VERSA BOOM VERSA BOOM. Assembly Instruction Manual. John Deere, Cab - 2/4 WD Tractor JD-7220, JD-7320, JD-7420 & JD-7520

Transcription

1 VERSA BOOM Assembly Instruction Manual Published Date Manual P/N John Deere, Cab - 2/4 WD Tractor JD-7220, JD-7320, JD-7420 & JD-7520 VERSA BOOM 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. ALAMO INDUSTRIAL 1502 E. Walnut Seguin, Texas Alamo Group Inc.

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3 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! WARRANTY INFORMATION: Read and understand the complete Warranty Statement found in this Manual. Fill out the Warranty Registration Form in full and return it to within 30 Days. Make certain the Serial Number of the Machine is recorded on the Warranty Card and on the Warranty Form that you retain.

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5 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 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 necessary. 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 has never gone out to look at the equipment and merely calls inquiring of the problems described to him by the operator or customer. Most calls received by Alamo Industrial Service can be classified into approx. 6 general categories. 1. Hydraulic or Mechanical Trouble Shooting. 2. Request for Technical Information or Specifications. 3. Mounting or Fitting Problem. 4. Special Service Problem. 5. Equipment Application Problems. 6. 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 Manual or Service Manual, many of these are available via the Alamo Industrial Internet site ( Attempt to diagnose or repair problem before calling. 2. If a call to Alamo Industrial is needed, Certain Information should be available and ready for the Alamo Industrial Service Staff. Such information as, Machine Model, Serial Number, Your Dealer 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 database of problems and related solutions, which will expedite a solution to future problems of a similar nature. 3. The technician may be asked to provide detailed information about the problem including the results of any required trouble shooting techniques. If the information is not available, 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 , Technical Service Dept. PH: Versa Boom (7220, 7320, 7420, 7520 Asy. Man.) 12/ Alamo Group Inc. 0-1

6 INDEX - VERSA BOOM ITEM PAGE NO. INDEX VERSA BOOM Introduction (Index Section) Index to 0-3 SECTION 1 Safety Section to 1-6 SECTION 2 General Information to 2-6 Assembly Area Preparation to 2-3 Tools Required and/or Recommended Recommended Hose End Torque Specifications Recommended Bolt Torque Specifications Warning, Danger And Caution Information SECTION 3 Wheel Weight Installation to 3-4 SECTION 4 Mainframe Installation to 4-17 Mainframe Component Identification Remove Tractor Components from Tractor Install Mounting Brackets to tractor to 4-4 Fit Versa Frame to Mounting Brackets to 4-6 Install Rear Axle Stabilizer Bracket to 4-8 Welding mounts to Versa Frame to 4-11 Hydraulic Tank & Install Tank Mounting Lugs Boom Installation to 4-13 Cutter Valve Installation to 4-17 Head Connection to 4-16 SECTION 5 Pump, Drive Shaft, Cylinder Control Valve & Cutter Valve Connections 5-1 to 5-8 Drive Shaft & Pump Component Identification to 5-3 Prepare Tractor Front Bolster Install Pulley Adapter Drive Shaft Universal Joint Timing Install Pump Mount Weldment to Tractor Install Drive Shaft, Shaft half & Tube Half to 5-6 Install Pump to Drive Shaft and to Pump Mount Weldment to 5-7 Pump And Drive Shaft Schematic Alamo Group Inc. 0-2 Continued Next Page

7 INDEX - VERSA BOOM ITEM PAGE NO. SECTION 6 (Standard Remote Handle / Cable Controls) Cylinder Control Valve to 6-12 Control Valve Mount Bracket Tractor Cab Preparation for Valve Handle / Cable Controls Handle / Cable Control Assembly Cable to Valve Installation Mounting Cylinder Control Valve to 6-7 Hydraulic Schematic Control Valve Hydraulic House / Cable Connections Wiring Harness Schematic Connect Wiring Harness Remote Cable control Installation SECTION 7 (Optional Remote Joystick Controls) Joystick Mounting to 7-14 Joystick Mounting Components to 7-6 Electrical Connections to Tractor Electrical Starter System Decal Installation for Joystick Option Wire Harness from Joystick to Valve to 7-10 Wiring Schematic, Bottom of Joystick Console Wiring Schematic, Wire Harness at Console Connection Control Valve Connections / Functions SECTION 8 Versa Mower Optional Heads to 8-6 Versa Flail Head to 8-3 Versa Ditcher Head to 8-4 Timber Cat Head X-Frame Square Head SECTION 9 Filling Hydraulic Tank & Initial Start-Up to 9-3 SECTION 10 Start-Up Instructions to 10-3 SECTION 11 Boom Rest & Swing Stop Lug to 11-3 Boom Rest Installation Boom Swing Stop Lug SECTION 12 Tractor Specifications & Component Identification to Versa Boom (7220, 7320, 7420, 7520 Asy. Man.) 12/ Alamo Group Inc. 0-3

8 NOTES 2004 Alamo Group Inc. 0-4

9 Section 1 SAFETY SECTION Versa Boom John Deere Tractor JD 7220, 7320, 7420, Alamo Group Inc. Section 1-1

10 SAFETY Read these assembly instructions through completely and understand them before proceeding with the assembly of the equipement. A safe and careful operator is the best operator. Safety is of primary importance to the manufacturer 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 assembling, 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! Serious injury or possible death! Decals are Black and Orange. DANGER! Imminent death/critical injury. Decals are Red and White. (SG-1) 2004 Alamo Group Inc. Section - 1-2

11 SAFETY PELIGRO! Si no lee Ingles, pida ayuda a alguien que si lo lea para que le 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) PELIGRO! Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. (SG-3) LEA EL INSTRUCTIVO!! WARNING! WARNING! DANGER! 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) 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) Never work under the Implement, the framework, or any lifted component 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) WARNING! Use caution and wear protective gloves when handling sharp objects such as blades, knives, and other cutting edges. Be alert to worn component surfaces which have sharp edges. Sharp surfaces can inflict severe laceration injuries if proper hand protection is not worn. (SG-37) 2004Alamo Group Inc. Section - 1-3

12 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! 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) 2004 Alamo Group Inc. Section - 1-4

13 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 Equipment use the Tractor flashing warning lights and follow all local traffic 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 expensive and its presence could present a hazard. Do not check for leaks with your hand! Use a piece of heavy paper or cardboard. Highpressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene. If oil does penetrate the skin, have the injury treated immediately by a physician knowledgeable and skilled in this procedure. (SG-15) WARNING! Always read carefully and comply fully with the manufacturers instructions when handling oil, solvents, cleansers, and any other chemical agent. (SG-22) DANGER! 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 maintained 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) 2004Alamo Group Inc. Section - 1-5

14 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 Implement, an operator on prescription or over-the-counter medication must consult a medical professional regarding any side effects of the medication 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! Operate the Tractor and/or Implement controls only while properly seated 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! 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) WARNING! Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Wash Hands after handling. (SG-31) WARNING! Use extreme caution when getting onto the Implement to perform repairs, maintenance and when removing accumulated material. Only stand on solid flat surfaces to ensure good footing. 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) WARNING! 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) WARNING! 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) 2004 Alamo Group Inc. Section - 1-6

15 Section 2 VERSA BOOM General Information John Deere Tractor JD 7220, 7320, 7420, Alamo Group Inc. Section - 2-1

16 General Information To help you assemble your new Versa and mount it to your tractor, we provide you with drawings, instructions and general information. When needed, you can get information or clarification from Alamo Group Customer Service or from engineering departments over the phone. This publication provides general information not specifically for your case or tractor, but, in connection with the drawings, this publication offers you some valuable assistance - please read it thoroughly. These mount kits are made for selected tractors with standard configurations. Only the noted options and tire sizes listed on the installation drawings will work with these mount kits. Other options, front axles, or different tire sizes may prevent the mount kit from fitting your non - standard tractor. Alamo Group cannot take responsibility for these problems or any modifications made to the unit. These instructions have been prepared to assist you in the correct procedure for mounting an Alamo Group A-Boom on your tractor. Throughout these instructions, references are made to right or left directions. Right and left are determined by sitting on the tractor seat and facing the direction of travel. This is the Safety-Alert symbol. When you see this symbol on your machine or in these instructions, be alert to the potential for personal injury. Follow recommended precautions for safe assembly and operating practices. DANGER! WARNING! CAUTION! A signal word - DANGER, WARNING, or CAUTION - is used with the Safety Alert symbol identifies the most serious hazards. Safety signs with signal word WARNING are typically used to point out more serious hazards. General precautions are listed on CAUTION safety sign. CAUTION also calls attention to safety messages in these instructions. NOTE: Included in the packing box of this unit is a replacement filter element for filter assembly in the tank. This mower unit's hydraulic components have been carefully cleaned and packaged at the factory to prevent contamination from entering the system. However, dust and dirt particles may enter into the sealed components through transportation, handling, rain or just sitting in a dirty or harsh environment. Therefore to assure that the hydraulic system is properly clean please adhere to the following procedure. 1. Prepare the area where the unit is to be assembled. The area should be on a hard concrete floor that has been swept clean of all dust and contaminants. Un-package the mower unit carefully so that the seals on the hydraulic components are not broken or pulled off. Lay out parts to make location easy. Figure 1 2. Inspect and clean all hydraulic hoses and fittings prior to installing them onto the tractor or mower. If dirt or material is seen in any of the parts, they should be washed and cleaned thoroughly with an oil-compatible solution. Do not blow the material further into a hose since this sometimes does not remove the foreign material and can cause damage to hydraulic components down stream Alamo Group Inc. Section - 2-2

