Alamo John Deere 6615 User manual

© 2003 Alamo Group Inc.
ALAMO INDUSTRIAL
1502 E. Walnut
Seguin, Texas 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 properly
mounted to the tractor. Alamo Group is not responsible for modifications to the MountKit to
accommodatethesedifferences.
A-BOOM

TO THE OWNER/OPERATOR/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 chance of accidents.
BEFORE YOU START!! Read the safety messages on the implement and shown in your
manual. Observe the rules of safety and common sense!
WARRANTYINFORMATION:
ReadandunderstandthecompleteWarrantyStatementfoundinthisManual. FillouttheWarranty
RegistrationForminfullandreturnitwithin30Days. MakecertaintheSerialNumberoftheMachine
is recorded on the Warranty Card and on the Warranty Form that you retain. The use of "will-fit"
parts will void your warranty and can cause catastrophic failure with possible injury or death.

©2003Alamo Group Inc. Index-3
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
INTRODUCTION
ABOUT THIS MANUAL:
Theintentofthispublicationtoprovidethecompetenttechnicianwiththeinformationnecessary
to perform the CORRECT Assembly to the Alamo Industrial Product. This will, in turn provide for
complete customer satisfaction
ItishopedthattheinformationcontainedinthisandotherManualswillprovideenoughdetailto
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. Hydraulicor MechanicalTrouble Shooting.
2. Request for Technical Information or Specifications.
3. Mountingor FittingProblem.
4. Special Service Problem.
5. Equipment Application Problems.
6. Tractor Problem Inquiries.
HOW YOU CAN HELP:
Makesurethe callisnecessary! Most of thecallsreceived maynotbenecessary iftheDealer
Service Technician would do the following.
1. Check the Service Information at your Dealership provided by Alamo Industrial, This
wouldinclude,ServiceBulletins,InformationBulletins,PartsManuals,OperatorsManuals, Assembly
ManualorServiceManual,manyoftheseareavailableviatheAlamoIndustrialInternetsite(www.Alamo-
Industrial.Com). Attempt to diagnose or repair problem before calling.
2. IfacalltoAlamoIndustrialisneeded,CertainInformationshouldbeavailableandready
fortheAlamoIndustrialServiceStaff.Suchinformationas, MachineModel,SerialNumber,YourDealer
Name,YourAccountNumberandAnyotherinformationthatwillbeuseful. Thisinformationisvitalfor
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
©2003Alamo Group Inc. Index-4
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
WheelCounterWeightInstallation.................................................... 2-3
Section 3
FrontPumpDriveParts.....................................................................3-2
CrankshaftPulleyPreparation...........................................................3-3
PumpDriveshaftAssembly...............................................................3-3
PumpDriveshaftHalf, ShaftEnd.......................................................3-4
PumpMountPlate..............................................................................3-4 to 3-5
PumpDriveShaft, TubeEnd.............................................................3-5
PumpInstallation................................................................................3-5 to 3-6
FrameRailSupportInstallation......................................................... 3-7
Section 4
FrameRail 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
HydraulicTankCounterWeightInstallation...................................... 6-2
HydraulicTankOilLevelSightGauge............................................... 6-3
HydraulicTankDecalInstallation.......................................................6-3
CabDecalInstallation........................................................................6-4
INDEX -ASSEMBLY INSTRUCTION

©2003Alamo Group Inc. Index-5
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INDEX -ASSEMBLY INSTRUCTION
Page
Section 7
CutterMotorControlValve................................................................ 7-2
BoomInstallation /Boom Hoses....................................................... 7-2 to 7-3
Pump/TankHoseInstallation...........................................................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
ControlValveOperation(StandardMechanical)............................... 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
TractorIgnitionWireConnection....................................................... 9-6
Connect Wire Harness to Joystick....................................................9-6
TractorFloorMatre-Install.................................................................9-6
TractorCabDecalInstallation........................................................... 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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©2003Alamo Group Inc. Index-6
NOTES

SAFETY
SECTION
Safety Section 1-1
©2003AlamoGroupInc.

Safety Section - 2
SAFETY
© 2003Alamo Group Inc.
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
Readtheseassemblyinstructionsthroughcompletelyandunderstandthem
beforeproceedingwiththe assembly oftheequipement.
Asafeand carefuloperatoris thebestoperator. Safetyisofprimaryimportancetothemanufac-
turer and should be to the owner/operator. Most accidents can be avoided by being aware of
yourequipment,your surroundings,andobservingcertain precautions. The firstsectionofthis
manual includes a list of Safety Messages that, if followed, will help protect the operator and
bystandersfrominjury or death. Readandunderstandthese SafetyMessagesbeforeassem-
bling,operatingorservicing this Implement. Thisequipmentshouldonlybe operated bythose
personswhohaveread the Manual, whoareresponsibleandtrained, and whoknowhowtodo
sosafelyand responsibly.
TheSafetyAlertSymbolcombinedwithaSignalWord,asseenbelow,isusedthroughoutthis
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
Wordareintendedtowarntheowner/operatorofimpendinghazardsandthedegreeofpossible
injuryfacedwhenoperatingthisequipment..
CAUTION! ThelowestlevelofSafetyMessage;warnsofpossibleinjury. Decals
located on the Equipment with this Signal Word are Black and Yellow.
WARNING! Serious injury or possible death! Decals are Black and Orange.
DANGER! Imminentdeath/criticalinjury. DecalsareRedandWhite.(SG-1)
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.

