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