17 General Information 3. Be sure your Mount Kit shipment agrees with the Installation Make certain that you have been sent the correct Mount Kit for your tractor. Make sure that all hydraulic fittings are not damaged or open to the elements, if any of the hydraulic components are contaminated do not use them until they are cleaned or replace them.. During Assembly or operation a damaged fitting could cause a leak severe enough to drain the hydraulic fluid and cause the Versa to fail. Versa Main Frame Packing Box The tools you will need at the assembly site are as follows: Versa Tank 1. A welding setup, including correct head gear, eye shields, and protective clothing. 2. Impact wrench or socket and ratchet set. 3. Rubber mallet. 4. Box-end, allen, and crescent wrenches. 5. Drift pins. 6. Phillips and straight-blade screwdrivers. 7. Forklift or hydraulic floor jacks with rolling back boards. 8. Small crane hoist or block-and-tackle. 9. Multidirectional Levels. 10. Paint Scraper. 11. Safety shoes, safety glasses, and gloves. A hard hat should be worn by anyone working under the crane hoist or block-and-tackle. 12. Hydraulic Filter Pump Cart. 13. Torque Wrench, 3/4 and 1/2 drive type. Remember to follow each step closely and cautiously. Be aware of all support personnel at all times. Keep the assembly area as clean as possible; clean up all spills when they occur. A safe assembly area and a crew that is sensitive to the dangers involved in putting this implement together will help protect lives. Keep all unauthorized personnel from the area. Do not assemble the Versa in an area where children play. Do not allow children near the assembly site nor allow them on or near the tractor after assembly. There is no safe place for anyone except the operator on the tractor and those helping with the assembly Alamo Group Inc. Section - 2-3

18 General Information RECOMMENDED TORQUE VALUES CHART: RECOMMENDED HOSE END TORQUE VALUES FOR 37 DEGREE ANGLE STEEL HOSE END FITTINGS DASH NOMINAL TORQUE VALUE* SIZE SIZE (IN.) (IN.LBS.) (FT.LBS.) -4 1/ / / / / / / * Straight threads do not always seal better when higher torques are used. Too much torque causes distortion and may lead to leakage. RECOMMENDED TORQUE VALUES CHART: RECOMMENDED TORQUE IN FT.-LBS. (Nm) COARSE AND FINE THREADS 2 (B) 5 (D) 8 (F) Bolt Plain Three Six Dia. Head Dashes Dashes 1/4" Not used 10 (14) 14 (19) 5/16" Not used 20 (27) 30 (41) 3/8" Not used 35 (47) 50 (68) 7/16" 35 (47) 55 (75) 80 (108) 1/2" 55 (75) 85 (115) 120 (163) 9/16" 75 (102) 130 (176) 175 (237) 5/8" 105 (142) 170 (230) 240 (325) 3/4" 185 (251) 300 (407) 425 (576) 7/8" 160 (217) 445 (603) 685 (929) 1" 250 (339) 670 (908) 1030 (1396) 1-1/8" 330 (447) 910 (1234) 1460 (1979) 1-1/4" 480 (651) 1250 (1695) 2060 (2793) 2004 Alamo Group Inc. Section - 2-4

19 General Information IMPORTANT: Change the return filter in tank and suction filters after the first 200 hours of operation. Change the filters again at 700 hours; then, change the oil and filters at 1600 hours. After that, continue to change the filter every 800 hours and the oil every 1600 hours. Hydraulic oil to be used is Universal Tractor Hydraulic. Use the above procedures as part of a good filter maintenance program. Between filter changes, monitor condition of filter by reading Pressure Gauge mounted on filter on top of the Tank. If pressure reads 15 psi or greater at 1800 RPM engine speed and normal operating temperature (140 deg. F. or greater), filter element should be changed. Pressure gauges are color-coded to help indicate when to change element. WARNING! CAUTION! Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard to search for leaks. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. To prevent personal injury, always wear SAFETY SHOES, SAFETY GLASSES, and GLOVES. A HARD HAT should be worn by anyone working under a Crane Hoist or Block-and Tackle. WARNING! When working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. Watch out for others. CAUTION! ALWAYS USE GLOVES WHEN HANDLING THE BLADES! Before re moving or installing blades, make sure that the head is leaned back past the vertical position. If the head is not, the blades can come off suddenly when the bolts are removed. WARNING! Block up or securely support components before working under or around lifted components. Inadvertent falling can cause serious injury or death. CAUTION! The operator should not leave his seat with this valve engaged or with the tractor engine running. Allow approximately 60 seconds for the blades to come to rest after turning the switch off before dismounting Alamo Group Inc. Section - 2-5

20 NOTES 2004 Alamo Group Inc. Section - 2-6

21 Section 3 VERSA BOOM Wheel Weight Installation John Deere Tractor JD 7220, 7320, 7420, Alamo Group Inc. Section 3-1

22 Rear Wheel Counter Weight Fill Left Rear Wheel with Liquid: The Left Rear Wheel must be filled with liguid. Alamo Industrial recommends a Calcium Cloride Water Mixture. The recommended Ratio of a 30 / 70 mix (30% Calcium Cloride and 70% Water), this mixture will add weight at about 10.5 lbs per gallon. Follow the Mixture procedures furnished by the Manufactured of the Brand of Calcium Cloride that you are useing. It is also recommended that a trained 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. 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 Item Part No. Qty Description Hex Head Bolt, 7/8" NC X 16" Wheel Weight Washer, Special Wheel Weight Casting, 1400 lbs. 4 5JRC 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 Alamo Group Inc. Section 3-2

23 Installing Wheel Weight 1. This Wheel Weight is 1400 lbs. Always use caution when working with it. 2. Locate the three Holes in LH Rear Wheel. Make sure these holes are 15/16" dia. if not, they must be reamed out. 3. Lift Left Rear Tractor Wheel till it just clears the ground. This will allow the Wheel to be rotated when aligning mounting holes for Weight. Rear Wheel Counter Weight 4. Using a forklift, lift Wheel Weight into Wheel. When Wheel Weight is centered in Wheel Secure Forklift and Set Parking Brake on Forklift. Insert one of the three bolts through Weight and Wheel (Rotate Wheel to align holes if needed). Install a Hex Lock Nut on 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 make sure the three special Washers (Figure 1 Item 2) are aligned with the Slots in the Wheel Weight. Tighten the three Bolts now. You will need an assistant to hold the other Side while you are tightening the Bolts. While tightening Bolts, check to make sure the three special washers are seated correctly. If these Bolts are tightened and washer are not seated into the recess on Wheel Weight, damage will occur. (See Figure 3) Figure 2 Wheel Special Weight Washers Mounting Part # Bolts (3) Wheel Weight Mntg Lock Nut Wheel Weight 1400 lbs. 6. Remove forklift away from Wheel and Weight. Re-check tightness of Wheel Weight retaining Bolts. Bolts should torque to 500 ft. lbs. Figure Alamo Group Inc. Section 3-3

24 Auxiliary Rear Wheel Counter Weight Installing Auxiliary Wheel Weight Kit. 1. The Auxiliary Wheel Weight is made up of three steel plates and mounting hardware. Each Auxiliary Weight weighs approx 136 lbs. When all three are installed on the existing 1400 lb. weight it will increase the wheel weight by 408 lbs. This makes the total bolt on wheel weights equal 1800 lbs. This will not include the amount of weight to the tire from the installed liquid which, will vary with the size of the tire and the liquid that is added. Auxiliary. Wheel Weight Kit No Qty Part No. Description Lockwasher, 7/8" Nut, 7/8" NC Bolt, 7/8"-NC X 5-1/2 GR Auxiliary Wheel Weight Plate, 136 lbs Each 2. Install Auxiliary Wheel Weights. The Auxiliary Wheel Weight bolt to the larger 1400 lb. wheel weight. There are two slots in the large weight that the 7/8" bolt heads will slide into. It is recommended that the tractor wheel is in position so these two slots has one facing front and one to the rear. Slide the two 7/8" bolts into the slots, the slots will prevent the heads of the bolts from turning. The Bolts in the large wheel weight will have to be aligned to the proper distance apart, to match the distance of the holes in the auxiliary weights. Slide the auxiliary weight over the two bolts, do this with all three weight for this kit. Install the lockwashers and hex nuts. Tighten the bolts to required tightness. See bolt torque charts in tractor preparation section. Wheel Weight P/N Figure 4 Auxillary Weight Attaching Stots Figure Alamo Group Inc. Section 3-4

25 Section 4 VERSA BOOM Mainframe & Boom Assembly John Deere Tractor JD 7220, 7320, 7420, Alamo Group Inc. Section 4-1

26 Versa Frame Installation 1 3 4, 5, 6 Tractor Frame (LH Side) 2 Inner Hyd. Tank Mounting Lugs Item Part No. Qty. Description Plate Side Support (LH or RH Side Same) Mount Angle, Tank Inner Mounts Versa Plate Mount, Weld On Bolt, Hex Head 3/4 -NC X 2-1/4 PL GR Lockwashers, 3/ Nut, heax 3/4 -NC PL Figure Alamo Group Inc. Section 4-2