Safety Section - 3
SAFETY
© 2003Alamo 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, 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!
WARNING! Performservice,repairsandlubricationaccordingtothemaintenancesection. Ensuretheunit
isproperlylubricatedasspecifiedinthelubricationscheduleandallboltsandnutsareproperly
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! 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! NeverworkundertheImplement,theframework,oranyliftedcompo-
nent unless the Implement is securely supported or blocked up to
preventsuddenorinadvertentfallingwhichcouldcauseseriousinjury
or even death. (SG-14)
WARNING! Usecautionandwearprotectivegloveswhenhandlingsharpobjectssuchasblades,knives,
andothercuttingedges. Bealerttoworncomponentsurfaceswhichhavesharpedges. Sharp
surfaces can inflict severe laceration injuries if proper hand protection is not worn. (SG-37)

Safety Section - 4
SAFETY
© 2003Alamo 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
lifttheheavypartsbyyourself.Gethelp from another employee or from
anoverheadcrane.
WARNING! The operator and all support personnel should wear hard hats,
safety shoes, safety glasses, and proper hearing protection at all
timesforprotectionfrominjuryincludinginjuryfromitemsthrownby
the equipment. (SG-16)
Alwayswearsafetyshoeswithsteeltoeswhenworkingonthisequipment.
Itisrecommendedthatthesafetyshoeshavemetatarsalguards.
When welding use Welding hood with the appropriate OSHA required
protectivelens,welding apron,andweldinggloves.
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)
DANGER! Never run the tractor engine in a closed building or without adequate
ventilation. The exhaust fumes can be hazardous to your health.
(SG-23)
WARNING!
WARNING!
WARNING!

Safety Section - 5
SAFETY
© 2003Alamo 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.
Thrownobjects coulddamge propertyorcauseseverebodilyinjurieseven
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)
DANGER! Do not operate this Equipment with hydraulic oil leaking. Oil is
expensiveanditspresencecouldpresentahazard. Donotcheckfor
leakswithyourhand! Useapieceofheavypaperorcardboard. High-
pressureoil 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)
WARNING! Always read carefully and comply fully with the manufacturers instruc-
tions when handling oil, solvents, cleansers, and any other chemical
agent. (SG-22)
DANGER! AllSafetyShields,GuardsandSafetydevicesincluding
(butnotlimitedto)-theDeflectors,ChainGuards,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
orbrokencomponents. Missing,broken,or wornitems
must be replaced at once to reduce the possibility of
injury or death from thrown objects, entanglement, or
blade contact. (SGM-3)
DANGER!

Safety Section - 6
SAFETY
© 2003Alamo 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 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! EngineExhaust, someofits constituents, andcertain vehicle
componentscontain or emitchemicalsknownto thestateof
Californiatocause cancerandbirthdefects or other
reproductiveharm. (SG-30)
WARNING! Batteryposts, terminalsand relatedaccessories contain lead
andleadcompounds, chemicals knowntothestateof Califor-
niatocause cancerandbirthdefects or otherreproductive
harm.Wash Handsafterhandling. (SG-31)
WARNING! Useextremecaution when getting onto the Implement to perform repairs, maintenance and
whenremovingaccumulatedmaterial. Onlystandonsolidflatsurfacestoensuregoodfooting.
Usealadderorraisedstandtoaccesshighspotswhichcannotbereachedfromgoundlevel.
Slipping and falling can cause serious injury or death. (SG-33)
WARNING! Avoidcontactwithhotsurfacesincludinghydraulicoiltanks,pumps,motors,valvesandhose
connections. Relieve hydraulic pressure before performing maintenance or repairs. Use
glovesandeyeprotectionwhenservicinghotcomponents. Contactwithahotsurfaceorfluid
can cause serious injury from burns or scalding. (SG-34)
WARNING! Avoidcontactwithhotsurfacesoftheengineormuffler. Useglovesandeyeprotectionwhen
servicing hot components. Contact with a hot surface or fluid can cause serious injury from
burns or scalding. (SG-38)

