Page 3 - INTRODUCTION; CONTACT ALAMO INDUSTRIAL:
© 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 ...
Page 4 - INDEX - ASSEMBLY INSTRUCTION
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...
Page 6 - NOTES
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Index -6 NOTES
Page 8 - SAFETY
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 thembefore proceeding with the assembly of the equipement. A safe and careful operator is the best operator. Safety is of primary ...
Page 9 - READ
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 letraduzca las medidas de seguridad. (SG-3) PELIGRO! !LEA EL INSTRUCTIVO! READ , UNDERSTAND , and FOLLOW the following Safety Messages....
Page 13 - Section 1
© 2003 Alamo Group Inc. Section1 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM TOOL REQUIREMENTS AND PRE-DELIVERY INSPECTION CHECKLIST Section 1
Page 16 - Tractor Mower Operation Inspection:
A-Boom (JD 6615/ 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 1 - 4 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)...
Page 18 - Section 2
© 2003 Alamo Group Inc. Section 2 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Wheel Weight Installation Section 2
Page 19 - Rear Wheel Counter Weight; Figure 1; Fill Left Rear Wheel with Liquid:
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 2 - 2 Rear Wheel Counter Weight Item Part No. Qty 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 Loc...
Page 20 - Installing Wheel Weight; Figure 3
© 2003 Alamo Group Inc. Section 2 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Rear Wheel Counter Weight Installing Wheel Weight 1. This Wheel Weight is 1400 lbs. Always use caution whenworking with it. 2. Locate the three Holes in LH Rear Wheel. Make sure theseholes are 15/16" dia. ...
Page 22 - Section 3
© 2003 Alamo Group Inc. Section 3 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-Boom Front Pump & Drive Shaft Installation Section 3
Page 23 - Pump / Drive Assembly Instructions; Installing Pump, Pump Drive Components and Hydraulic Tank:; Installing Pump Drive Components:
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 3 - 2 Pump / Drive Assembly Instructions Installing Pump, Pump Drive Components and Hydraulic Tank: This Section covers the installation of Pump Drive Components, Pump Assembly and the Hydraulic Tank. Some precautio...
Page 26 - Installing Pump Mount Plate & Tube End of Driveshaft:
© 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 helploosen the Bolts in the clamp Yoke (See Figure 10).This can be loosened with a ha...
Page 27 - Pump / Drive Assembly Instructions
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) Installing Pump: (continued) 5 . Mount Pump to Pump Plate. Remove...
Page 28 - Install Front frame Rail Supports:
© 2003 Alamo Group Inc. Section 3 - 7 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Install Front frame Rail Supports: 1 . Remove Bolts from Tractor Frame Rails. Find the front most 4 Bolts in the TractorFrame Rail, There are 4 on the RH side and 4 onthe LH Side. DO NOT REMOVE THE BOLTSFROM B...
Page 30 - Section 4
© 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 Installation Section 4
Page 31 - Frame Rail Set Up
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 level...
Page 32 - Frame Rail Installation
© 2003 Alamo Group Inc. Section 4 - 3 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Installation 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 Righ...
Page 33 - Frame Stiiffener Kit; Figure 2
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 4 Frame Rail Installation 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 Supp...
Page 34 - High Frame Mounting Tube Componnets
© 2003 Alamo Group Inc. Section 4 - 5 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Installation 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 ...
Page 36 - High Frame Installation; High Frame & King Post Asy; Figure 5
© 2003 Alamo Group Inc. Section 4 - 7 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 High Frame Installation NOTE: 2 Wheel Drive HighFrame and 4 Wheel DriveFrame looks the same ex-cept King Post and Bracingis higher up. The 2 WheelDrive and the 4 Wheel DriveHigh Frames will not inter-change. Hig...
Page 37 - Figure 7
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 4 - 8 Frame Rail Installation 1. Lay Out Components in Display. It is helpful to lay out the component in as neat adisplay as possible. Lay out the Bolts accord-ing to size and length. Lay out the Nuts andwasher by ...
Page 38 - Figure 9
© 2003 Alamo Group Inc. Section 4 - 9 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Installation Pre-Installing Frame Rails: (continued) 4. Front Rail Mounting Pad. There are two of these Pads; one is used on the left andone on the right. These Pads are the sameso it will not matter ...
Page 44 - Pre-Install Mounting Tubes for High Frame:
© 2003 Alamo Group Inc. Section 4 - 15 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Installation 9. Install Mounting Tubes . Loosely bolt the Front Angle Mount end of Mounting Tube(See Figure 32). Slide 1 Mounting Tube in ontop of the Frame Rail on each side, the endthat has the Ang...