27 Versa Frame Installation 1. Versa Frame Mounting Components. Shown in Figure 1 are the parts needed to mount the versa frame to the tractor. Follow instructions listed below and reference back to figure 1 as needed. Removed Tractor Parts that will not be used 2. Remove The factory Brackets. If there are factory mounting bracket on each side of the tractor which may be optional for mounting options on the tractor. They may have to be removed or they may not, check for any optional brackets that came with the tractor. Removed and not used. (See Figure 2) 3. Install RH Versa Frame Mounting Bracket. The bolt holes in the tractor frame will be used to mount the versa frame mounting brackets. The Mounting Bracket P/N (LH or RH ). The mounting brackets has an angle to them, make certain that they are mounted correctly. The RH Side of the Tractor is shown in Figure 2 & 3. The holes in the frame shows the two holes used to align the bracket (See Figure 3). When mounted the plate should slope to the rear (See Figure 4) on the RH side of tractor. Slide the bracket over the two bolts and start the nuts. The bolts will have to be put into the holes from the back side, this can be done by opening the engine access door right above the holes. Install the rest of the bolts and lockwashers on the bolt and tighten them. 4. Install LH Versa Frame Mounting Bracket. The LH frame mounting bracket will mount the same as the RH does (See Figure 5). The Bracket will angle toward the rear of the tractor and have a total of six bolt, lockwashers and nuts. Tighten these six (12 counting RH & LH Side) now to the required torque (See Bolt Torque Chart in Specifications Section). These 12 bolts will not need to be removed later so they can be tightened. Figure 2 Figure 3 Figure 4 RH Side of Tractor RH Side of Tractor 2004 Alamo Group Inc. Section 4-3

28 Versa Frame Installation 5. Install Versa Mounting Plate to Mounting Brackets. The mounting Plates (LH & RH side) will bolt to the mounting brackets using the six bolts on each side (use only 2 during the fitting process and it is best not to use locknuts). Bolt these plates to the outside of the mounting brackets on the RH side and to the inside on the LH side, (this is important for mounting after welding). Install 2 bolts and nuts (See Figure 8), snug them only as you will be removing them to weld frame after it is fitted (See Figure 6 & 7). 6. Check The Frame Mount Brackets & Frame Nounting Plates. It is very IMPORTANT that the frame mounting plates are bolted to the Frame mounting brackets correctly. Double check this now to be certain theyare. See figure 8 to make certain the RH side has mounting plate on the outside of mounting bracket, the LH side mounting plate is bolted to the inside of the frame mounting bracket. 7. Test Fit Versa Frame Under Tractor. The versa frame is slid under tractor from the Left hand side. Using floor jacks (or hoist) lift frame up under mounting plate till it fits as far to the front of plate as it will go (plate is curved downward in front. Make certain to have 9 distance from end of frame to the RH mounting plate (See Figure 8), the 9 distance is critical sa double check this before any welding. Once again make certain that the RH Mounting Plate is on the outside of frame bracket and the LH mounting plate is on the inside of the frame mounting bracke t (See Figure 8). This is important later after welding to ensure a fit.. Figure 5 LH Side of Tractor Figure 6 RH Side of Tractor Figure 8 LH Side of Tractor 2004 Alamo Group Inc. Section 4-4

29 Versa Frame Installation RH Side Look From front of tractor Frame Mounting Bracket RH Side Mounting Plate RH Side Frame Mounting Bracket LH Side Versa Frame Figure 8 9 Distance Mounting Plate LH Side 8. Leveling The Versa Frame. First Make certain the tractor itself is level, Make certain the tractor tires are the correct sizes and that they are aired to manufacturers recommendation. Keep in mind changing tires after mounting versa boom can change the level of the mower. The Versa Frame should be lower in the front by approximately 1/8 than in the back, this allows the mower to operate with the front of the mower a little lower than the rear. The versa frame must be out to the RH side from mounting plate by 9 (9-1/4 Max) As shown above (See Figure 8). Once the measurements are correct check the versa frame for level (See Figure 9). These level 2004 Alamo Group Inc. Figure 9 Section 4-5 Tack Weld Here Both Sides LH Side Shown checks can be done on the LH or the RH side using a bubble level (See Figure 9) if leveled correctly, recheck all measurements (See Figure 6). Do Not Tack weld the mount plates to the frame until all measurements and level has been checked, Make certain that the versa frame is square with the tractor frame. Tack welded to the Versa Frame lightly to secure it so as not to move. The Tack weld must be light enough that they can be broken loose if realignment is needed. DO NOT unbolt Versa frame (Mount Plates) from Frame Mounting Brackets yet.

30 Versa Frame Installation 9. Aligning Versa Frame with Mounting Brackets. The Versa Frame must be aligned with the mounting frame to where it will extend out past mounting plate 9 on the right hand front side as shown in Figure 8 & 10. This measurement is important and must be correct in order for mower to operate correctly. The Versa Frame should be lower in the front by approximately 1/8 than in the back, this allows the mower to operate with the front of the mower a little lower than the rear. Once the measurements are correct check the versa frame for level again. These level checks can be done on the LH side using a bubble level (See Figure 8) if leveled correctly then tack weld the versa frame to the mounting plate on both sides of the tractor, the tack welds need to be strong enough to hold the versa frame up. Recheck all measurements (See Figure 6). Make certain that the RH side (Shown) and the LH side mount plate is tack welded to the Versa Frame. The Tack weld must be sufficient enough to support the versa frame to the mounting plate when unbolted. 10. Tack weld Mount plates to Versa Frame. The mount plates should be tack welded to thr versa frame as instructed in step 8 & 9. Looking at RH Side from front of tractor Figure 10 RH Side Figure 11 Tack Weld Here, Both Sides 9 Tack Weld Here Tank Mounting Lugs to be welded to Versa Frame LH Side Front Of Tractor 11. Install Frame Stabilizer to Axle and Versa Frame. There is a stabilizer weldment (P/ N ) that connect to Versa Frame and tractor rear axle. Front of the stabilizer will bolt to a flat bracket (P/N ) that will be tack welded to the Versa Frame. Rear axle will keep the factory 3 point stabilizer bracket bolted back up below the stabilizer bracket. (See Figure 12). After bolting the flat stabilizer mounting bracket to the front of the stabilizer, tack weld it to the versa frame. (See Figure 12) DO NOT Remove Versa frame yet the Hydraulic Tank must be fitted to the Versa frame and the mounting tabs welded on to the versa frame (See Step 13 & Figure 14). Tractor 3 Point Stabilizer Stabilizer Weldment Figure 12 Tractor RH Axle Housing Flat Axle Mount Bracket 2004 Alamo Group Inc. Section 4-6

31 Versa Frame Installation 12. Pre-Fit Hydraulic Tank. Make certain that the Versa Frame has been tack welded to the mounting plate on the LH & RH side of Versa Frame (See Figure 9, 10 & 11). The Hydraulic Tank will need to be pre-fit to the Versa Frame. Using an over head hoist align the outside Tank Mounting holes in tank with the holes in the Versa Frame. Snug the two bolts of tank for the two outer holes. These holes are slotted so the tank can be moved forward or back to give Hydraulic tank and tractor components (Fuel Tank) clearance (See Figure 11 & 12). When you have sufficient clearance with the tractor components and hydraulic tank install the inner two tank mounting lugs to the Tank with the two bolts supplied. The Tank Mounting lugs will sit on the Versa Frame on the inside of the tank. Tack weld the lugs to the versa frame. Remove the Tank from the versa frame and set it aside for now (See Figure 11 & 14). The Tank Mounting Lugs can be welded now or wait until the versa frame is unbolted and removed. Figure 13 Figure 13A Rear Axle c cccccccccc cccccccccc Boom Frame c 3 Point Stablizer Item Part No. Qty. Description Plate, Stabilizer Strap Axle Stabilizer Weldment Rectagular Tube (2 X 4 X 52-1/2 Long) Axle Stabilizer Top Strap Weldment Axle Mount Plate Mount Angle, Upper Stabilizer Tube Mount Bolt, hex Head 3/4 -NC X 2 PL GR Lockwasher, 3/ Nut, Hex 3/4 -NC 2004 Alamo Group Inc. Section 4-7

32 Versa Frame Installation 13. Install the Versa Frame Step. The Versa Frame Step will be welded to the side of the versa frame (See Figure 15). Align the step to where it will not interfere with the tractor components and is accessible for the operator. Tack weld it to the versa frame, Some Models will not use this step as the tractors factory setep is retained and it is not needed. Even though the step may be sent it may not be needed. 14. Remove and Weld Versa Frame. The Versa frame will need to be unbolted and removed. This will allow for welding the mounting plates, tank mount lugs, the step and the axle stabilizer mounting bracket to the versa frame. The welds need to welded securely to the frame, weld both sides of the mounting components (See Figure 16). Touch up the paint around the welded areas while the versa frame is off the tractor. 15. Reinstall Welded Versa Frame. With all the mounting components welded to the versa frame, bolt the versa frame back onto the tractor. Make certain that the bolts are installed on both sides. There are six bolts on each side that mount the mounting plates to the tractor front & rearmount plates. (See Figure 17). Bolt the axle stabilizer weldment to the mounting bracket that was welded to the versa frame. (See Figure 14). Figure 14 Outer Tank Mounting Hoiles Figure 15 Inner Hyd. Tank Mounting Lugs Weld on Step 16. Torque the Mounting Bolts. The mounting bolts for the versa frame must be torqued to specifications, this will require a large torque wrench and two a person operation. See the Bolt Torque chart in the General information section of this manual or in the operators manual. It is recommended that the bolts be marked as they are torqued to show they have been done, this can be dome with a marker, paint or a method of your choice. (See Figure 18). Weld Here Figure 16 Weld Here Weld Here Weld Here 2004 Alamo Group Inc. Section 4-8

