rest Plate Axle Mounted Boom Rest
2003 Alamo Group Inc
Boom Marked Here
Boom Mark HereBolt on Boom Rest
Marked Here Boom Rest Hook C-Clamp
Boom Rest Plate & Hook Installation
Boom Swing Stop Installation
Boom Swing Stop installation
High Frame
King Post Lift Cyl Lug
2003 Alamo Group Inc
A-Boom JD 6615 / 7615 Asy Instruction Manual 07/03
Section 13
2003 Alamo Group Inc
A-Boom JD 6615 / 7615 Asy Instruction Manual 07/03
Section 13
Page
A-Boom JD 6615 & JD7615 Assembly Manual 2003 Edition P/N
2003 Alamo Group Inc
A-Boom JD 6615 Asy Instruction Manual 05/03