Page 46 - Tack Welding Frame Rails:
© 2003 Alamo Group Inc. Section 4 - 17 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Installation Tack Welding Frame Rails: 1. Tack Weld Frame Rails to Front Mount- ing Pads. Check to make sure that the Framerail is still aligned on front rail Mounting Pad,Frame Rail should not inter...
Page 48 - Tack Welding Frame Rails:
© 2003 Alamo Group Inc. Section 4 - 19 A-Boom(JD 6615/ 7615 Asy Instruction Manual) 07/03 Frame Rail Installation Tack Welding Frame Rails: (continued) 6. Tack Weld Front and Rear Angle Mounts. The Angle Mounts should be tackWelded to the Frame Rails in 4 places each.This works best by weld a tack W...
Page 54 - Section 5
© 2003 Alamo Group Inc. Section 5- 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-Boom Frame Rail & High Frame Final Installation Section 5
Page 58 - Frame Rail Installation 4 WD
© 2003 Alamo Group Inc. Section 5- 5 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Frame Rail Installation 4 WD Re-Install High Frame to Tractor: 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 Wel...
Page 62 - Final Installation; Section 6
© 2003 Alamo Group Inc. Section 6 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-Boom Hyd. Tank, CWT & Decal Final Installation Section 6
Page 64 - Decal Installation; Tank Oil Level Sight Gauge:; Tank Decal Installation:
© 2003 Alamo Group Inc. Section 6 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Decal Installation Tank 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 mayhave to have the Paint touched up, or repaintedcompletly. ...
Page 65 - Cab Decal Installation:
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 6 - 4 Decal Installation Cab Decal Installation: 1. Install Decals on Windows inside Cab There are 8 decals that need to be installed on Windows and insideCab of Tractor. Clean all surfaces before installingDecals. ...
Page 66 - Boom Installation
© 2003 Alamo Group Inc. Section 7 - 1 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Boom Installation Section 7
Page 67 - Cutter Motor Control Valve Asy:
A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 7 - 2 Boom Installation Cutter Motor Control Valve Asy: 1. Cutter Motor Control Valve Asy. Install the Cutter Motor Control Valve Asy to the LH side ofHigh Frame, it will not have the Hoses attached asshown, the Hose...
Page 68 - Figure 6
© 2003 Alamo Group Inc. Section 7 - 3 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 Boom Installation 4. Attach the Rod end of the Lift Cylinder (7) to the Lift Section with Pin (8), Bolt (9) andNut (10) (also see Parts Section on the BoomAssembly) (See Figure 3). 5. Attach the Swing Cylinder ...
Page 69 - Hose Installation; Front of Tractor; Figure 8
A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 7 - 4 Hose Installation Pump / Tank Hose Installation: 1. Suction Hose, Tank to Pump. The Suction hose connects to the front RH side of Tank (SeeFigure 8) and runs through a Hose Ring that iswelded to the frame Rail ...
Page 70 - Hose Installation
© 2003 Alamo Group Inc. Section 7 - 5 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 Hose Installation Pump / Tank 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,...
Page 72 - Standard; Cylinder Control; Section 8
© 2003 Alamo Group Inc. Section 8 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Standard Cylinder Control Valve Installation Section 8
Page 73 - Cylinder Control Valve Installation; Control Handle Assembly Installation :
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 8 - 2 Cylinder Control Valve Installation 1. The controller assemblies will be bolted together using a tie rod bolt. The controlhandles are the same and the cables are thesame, it is where they are connected to thec...
Page 74 - Figure 4
© 2003 Alamo Group Inc. A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Section 8 - 3 Start Off Ign A c c A c c Tractor Ignition Switch Push/ Pull Switch Tractor Starter R e d & White or White Wire Red Wire Yellow or Orange Wire 10Amp Spade Fuse Quick Splice A c c Service Wire Line Connecto...
Page 75 - Standard Control Valve Operation:
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 wir...
Page 77 - System Schematic; Cylinder Hydraulic Control Circuit:
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 8 - 6 Cylinder Control Valve Installation System Schematic (Typical 17' through 23' with 4 Spool Valve) 12 12 12 12 Filter Hyd. Tank Motor Control Valve Motor Return Motor Pressure M 1 M 2 Control Valve Tilt Cyl. Di...
Page 81 - REMOTE CABLE OPERATION AND INSTALLATION:
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 Eyeonto the cable end until it bottoms on the cable.Turn the eye to align with the spool end andsecure the jam nut ag...