33 Versa Frame Installation 17. Mount Hydraulic Tank to Versa Frame. The hydraulic tank will be shipped fully assembled with the return filter, suction tube and fittings (See Figure 16). Using an over head hoist lift the tank to the tractor, use caution not to hit the tractor with the tank (See Figure 17). Lower the tank down onto the versa frame with the tank out away from the versa frame (See Figure 18) then push the tank inward toward the tractor until the inner mounting lugs align (See Figure 19). Install the inner mounting bolts and the outer mounting bolts into the tank, torque these mounting bolts to specifications (See Figure 20). 18. Install Boom Frame w/ King Post. The Boom frame will have the Kingpost welded to it from the factory (See Figure 29, 30 & 31). The boom Frame will slide into the versa frame and be retained by two long pins that are inserted from the front through the versa frame and the boom frame (See Figure 28). There are two large bolts that will be inserted into the upright of the boom frame and the upright of the versa frame (See Figure 27), these are located near the top on the RH side. One bolt in front and one in back. 19. Connect Boom to Boom Frame King Post. The boom will connect to the king post. You will need an overhead hoist for this (See Figure 27). Remove the Boom pivot pin from boom. Lower boom down over turning arm that is on top of the king post, align and reinstall pivot pin. Tighten the pivot pin retaining bolt. Using the hoist lower the boom down to the ground. The Boom will have the Cylinder hoses (except Swing & lift Cylinders) run through the boom (See Figure 28). The Motor Pressure and Return lines (Steel Tubes) are on the front side of boom, These lines will connect to the hoses from the cutter motor control valve block mounted on front of the boom frame front bottom RH side (See Figure 26, 29, 30 & 31). Figure 17 Figure 18 Figure Alamo Group Inc. Section 4-9

34 Versa Frame Installation Figure 20 Figure 21 Outer Tank Mounting Bolts Figure 22 Figure 23 Inner Tank Mounting Bolts 20. Install Upper Rear Axle Brace. The upper rear axle brace will consist of a plate with holes that will bolt to the lower rear axle brace on the RH rear axle. This plate will protrude to the front of the axle. There will be a piece of rectangular tubing with two holes in one end. The are L shaped brackets that will bolt to the tubing (on the boom frame end. These L shaped brackets should be bolted to the tube and the tube slid in on top of the plate with holes at the rear axle, tube should lay flat on plate. Tack weld the L brackets to the boom frame where they met the frame. Go to the rear axle and tack weld the rectangular tube to the axle plate. Once the tube, Plate and L shaped brackets ate tacked and straight they can be welded completely. (See Figure 26 & 28). The Axle Brace should already be bolted to the rear axle of tractor. The L Shaped brackets must be welded securely to the versa frame (lower Brace) and the boom frame (upper brace) Alamo Group Inc. Section 4-10

35 Versa Frame Installation Install Boom Frame retaining PinsRetaining Pin Figure 24 Figure 25 Axle Strap Upper Rear Axle brace Rectangular Tube L Shaped Brackets Rear Axle c Upper Brace Plate 1 1 cccccccccc cccccccccc Boom Frame c 3 Point Stablizer Figure 26 Lower Rear Axle Brace Channel Brace Lower Brace Lug 2004 Alamo Group Inc. Section 4-11

36 Versa Boom Installation 21. Cutter Valve. The cutter valve is mounted on the versa boom frame and should be already bolted on to it when it is shipped to you. If it is not then you will need to bolted it on. The mounting plates for the valve is attached to the versa boom frame on the RH side and to the front, the valves will bolt on to it but the valv emust be bolted on so the correct ports are facing the correct direction (See Figure 30) note that the releif is opointing toward the front of the tractor and the pressure line from the pump is right above that (See Figure25, 27, 32, 33, 34). 21. Connect the Motor Hoses to the Cutter Valve. The Motor has two hose connected to it. It is important to ID which hose is which through the sleeving as these hose must correctly be attach to the cutter valve and to the boom (See Figure 33, 34 & 35). The ports on the cutter motor control valve are marked, the pressure port to motor will be marked M1, the return port from the motor will be marked M2. The two steel tubes on the boom are not marked, but they have two different ends on the steel tubes, the tube with the square 90 turn is the pressure tube (M1). The tube with the 90 bend in the tube itself is the return line (M2) (See Figure 35). If these hoses are connected backwards the only thing that will happen is the motor will turn in the wrong direction causing the blade to cut in the wrong direction. Make certain these hoses are in the sleeving material and the fitting are securely tightened at both ends. Large Retaining Bolts Figure 27 Figure 29 Figure Alamo Group Inc. Section 4-12

37 Versa Boom Installation Cylinder Control Valve Figure 31 Figure 32 Cutter Motor Control Valve Connect the Pressure Hose from Motor Here Pressure Hose To Motor (M1) Return Hose To Tank Connect the Return Hose from Motor Here Figure 33 Return Hose From Cylindr Control Valve Figure 34 Pressure Hose From Pump Return Hose From Motor (M2) Pressure Hose (M1 at Valve) Figure 35 Return Hose (M2 at Valve) 2004 Alamo Group Inc. Section 4-13

38 Versa Boom Installation 22. Connect the Head to the boom. Shown here is the rotary head option, it is listed as a reference to connecting the motor hoses (See Figure 36 to 39). Connect the head pivot pin through the hitch post and the boom, use a hoist to lift and position the boom (See Figure 36). Next install the lift cylinder lift link and lift link pin (See Figure 38) Rear of Mower Pressure Hose In connects to back of boom 23. Connect the Motor Hoses to the boom. The Motor has two hose connected to it and running to the boom. With the head positioned with the front of the mower (Door Side) facing the front (See Figure 36). The two mower head hoses can be connected. Looking at the boom there will be two steel caps screwed onto the fittings at the end os the boom (See Figure 37). On the mower head the hose at the rear is the pressure hose and the cap at the rear of the boom is the pressure fitting (See Figure 39). The hose at the front of the mower head is the return hose and the fitting (Capped fitting) at the front of the boom is the return fitting (See Figure 39). If these hoses are connected backwards the hoses may be damaged when head is folded into the upward position and the motor will run backwards. Looking down from top the cutter head and looking forward the motor and blades should rotate clockwise. Front of Mower Figure 36 Figure 37 Return Hose out connects to front of boom Return Hose out connects to front of boom Figure 38 Figure 39 Pressure Hose In connects to back of boom 2004 Alamo Group Inc. Section 4-14

39 Versa Boom Installation Boom Cylinders : Hoses 1. Hoses on Booms are shipped folded back inside Boom. Hoses must be pulled out and moved to clear, then routed in the end of Boom before installing Boom on the King Post (See Figure 2) 2. Pull the Lift Cylinder out to its full stroke, Boom to aid in the installation of the Lift arm (See Figure 40). When Pulling Cylinder Out, attach a Hose to the Rod end and lay the Hose in a drain pan. This will catch any Oil expelled when Cylinder is pulled out. Figure Attach the Rod end of the Lift Cylinder (7) to the Lift Section with Pin (8), Bolt (9) and Nut (10) (also see Parts Section on the Boom Assembly) (See Figure 3). 5. Attach the Swing Cylinder. The Swing Cylinder attaches to the King Post on the Rod End and to the High frame on the Butt end of cylinder, There are two holes on the High frame that cylinder can be connected to. The outer Hole is the one that cylinder pin should be put in for a rear swing A-Boom. A Forward Swing A-Boom is rare, majority wil be rear Swing (parks to the rear for Transport.) (See Figure 6 & 7). Note on Swing Cylinder Pins there is a washer that should be installed under cylinder on base end (See Figure 42) 6. Boom Lifting Lugs. There are two eyes welded to the boom that are installed on boom to aid in lifting boom, These can be used for mounting and/or changing heads (See Figure 43) Note: Additional support may be need at the end of the Boom to aid in installation. Approximate Lift pont Lifting Lugs welded on here 1 3,4,5,6 8,9, Figure Alamo Group Inc. Section 4-15

40 Boom Installation Versa Boom Installation Attach Swing Cylinder to King Post and High Frame Lifting Lugs welded on here Figure 42 Figure 43 Tank Hose Installation: 1. Check Hose Connection from Pump to Cylinder Control Valve. This will be the small hose connection on the RH side of the pump (See Figure 44) for this hose, this hose cannot be connected to Cyl. Control valve untill later. 2. Check Hose Connection from Cutter Valve to Motor. The Hose from the Cutter / Motor Control Valve runs down the Boom using Steel lines and Hoses (See Figure 44) 3. Check Hose Connection Return Hose from Motor to Cutter / Motor Control Valve. Connect the hose from the Motor return to the Cutter / Motor Control Valve (See Figure 44). 4. Check Return Hose from Cutter Valve to Tank. Connect the return hose from the Cutter / Motor Control valve to the Tank. (See Figure 40). This hose will run down under tractor to the left side. (See Figure 44, 45,46& 47) anfd then back up the LH side to the Tank. (See Figure 47). The return hose connects to the return Filter Housing (See Figure 20). 5. Check Return Pressure Gauge. The Return Pressure Gauge is a low Pressure Guage that displays uses in Green and Red Fields, Return should stay in the Green when Oil is warm and Tractor is running. Gauge may read in the red when oil is cold and engine RPM is run to high, RPM should be keep low untill the oil warms up. (See Figure 47) Alamo Group Inc. Section 4-16