©2003Alamo 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

A-Boom (JD 6615/ 7615 Asy Instruction Manual) 07/03
©2003Alamo Group Inc. Section 1 - 2
Assembly
Tools, Supplies and Equipment Needed
Toolsthatarerecommended tocompletethisassembly.Therearenumberofdifferentways
to do things, some items are recommended to make assembly easier but may not be
required.
1. 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).
2. Compressed Air, Air must be filtered and dry. A Safety air nozzle for blowing out Hoses and
Fitting prior to assembly. (Required).
3. Complete Air Impact Sockets, 1/2" Drive and 3/4” drive (Recommended).
4. Torque Wrench, 400-ft lb. rating, can use a Torque Amplifier Wrench. (Required)
5. Complete Set of Hand Wrenches from 7/16" to 2" (Recommended).
6. Assortment of Screwdrivers, (Short ones and Long ones). (Required)
7. Electric Grinder or Air Grinder, Size according to needs (Required).
8. 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. FlameProof orflameretardant MaterialtoCover andprotectTractor finishandcomponents
during assembly. (Required)
11. A good fire Extinguisher on hand before any welding or grinding begins. (Required)
12. Clean dust free work area, clean Lint Free towels or wipes. Do not do any welding, use
compressedAir orlay outanycomponent unlessarea isclean. Material thesize ofa human
hair can contaminate the Hydraulic System (Required).
13. A place to keep all Components separate and clean untill ready for them (Recommended)
14. Electrical Butt connectors and Electrical Pliers. (Required)
15. Paint Scraper to remove Paint before welding. (Recommended)
16. Floor Jack, 2-1/2 Ton capacity (Required)
17. An asortment of large C-Clamps (Required)

©2003Alamo Group Inc. Section1 - 3
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
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.
----- Valveoperation plateis 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
©2003Alamo 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)
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.

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

©2003Alamo Group Inc. Section 2 - 1
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
A-BOOM
Wheel Weight
Installation
Section 2

A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
©2003Alamo 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 Locknut, Top Lock 7/8" NC
Note: some Older Units used a All Thread Rod with Hex Nuts Lock Nuts, with Flat Washer
and Lock washer. This was replaced with the Bolt Type shown above. These Bolt and Nut
combinations will replace the old All Thread type.
1
2
34
Rotate Washer to Match Bolt
Circle dia. and Washer fits into
Wheel Weight Slot.
Bolt is shown extra long in
drawing for illustration only
Figure 1
Fill Left Rear Wheel with Liquid:
TheLeftRear Wheelmustbefilledwithliguid.AlamoIndustrialrecommendsaCalciumCloride
WaterMixture. Therecommended Ratio ofa30/ 70mix(30%Calcium Cloride and70%Water),this
mixture will add weight at about 10.5 lbs per gallon. Follow the Mixture procedures furnished by the
ManufacturedoftheBrandofCalciumCloridethatyouareuseing.Itisalsorecommendedthatatrained
person installs the calcium Cloride. Calcium Cloride must be added in addition to the Steel Wheel
Wieght and the Counter Weight that hangs on the Left Side. It is Not recommended to use straight
Water in the Wheel as this would not provide protection against freezing. A 30/70 Calcium Cloride
Water mixture provides anti-freeze to approx -50 deg. F. below 0.

©2003Alamo Group Inc. Section 2 - 3
A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/03
Rear Wheel Counter Weight
Installing Wheel Weight
1. ThisWheelWeightis1400
lbs. Always use caution when
working with it.
2. Locate the three Holes in
LHRear Wheel.Make surethese
holes are 15/16" dia. if not, they
must be reamed out.
3. Lift Left Rear Tractor
Wheeltillitjustclearstheground.
This will allow the Wheel to be
rotated when aligning mounting
holes for Weight.
4. Using a forklift, lift Wheel
Weight into Wheel. When Wheel
Weight is centered in Wheel Se-
cureForkliftandSetParkingBrake
on Forklift. Insert one of the three
bolts through Weight and Wheel
(Rotate Wheel to align holes if
needed).InstallaHexLockNuton
inside. Insert the other two Bolts
through Weight and Wheel and
start the other two Locknuts. Do
not tighten yet. (See Figure 2)
5. Looking at the outside
makesurethethreespecialWash-
ers (Figure 1 Item 2) are aligned
withtheSlotsintheWheelWeight.
Tighten the three Bolts now. You
will need an assistant to hold the
otherSidewhileyouaretightening
the Bolts. While tightening Bolts,
checktomakesurethethreespe-
cialwashersareseatedcorrectly.
If these Bolts are tightened and
washer are not seated into the
recess on Wheel Weight, dam-
age will occur. (See Figure 3)
6. Remove forklift away from
Wheel and Weight. Re-check
tightnessof WheelWeight retain-
ing Bolts. Bolts should torque to
500 ft. lbs.
Wheel Weight
Mounting Bolts
(3)
Wheel Weight
1400 lbs.
Figure 3
Figure 2 Wheel Weight Mntg
Lock Nut
Special Washers
Part # 02971569