Page 84 - Section 9
© 2003 Alamo Group Inc. Section 9 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Optional Joystick - Wire Harness & Valve Installation Section 9
Page 85 - Optional Joystick Mounting; FIGURE 1
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 00...
Page 86 - Option Joystick Mounting; FIGURE 2
© 2003 Alamo Group Inc. Section 9 - 3 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Option Joystick Mounting Installing Joystick Mount to Trac-tor Seat: 1. Remove Tractor Seat Cushion. Remove Lower Seat Cushion from Tractor Seat. The SeatCushion should have three phillips head screwsacross th...
Page 87 - InstallingJoystick to Bracket:; Joystick Mounting 2 WD & 4 WD
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 4 InstallingJoystick to Bracket: 1. Bolt Joystick to Mounting Bracket. Set Joystick Assembly on Mounting Bracket.Make sure Joystick is mounted as shown, thePush Pull Switch in rear and Toggle Switch tothe front....
Page 88 - FIGURE 9
© 2003 Alamo Group Inc. Section 9 - 5 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 Joystick Mounting 2 WD & 4 WD Installing Wiring Harnessfor Joystick: (Continued) 4. Wires to be Connected. You will need to find the wire from the switch that activates theStarter Solenoid for the Tractor ...
Page 91 - Wire Harness / Valve Mounting 2 WD & 4 WD
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 8 Ph Wire Harness / Valve Mounting 2 WD & 4 WD Installing Wire HarnessTo Valve: 1. Wire Harness From Cab to Front. The wire harness runs out the bottom of theCab on the right hand side. Run Harnessalong RH F...
Page 94 - Joystick Plug (Bottom of Joystick Console)
© 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 Viol...
Page 95 - Wire Harness (Joystick Console Plug to Valve)
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 9 - 12 Wire Harness (Joystick Console Plug to Valve) Wire Harness Plug (New Style) E G SWING LIFT DIPPER TILT DOOR/ EXTEND Piston Pump Solenoid Soleniod Lock Valve Start Solenoid Loop T H 1 2 3 Grnd X N A 1 2 3 Grnd...
Page 98 - Head Installation
© 2003 Alamo Group Inc. Section 10 - 1 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Head Installation (Optional Heads) Section 10
Page 99 - Optional Mower Head Installation
A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 10 - 2 Optional Mower Head Installation Attaching Flail-Axe Head: 1. With a Forklift or Hoist, lower the boom Weldment on the Flail Axe Head. Align the boomWeldment with the Flail Axe Head Hitch Post. In-sert special...
Page 100 - Attaching Flail Head:
© 2003 Alamo Group Inc. Section 10 - 3 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 Attaching Flail Head: 1. With a Forklift 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 00...
Page 101 - Attaching Ditcher Head:
A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 10 - 4 Optional Mower Head Installation Attaching Ditcher Head: WARNING Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten...
Page 102 - Attaching Timber Cat Head:
© 2003 Alamo Group Inc. Section 10 - 5 A-Boom (JD6615 / 7615 Asy Instruction Manual) 07/03 Optional Mower Head Installation Attaching Timber Cat Head: 1. Attach the Timber Cat Head to the boom using the pins included with the head. Be careful not to damage the pivot bushings in the boom when inserti...
Page 104 - Fill Hydraulic Tank
© 2003 Alamo Group Inc. Section 11 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Fill Hydraulic Tank Section 11
Page 105 - Fill Hydraulic Tank with Oil:
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 11 - 2 Fill Hydraulic Tank Fill Hydraulic Tank with Oil: 1. DO NOT START TRACTOR untill you have filled Hydraulic Oil Tank to a level asshown in Sight Glass gauge and fill the Suc-tion Hose to Pump with Oil. 2. Remo...
Page 108 - Procedures
© 2003 Alamo Group Inc. Section 12 - 1 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 A-BOOM Hydraulic Start-Up Procedures Section 12
Page 113 - Boom Rest Plate & Hook Installation; Boom Rest Plate installation:; FIGURE 3
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 13 - 2 Boom Rest Plate & Hook Installation Boom Rest Plate installation: 1. Boom rest Mounted. Boom rest should already be mounted and tighten down to Tractor fromearlier assembly section. At the top of the Boom...
Page 115 - Boom Swing Stop Installation; Boom Swing Stop installation:
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03 © 2003 Alamo Group Inc. Section 13 - 4 Boom Swing Stop Installation Boom Swing Stop installation: 1. Position Boom Swing Stop Lug. BoomSwing Stop Log is used to prevent Boom from swinging backto far and hitting Cab. With Boom folded and restin onB...