41 Tank Hose Installation Pressure from Valve to Motor Return Hose To Tank Filter RH Side of Tractor Return Hose from Motor Figure 44 Pressure Hose from Return Hose Pump From Cyl. Valve Return Hose from cyl. control valve to cutter control valve Figure 45 Return Hose from Cutter Valve to Tank Tank Return Hose to Tank Return Filter Housing Figure 46 Return Hose from Cutter Valve to Tank LH Side of Tractor Figure 47 Return Hose Pressure Gauge 2004 Alamo Group Inc. Section 4-17

42 NOTES 2004 Alamo Group Inc. Section 4-18

43 Section 5 VERSA BOOM Front Pump & Drive Shaft Installation John Deere Tractor JD 7220, 7320, 7420, 7520 A-Boom (JD 6615 / 7615 Asy Instruction Manual) 07/ Alamo Group Inc. Section 5-1

44 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 precautions must be followed during the Assembly Process and before unit is ever started for the first time. 1. Tractor must be disabled to prevent accidental engine start and prevent daamge to components. 2. All Fittings, Hose, Cylinders, Tank must be kept plugged at all times, No part of the Hydraulic System can be left open at any time 3. All Tools, Work Area, Components and Workers Hands must remain Clean when working on any part of the Hydraulic System. 4. All components should be rechecked for tightness at least twice, Hose routing also double checked. Time Universal Joints Flange Yoke & Shaft End Tractor Engine Pulley 1.Pulley Adpater Use / Mounting Bolts & Washers (4 ea.) Clamp Yoke & Tube End 3. Driveline Asy Driveline Mounting Bolts Pump Pressure Ports (large port to motor, small port to cyl control valve supply 5. Pump Mount Plate Spacers (2) 7. Pump Mount Bolts & Washer (4) Pump Suction Port Figure Pump Mount Bolts & Washer Pump Mount Plate Bolts To Tractor Bolster 2004 Alamo Group Inc. Section 5-2

45 Pump / Drive Assembly Instructions Pump & Driveline Components: Item Part No. Qty. Description Pulley Adapter Bolt, Hex Head M10-P1.5 X 35MM PL GR Lockwasher, M A 1 Driveline Assembly Bolt, Hex Head 7/16 -NC X 1-1/4 GR Lockwasher, 7/ Spacer, Pump Mount (2 Hole) Pump Mount Plate Bolt, Hex Head M20-P2.5 X 60mm PL GR Lockwasher, 20mm Bolt, Hex Head 1/2-13NC X 1-1/2 GR Lockwasher, 1/ Pump & Fitting Asy. Installing Pump Drive Components: 1. Remove Front Cover (See Figure 2), Remove the 4 plastic plugs shown in figure 1 and discard them, they will not be needed. Remove the 2 Allen Head Cover Retaining Bolts. After removal, this front cover will not be used. The front Casting will have a Driveline Hole in it. (See Figure 3). This will be the same on 2 WD or 4 WD. Front Cover Front Cover Removed Plastic Plugs Figure 2 Cover Retaining Bolts (2) Pump Plate Mounting Holes Figure Alamo Group Inc. Section 5-3

46 Pump / Drive Assembly Instructions Installing Pump Drive Components: 2. Access to Crankshaft Pulley. The Factory Crankshaft Pulley will not need to be removed. The Pulley Adapter will be bolted to the Factory Crankshaft Pulley. 3. Install Pulley Adapter. The Pulley adapter to be used is a round plate with 4 threaded holes and four non-threaded holes in it. Notice this pulley adapter will not have a center hole in it (See Figure 4). The Non-treaded holes are used to mount the Adapter to the Pulley using bolts # (10mm 1.5 P X 35mm Gr.10.9) & Lockwasher # (10 mm). Do not use longer bolts to mount Pulley Adapter to Pulley than is supplied with mounting kit. 4. Driveshaft Assembly. The drive shaft is a two piece Assembly, an inner and outer shaft assembly (See Figure 5). The Shaft End has a four bolt flange yokes on it that connect to the Crankshaft Pulley Adapter. The Tube end has a splined clamp yoke on it that connects to the Pump. This Drive Shaft connects to the Pulley Adapter. Note that the Universals of the Driveshaft are in time. When installed in tractor they should be in time as shown, both Yokes the same. 4 Non-Threaded Holes Figure 4 Splined Clamp Yoke / Tube End Figure 5 4 Threaded Holes Pulley Adapter Part # Flange Yoke / Shaft End Drive Shaft Assembly 6. Install Shaft End of Driveline / Engine end. Install the Shaft 1/2 Assembly w/ Flanged Yoke into the Engine compartment of Tractor, install it from the LH front Side down and under radiator. (See Figure 6). This needs to be installed this way because the Flange Yoke will not go through the Crankshaft access hole in the front of the Tractor (See Figure 3). Bolt the Flange Yoke to the Pulley Adapter using the four 7/16" X 1-1/4" Bolts (Part # ), use the four Lock Washers (Part # ), put Locktite on the threads of the Bolts and install them into Pulley Adapter. To Tighten these four Bolts, use a long extension and go through the front Crankshaft Pulley access hole in front of Tractor. Do Not use bolts longer than 1-1/4" long, longer bolts will damage Crankshaft Pulley. Installing Pump Mount Plate & Tube End of Driveshaft: 1. Install Pump Mount Plate. Install Front Pump Plate # standard mount plate (See Figure 7) or # optional Pump Mount Plate w/ Pump Guard built on. (Not Shown) use the 2 Spacers on the JD 6615 Series, Do not install Pump Mount Plate without using these Spacers. The Spacers are for Tractor Hood Clearance. Insert the 4 bolts and lock washers into Pump Mount Plate and spacers (See Figure 7), tighten them to required Torque (See Bolt Torque Chart) Alamo Group Inc. Section 5-4

47 Pump / Drive Assembly Instructions Installing Pump Mount Plate & Tube End of Driveshaft: (Continued) 2. Driveline timing means the universal joints are both the same position when driveline half is slid together. If they are not timed, it will decrease the life of the universal joint and in some cases could cause a vibration. (See Figure 5 on previous page) 3. Install Tube End of Driveline / Pump End. Slide the Tube half of driveshaft through Pump Mount Plate and Tractor Crankshaft Access Hole (See Figure 8). You will have to align the Universals when doing this (time the Driveshaft). Slide the two together where the Universal are in time (See Figure 5 on previous page), this will help the driveshaft to operate smoothly. 4. Loosen Splined Clamp Yoke Retaining Bolts. Insert a bar through the Yoke to hold Driveshaft up and to help loosen the Bolts in the clamp Yoke (See Figure 10). This can be loosened with a hand Wrench or a Socket whichever is easier for you (See Figure 10). Some times it is easier to test fit the Tube End of Driveshaft to the Pump while the Pump is on the bench. Shaft 1/2 Assembly w/ Flanged Yoke Tractor Radiator Figure 6 Tractor Engine Left Hand front side of Tractor Spacer (2) Installing Pump: 1. Install Pump into Splined Clamp Yoke. Slide the Pump Splined Shaft into the Spline Clamp Yoke (See Figure 11). Leave the Bar stuck in through the Yoke as shown, this helps to stabilize the Yoke as you slide Shaft into the Yoke. Once Pump is slid into the Splined Yoke, keep the Pump supported; DO NOT let the Pump hang on the Yoke unsupported. 2. Pump / Driveshaft Yoke Gap Adjustment. After sliding Pump Shaft into Splined Clamp Yoke, the Pump and Yoke must be slid apart far enough to allow for a 1/16" to 1/8" Gap between them. The Yoke edge cannot touch the Pump Housing; it will damage the Housing and the Yoke if it does. This is a very critical adjustment (See Figure 12). 3. Tighten Clamp Yoke. After Gap between Yoke and Pump has been adjusted tighten the Bolts & Nuts on the Clamp Yoke (See Figure 12 & 13). Check Pump to Yoke Gap once more. Keep Pump Figure 7 Tube End of Driveshaft Splined Clamp Yoke Supported do not let it hang on Yoke. Figure 8 Standard Pump Mount Plate Shown Standard Pump Mount Plate Shown 2004 Alamo Group Inc. Section 5-5

48 Pump / Drive Assembly Instructions Bar to Hold Drive Shaft Bar to Hold Driveshaft Driveshaft, Spline Clamp Yoke End Figure 9 Loosen Clamp Yoke Bolt Figure 10 Bar to Hold Driveshaft Pump Assembly 1/16" to 1/8" Gap between Pump & Yoke (must) Splined Clamp Yoke Figure 11 Align Splines of Pump Shaft w/ Splines of Yoke Figure 12 Installing Pump: (continued) 5. Mount Pump to Pump Plate. Remove the Bar that is slid through the Driveshaft Yoke and push the Pump inward (See Figure 14). This will make the two piece Driveshaft slide together allowing the Pump to be pushed towards the tractor. Do this untill the Pump is against the Pump Plate (See Figure 15). 6. Install Pump Mounting Bolts. While holding in on the Pump (See Figure 15) start the two Pump Retaining Bolts. Make sure both Bolts are started well before you stop supporting pump. The Bolts should be snugged untill pump sits level before you stop supporting it (See Figure 16). Let go of the Pump, it may slide back some and leave a slight gap between Pump and Mounting Plate (See Figure 16). 7. Tightening Pump Mounting Bolts. There is a shoulder on Pump Flange that must line up through hole in Pump Mounting Plate (See Figure 14), if the Pump is slid back as in figure 14 try to push it inward untill it is against Pump Mount Plate as shown (See Figure 15). Slowly and alternating from Left to the Right side, tighten the Pump mounting bolts untill they are tight. DO NOT FORCE Pump through Pump Mount Plate, if it will not freely slide in check for a problem of some kind. Excess force could damage Pump Housing. (See Figure 16). Do Not remove any Plastic caps from Pump inlet or outlet at this time, keep all openings plugged and sealed to keep them clean Alamo Group Inc. Section 5-6

49 Pump / Drive Assembly Instructions Gap? Check, this must have a gap between Pump & drivesahft Figure 13 Figure 14 Figure 15 Pump Retaining Bolts (2) Figure Alamo Group Inc. Section 5-7

50 NOTES 2004 Alamo Group Inc. Section 5-8

51 Section 6 VERSA BOOM Standard Cable Cylinder Control Valve Installation John Deere Tractor JD 7220, 7320, 7420, 7520 This section will not apply to the optional joystick control system, this section only applies to the handle / cable control system. See the optional Joystick control system section Alamo Group Inc. Section 6-1

52 Control Handle Assembly Installation : 1. Control Handle Mount is bolted to the right hand door post of Cab. There is a cup holder bolter to the door post that will be removed to bolt the bracket for valve controls. The cup holder will be reinstalled over the bracket (See Figure 1) 2. Install Cables Through Floor. Inspect under the floor and between floor mat and floor on the RH side of cab for any lines, wires or braces that might be under it. Using a 2" hole saw cut a hole through floor mat and floor in a place where saw will not hit anything on under side of floor. (See Figure 2). Before running cable through floor mark the cable on both ends with identifications (numbers or what you want) so the cables can be identified as to which is which from either end. Run the cables and wire harness through the hole that was cut in the floor and floor mat. 3. Install Boot over cables and wire harness. There is a boot that is in mount kit that will slide down over the cables and the wire harness. Make certain the cables and wire harness are inserted far enough into the cab to mount to remote control handles later after they are bolted to the mount bracket. The hole in this boot may have to be cut to get the cables and wire through it. (See Figure 3). Hole around cables through floor can be sealed under Mat by using a putty type calking sealer available at most hardware suppliers, this will keep moisture from getting under floor mat. 4. Control Handle Assembly. Remove the Cross- Screw from the bottom of the Control Handle Assembly. DO NOT remove the screws that fasten the two housings halves together (See Figure 4). 5. Threaded Plunger Rod. While holding the housing, fully shift the Handle in the Control Stick Assembly to expose the female-threaded end of the Plunger Rod (See Figure 5). 6. Threaded Cable End. While holding the Handle to expose the Plunger Rod, thread the Threaded Bead of the Cable into the end of the Plunger Rod and tighten securely. Release the Handle, allowing the Cable to pull into the Control Stick Assembly (See Figure 6). Cylinder Control Cables Cup Holder Bracket Figure 1 Figure Alamo Group Inc. Section 6-2 2" Hole Saw Figure 3 Control Handle Mount Bracket 7. Attach Cable To Plunger. Once Cable is attached to Plunger Rod, slide the silver Conduit Sleeve into the bottom of the Control Stick Assembly and align the groove in the Conduit Sleeve with the Cross- Screw Hole (See Figure 7)

53 Cylinder Control Cables 8. Reinstall Cross - Screw. Install the Cross- Screw and tighten securely. Work the Handle to make certain the cable is moving freely and not binding (See Figure 8). 9. Connect Control Handles to Cab Mount. The control handle assembly will be mounted to the cab mounting bracket with three bolts. These same three bolts will also mount the motor cut off switch mounting bracket. First insert the three bolts through the control stick for the Lift Cylinder operation. Second insert through the control stick for Tilt Cylinder control. Third insert the Cut off Switch mounting Bracket over the three bolts, The Motor cut off switch can be mounted else where if wanted, mounting here is recommendation (See Figure 9). The Cables will have to be adjusted to a center neutral position, this will be done at the control valve cable connection. NOTE: Thisd model tractor the RH Door does Not open from the factory and is bolted shut from the factory. Control Stick Assembly Threaded Plunger Rod Figure 4 Cross-Screw Figure 5 Threaded Cable End Cross-Screw Hole Cross-Screw Retaining Ring Cross-Screw Figure 6 Figure 7 Conduit Sleeve Figure 8 Figure Alamo Group Inc. Section 6-3

54 Cylinder Control Cables Cylinder Control Valve Cables To Valve Spools: The Remote Control Cables Connection to the valve and the Control Handle assembly. See Figure 10 for listing of items (1 thru 8 ) listed in assembly steps. 1 Remove the phillps head screws that are in the valve body next to the spool end (8). There are bolts in kit that will be used to replace these screws when needed (See Figure 10). 2. Slide the Bolt flange (8) 3. Thread NF jam nut entire length of threaded hub and onto the cable (7). 4. Place flange on sleeve and thread flange / sleeve assembly entire length of threaded hub and onto cable (2 & 6). 5. Thread NF jam nut onto cable threaded rod until it bottoms (3). 6. Place connector onto threaded rod and against jam nut. Align connector so it will mate with spool terminal and secure jam nut against connector (4). 7. Slide the connector onto spool and align the holes. Insert pin through connector and spool holes (5). The control cables will need to inserted through the floor of the tractor cab and the Control Levers will need to be assembled to the cables before continuing with the next assembly steps. 8. With cable attached to the valve and control levers, turn the flange / sleeve assembly onto the threaded hub until it is flush with the valve face. When turning the flange / sleeve assembly make certain that the control levers remains in the neutral position. 9. Tighten the NF jam nut against the sleeve to lock in position (6). 10. Bring flange into position and bolt assembly to valve housing. Tighten screws sufficiently to flatten lockwashers / secure flange (8). Caution, overtightening flange bolts will distort flange. Figure Alamo Group Inc. Section 6-4

55 Cylinder Control Cables 11. Cylinder Control Valve.The Cylinder control valve is shipped with the fittings already assembled to it. The control valve will be shipped un attached to anything (See Figure 11). The Control valve will bolt to the valve mount bracket using three mounting bolts (See Figure 12 & 13). The bracket will then bolt to the Versa Mount frame. Look on top of the versa frmae there will be a lug with two bolt holes weled to the versa frame. The valv emust be mounted in such a way thar the spools (where the Cables connect point toward the cab of the tractor. the fittings on the valve will point away from the tractor, this will allow you to stand facing the tractor and work on the valve and will keep the control cablse from making a 90 degree bend. (See Figure 13 & 14) 12. Adjust the Control Handles to a Neutral Position. The Handles can be adjusted to a neutral position by going to the control valve. Loosen the flange bolts and the jam nut at the top of the flange sleeve. Turn the flange sleeve and this will move the control handles. The will allow the control handles to be aligned evenly. Tighten the jam nut and flange bolts when the handles are adjusted to the desired position (See Figure 10) 13. Check the Three Retaining Bolts. The threaded portion of the three retaining bolts will stick out of ther nuts at the RH hand side of control handle mount, these can be cut off with a hack saw if desired (See Figure 9). Figure 11 Figure 12 Figure 13 Figure Alamo Group Inc. Section 6-5

56 Cylinder Control Valve Installation Cylinder Hydraulic Control Circuit: (See Figure 11 thru 21) 14. Hydraulic power for the cylinder control circuit is taken from the second (smaller) stage of the hydraulic pump. Oil is supplied through hose 2 to the four spool control valve where it is directed to the appropriate cylinder through the cylinder hoses. All of the cylinders are double acting. The system is protected from excessive pressure by an adjustable pressure relief valve located on the inlet section of the valve. The pressure relief valve is factory set at 2000 PSI for the booms. In addition, at least 3 individual cylinder circuits are protected by a non-adjustable work port relief valve (See Specifications in the Service repair Manual). 15. One way restrictors are added to the valve sections such that the return flow from the cylinders when performing gravity aided function will slow the flow of return oil and allow for a more controllable movement of the boom. (See the specifications for size of restriction and location in the Service repair Manual). 16. Oil is returned from the valve through Return hose to the Cutter / Motor Control valve where it then passes through Return hose into the return filter and into the tank. 17. The valve utilized on the Versa Boom mower to facilitate the control of the boom movement functions, open center, sectional, manually operated valve. The manual operation is performed with the use of normal directly attached valve handles or through the use of cables and remote mechanical levers. 18. Although similar in appearance, each valve section is specifically designed to perform the specified function for which it is assigned. The Valve is shipped assembled and should not be disassembled during unit assembly. 19. Hydraulic Cylinder Hoses. The Hoses for the Hydraulic Cylinders will be marked with bands that have the Part Numbers on them. These part numbers will vary with the size of the Boom Model. The 28 ft. model will have more hoses for the Boom Extend Function, the model with the Hydraulic Door on cutter head willhave more hoses. To find which Hose you have you will need to consult the Parts / Operators manual. When connecting the Hoses to The Valve use these numbers to connect the correct hoses to the correct ports. It may be required that you do some tracing of hoses to find which hose is hooked to which end of a Cylinder. Listed below is a list of which end of Hydraulic Cylinder should be connected to which Port on valve. (See Figure 2 & 3) MECHANICAL VALVE MODELS Cylinder Base End / Port Rod End / Port Tilt ("B") ("A") Standard Dipper ("B") ("A") Standard Lift ("A") ("B") Standard Swing ("A") ("B") Standard You must consult the Parts Manual to determine correct Hoses used on the Model you have. Also the type Head used will make the Hose vary. There is a Electrical control valve Option, this will make a difference of which hose is connected where. If the hoses are connected to the wrong side of valve it should not damage any thing, it will mean that the control lever function will be reversed or may not work at all because the Relief Valve is in the wrong direction of Oil Flow to operate.. Changing the Hoses on the hose ports of the valve will change this Alamo Group Inc. Section 6-6

57 Cylinder Control Cables Standard Control Valve Operation: 20. The Standard Tandem (Dual) Pump System is Shown, there is a Single Pump System Option available. The Single Pump only supplies the Hydraulics for the Cutter Head Motor and the Tractor Hydraulic System is used to supply the Boom Cylinder movements. The Schematic is very much the same except the Cylinder Control Valve Hose connections are run to and from the tractor instead of the way they are shown in the Schematic on the next page. (See System Schematic drawings for Pump Repair Section) Return Pressure One Way Restrictors "B' Side Ports Inlet Cover "A" Side Ports Handle Figure 15 Swing Lift Dipper Tilt End Cap 21. The Control valve will bolt on the top of the Frame on the right hand side. There is a tab welded to the Frame that has two holes in it, the Valve mount plate will bolt to this tab and the valve will bolt to mount plate (See Figure1 6) The Valve in Figure 6 shows the Hoses and Control Cables already connected, this is for illustration only. The Control Cables and Hoses are connected after the Valve is bolted to the mount plate. Most of the Hoses shown in figure 6 are running from the Boom. These Hoses must be connected to the correct Port on the valve and to the correct side to operate correctly. Cylinder Hydraulic Control Circuit: (See Figures 17) Figure 16 The Hydraulic Schematic above shows a 4 Spool System. When you assemble this you will not have to assemble the Valve, it will come to you already assembled as a 4 Spool valve assembly. Hoses must be connected to the correct Valve Port so the Control Funtions will operate in the correct direction (See Figure 18) 2004 Alamo Group Inc. Section 6-7

58 Cylinder Control Valve Schematic System Schematic (4 Spool Valve) Dipper Cylinder Tilt Cylinder Swing Cylinder Return Filter Hyd. Tank 12 Cyl. Control Valve A B A B A B A B Suction Hose Lift Cylinder Motor Pressure Hose M Cutter Valve M1 M Suction Hose Cyl Valve Return Hose M1 123 Motor Motor Return Hose M M2 Front Of Mower Figure 17 Motor Pressure Hose 2004 Alamo Group Inc. Section Pump (RH View) Cyl Valve Pressure Hose

59 Cylinder Control Cables Figure 18 Item Function 1 Return Hose From Cyl Valve to Cutter Valve ("A" Port) 2 Pressure Hose From Pump to Valve ("B" Port) 3 Swing Cylinder Base End ("A" Port) 4 Swing Cylinder Rod End ("B" Port) 5 Lift Cylinder Base End ("A" Port) 6 Lift Cylinder Rod End ("B" Port) 7 Dipper Cylinder Rod End ("A" Port) 8 Dipper Cylinder Base End ("B: Port) 9 Tilt Cylinder Rod End ("A" Port) 10 Tilt Cylinder Base End ("B" Port) 11 Swing Cylinder Control Cable 12 Lift Cylinder Control Calble 13 Dipper Cylinder Control Cable 14 Tilt Cylinder Control Cable 2004 Alamo Group Inc. Section 6-9

60 Emergency Stop Switch "ON - OFF" Schematic Black Blue Push/ Pull Switch Solenoid Cutter Valve 10Amp Spade Fuse Yellow or Orange Wire Red Wire Acc Service Wire Quick Splice Line Connector Red & White or White Wire Ign Acc Start Billet Terminal Tractor Starter Off Acc Figure 19 Tractor Ignition Switch 2004 Alamo Group Inc. Section 6-10

61 "ON - OFF" Switch Installation Wire Harness: (Standard Mechanical Valve) 1. Starter Safety Switch Schematic, Mechanical Cable Operated Valve Type, 2. Figure 4 illustrates a common wire harness connection for Versa Boom mowers with mechanical cable controls. 3. Individual installations may vary and are dependent on the electrical and safety system designs of the tractor to which the mower is mounted. 4. Consult the specific mounting instructions to determine the correct wire routing for each specific unit. To ID wires and components of tractor ignition system consult the tractor manufactures manuals. Common Problems: 1. The tractor won t start: The mower on/off switch, if left in the on position will not allow the tractor to restart. Be sure to push the switch into the off position and account for all the tractor safety interlocks to enable the tractor to start. Failure of the tractor starter safety lock system is normally attributed to a failure of the mower on/off switch. Check continuity at the switch. Check for loose connections. 2. Cutter motor won t start: Normal causes of this type of malfunction include failure of the push/pull switch, failure of the solenoid coil, loose connections, loss of ground, or a blown fuse. If the mower won t start, check continuity of the system with a test light to find an electrical problem. Problems may also exist in the cutter valve and other systems. 3. The problem may not be in the electrical system, but because there are so many connections that could be malfunctioning it is the best place to start checking. If the electrical connections are ok, go on to the Tractor connections and/or the Tractor components to check for the malfunction. Some times the service technician thinks the best way to eliminate the Mower electrical connection problem is to bypass them; this should never be done, eliminating the starter safety system is dangerous and hard on the Hydraulic System, The Hydraulic System will be trying to start at a low RPM which is not good. Standard Control Valve Operation: 1. This Control valve is the Standard 4 Spool that is remote cable Controlled, The 28 ft model used a 5 Spool valve with the 5 Th. Spool operating the Boom Extension. THIS SECTION WILL NOT apply to the OPTIONAL ELECTRONIC JOYSTICK CONTROLS. This Section mostly shows the 4 Spool Valve, The 5 Spool Valve is mainly the same with the 5 Spool operating the Hydraulic Door option on the Rotary head or the Boom Extension Cylinder on the 28-ft Model. (See Figure 5 & 6) 2004 Alamo Group Inc. Section 6-11

62 Cylinder Control Valve Installation REMOTE CABLE OPERATION AND INSTALLATION: 1. Remote operation of the boom movement control valve can be achieved with the use of cables and remote actuator handles. The remote operation system is standard equipment on cab tractor units and can be installed on ROPS tractors as well (See Figure 4). Four cable lengths are available and should be ordered based on the length required to reach from the valve to the Operator s location with out binding or kinking. Cable lengths are limited to 48,60,72 and 102 inches. 2. To install the cables to the valve, each valve section will require a cable installation kit (4 kits for a 4-spool valve.). Each individual valve connection kit can be ordered using part number Figure 4 displays the contents of each kit. Cables are not included in Cable Connection Kit Alamo Group Inc. Section 6-12

63 Section 7 VERSA-BOOM Optional Joystick - Wire Harness & Valve Installation John Deere Tractor JD 7220, 7320, 7420, Alamo Group Inc. Section 7-1

64 Optional Joystick Mounting Tractor Seat with Seat Cushion Removed Three Existing Holes FIGURE Item Part No. Qty Description Flatwasher, 3/8" Lockwasher, 3/8" Bolt, 3/8" NC X 1" Locknut, 5/16" Toplock Flatwasher, 5/16" Bolt, 5/16" NC X 1" Bracket, Seat Mounted Joystick Joystick (Shown as Illustration Only) Tractor Seat This mounting only applies tothe optional joystick control system and will not apply to the handle / cable control system 2004 Alamo Group Inc. Section 7-2

65 Installing Joystick Mount to Tractor Seat: 1. Remove Tractor Seat Cushion. Remove Lower Seat Cushion from Tractor Seat. The Seat Cushion should have three phillips head screws across the front edge (See Figure 2). Once these screws are removed, lift up on the front of the Seat Cushion which should slide forward and out. Option Joystick Mounting 2. Joystick Bracket mounting holes. The three mounting holes are already in the Standard Seat Mounting Plate. If a custom Seat or for some reason these three holes have to be drilled, use caution not to drill them in to where the bolts will interfere with the Tractor Seat Slide Adjustment Rail. FIGURE 2 3. Bolt Mounting Bracket to Seat. Insert the three 5/16" Bolts with Flatwashers on them through the holes in the Seat Plate (See Figure 4). The Mounting Bracket is under the Seat Plate as shown in the drawing. Install the three 5/16" Locknuts on the Bolts from the Bottom. Tighten the three Bolts and nuts. 4. Re-install Tractor Seat Cushion. Reinstall Tractor Seat Cushion in reverse of step 1. Test Seat to make Sure that it does not bind when slid forward or back as adjustment. If there is a Bind, check and correct problem. FIGURE 3 FIGURE 4 FIGURE Alamo Group Inc. Section 7-3

66 Joystick Mounting 2 WD & 4 WD InstallingJoystick to Bracket: 1. Bolt Joystick to Mounting Bracket. Set Joystick Assembly on Mounting Bracket. Make sure Joystick is mounted as shown, the Push Pull Switch in rear and Toggle Switch to the front. (See Figure 6) 2. Installing Joystick Mounting Bolts. Find the two 3/8" bolt, put Lockwasher and Flatwasher on them. Start these bolts from the bottom up through Bracket and into Joystick Console. The Joystick Console holes are threaded so no Nuts are needed. Tightened the two retaining Bolts (See Figure 1 Item 3 and Figure 2). FIGURE 6 Installing Wiring Harness for Joystick: 1. It is recommended that the Wires for Joystick be connected at the Tractor Ignition Switch. But they can be connected as explained below. If connected as shown below Wires must be traced to find the correct wires. 2. Preparing Tractor Floor Mat. First thing to do is remove the Battery Cables from Battery, Do Not perform any work on Tractor unless this has been done. Raise the Floor Mat up on the RH Side by the RH Door, You will need to fold it back approx. 12 to 14 inches (See Figure 8). DO NOT Tear or Cut any Holes in Floor Mat, as it will NOT be required. You will also find a large oblong shaped rubber plug, this will be pulled up later but it is not necessary at this time. 3. Tractor Wiring Harness. Under the Floor Mat on the right hand side you will find a Tractor Wiring Loom Running across Floor, remove the plastic cover that is over the wire loom. Using Tractor Manufacturers Service Manual Identify Which Wire is in this Loom. FIGURE 7 Wire Cover FIGURE Alamo Group Inc. Section 7-4

67 Installing Wiring Harness for Joystick: (Continued) Joystick Mounting 2 WD & 4 WD 4. Wires to be Connected. You will need to find the wire from the switch that activates the Starter Solenoid for the Tractor This wire will need to be cut to form 2 ends. You will need to locate the Ignition Switch Power Wire; this wire will have current only when Ignition Switch is on. This Wire will have a wire Tee d into it. (See Figure 9) 5. Wire Harness Through Cab. There is a large rubber plug in floor; this is where the Joystick wiring harness will be put through the cab floor. This plug can be pulled up through the floor (See Figure 10). it will be required to cut a hole in this plug for the Wire harness to run through. * FIGURE 9 Starter Wires 6. Insert it Wire harness through Floor Plug till the 4 wires that are not in the wire Harness are even with the Floor. The wires that are sticking out of harness will be run under Floor mat and under dash panel to switch or connected to the tractor harness. These wires are made long because of the different places they can be connected on various models. * * * * * 7. Connecting Harness Wires. There are 4 wires that must be connected inside Tractor. 1. Red Wire (power supply), 1 Black Wire (Ground) and 2 Brown Wires (Neutral Safety Switch). These will have to be spliced into Tractor circuits. (See Figure 13). FIGURE 10 Rubber Plug FIGURE 11 FIGURE Alamo Group Inc. Section 7-5

68 Joystick Mounting 2 WD & 4 WD Installing Wiring Harness to Joystick: (Continued) 8. Ground Wire. The Black wire at the harness (See Figure 11 and 13) can be connected inside the cab floor, or it can be run down through the floor and connected to the frame below the cab. If grounding to the Cab floor connect ground now. 9. Install Wiring Harness to Joystick. Pull the Wiring Harness up till it touches the bottom of the Joystick connection (See Figure 14). Align the Plug Guides (there are 1 wide and 2 narrow lugs) that prevent the plug from being installed wrong. Screw the plug retainer onto the Joystick Plug, this will be hand tightened. Battery ACC Wire Tractor Ignition Switch Joystick Wiring Harness Starter Brown Wire of Harness Red Wire of Harness Ignition Brown Wire of Harness Black Wire Ground Shown here is typical Ignition connection, Your Ignition may vary but the function will not. Tractor Ignition Wire Cut Tractor Starter Wire to Starter Solenoid and reroute through Joystick Harness Brown wires. FIGURE 13 FIGURE 14 FIGURE Reinstall Floor Mat. DO NOT cut Floor Mat. Make sure you have remounted the wire harness protector over wire harness under floor mat (See figure 8). Push the wire harness over against the side panel (See Figure 15). Put the floor mat down as it was originally. When finished floor mat should be as smooth as it was before installation Alamo Group Inc. Section 7-6

69 Joystick Mounting 2 WD & 4 WD Installing Warning and Instruction Decals: FIGURE Always clean windows before installing decals. Windows must be dry and free of any oil, after cleaning do not touch windows before decals are installed. Take precaution to make sure decals are right side up and straight when installing them, they cannot be taken off and redone. 2. Identify Decals. Lay all the Decals out and ID each one so you will know which is installed where. The Decals will have the Part Number on them in the lower corners. Decal No. Description Notice to Owner Important - Boom Rest Attention - Boom Swing Proper Engine Operating Warning - Hose Burst Multi - Hazard FIGURE Multi-Hazard - Danger Decal. This is installed on the Left Side Window of Cab on the inside to Drivers Left. (See Figure 16) 4. Warning Hose Burst Decal. This installs on the Right Side Window of Cab on the Inside to Drivers Right (See Figure 17) 5. Notice To Owner Decal. This installs on the inside top rear of Right Door Glass (See Figure 18) 6. Attention Boom Swing Decal. This installs on the inside top rear of Right Door Glass (See Figure 18) 7. Important Boom Rest Decal. This installs on the inside top rear of Right Door Glass (See Figure 18) FIGURE Proper Engine Operating Decal. This installs on the inside top rear of Right Door Glass (See Figure 18) Alamo Group Inc. Section 7-7

70 Wire Harness / Valve Mounting 2 WD & 4 WD Installing Wire Harness To Valve: 1. Wire Harness From Cab to Front. The wire harness runs out the bottom of the Cab on the right hand side. Run Harness along RH Frame rail of Tractor to the front of the Tractor (See Figure 19). Note the wire harness runs along with the hydraulic Hose from the Tractor Stack Valve to the front of the tractor. Do Not tie the Harness or Hoses to the Tractor frame rail at this time. 2. Wire Harness & Front Rail Support. The wire harness runs behind the front rail support on the RH side along side the hoses from the rear Tractor Stack valve. (See Figure 20). Do not tie any hoses or wire harness at this time. Run Wire Harness along the front RH side untill it reaches the front of the Tank (See Figure 21) 4. Gaskets on Valve Terminals. There are 5 wire terminals on Valve, A Gasket will have to installed on each one. These gaskets will only fit one way, there are 4 slots in gasket. 1 Slot is wider than the other 3, align these slots with correct terminal on Valve. (See Figure 22 & 23). These Gaskets must be used. FIGURE 19 FIGURE 20 Wire Harness runs along Tractor Frame Rails Run Wire Harness behind frame support Ph Wire Harness Plug Gaskets FIGURE 21 FIGURE Alamo Group Inc. Section 7-8

71 Wire Harness / Valve Mounting 2 WD & 4 WD PhoPht Installing Wire Harness To Valve: (Continued) 5. Wire Harness Terminal Identification. The Wire Harness Terminal Plugs are marked in writing on the plug. Swing, Lift, Dipper, Tilt and Door terminal plugs (5 Total). The Valve terminals are in this same order starting at the bottom and coming up on the valve. You will need to have a short handle Phillips screwdriver for this. (See Figure 26). 6. Wire Harness Terminal Installation. You will need to feed wire harness under the fitting across tank (See Figure 24) lay the Plugs out in the Order they are to be installed starting at the bottom terminal. Plug Gaskets FIGURE Terminal Connections. Make sure that each terminal Plug on Valve has had the Gasket installed on it, then Install Swing Terminal and tighten Plug Retaining Screw. Continue this with all 5 plugs starting at the bottom and coming up (See Figure25) PLUG FUNCTION 1 Bottom Plug Swing Terminal 2 2 nd Plug Up Lift Terminal 3 3 rd Plug Up Dipper Terminal 4 4 th Plug Up Tilt Terminal 5 Top Plug Door Terminal Connect and tighten all 5 terminal plugs one at a time till all 5 are connected. (See Figure 26) Door Tilt Dipper Lift Swing Photo without Pump & Hoses shown for illustration only FIGURE 25 FIGURE 24 Short Handle Phillips Screwdriver FIGURE 26 Terminal Plugs 2004 Alamo Group Inc. Section 7-9

72 Wire Harness / Valve Mounting 2 WD & 4 WD Installing Wire Harness To Valve: (Continued) 8. Solenoid Lock Valve Connection. Solenoid Lock valve is mounted on the Valve Tilt Port on the RH Side (See Figure 27). Find the two wires in harness that has eye terminals on them. Connect them to the Solenoid Lock Valve (See Figure 27) 9. Servo Control Manifold Solenoid. Locate the last Plug in the harness. This Plug is a two wire self sealing push connector. the Control manifolds Solenoid is located on the top of the Pump and activates the Pump when engaged. (See Figure 28 and 29). NOT USED ON A-BOOM, Disregard this Section FIGURE 27 Solenoid Lock Valve 10. Wire Harness Completed. Pull the Wire harness back toward Cab to remove any excess slack, only enough to remove slack not to make Wire Harness tight. Do Not tie wire harness or hoses to Tractor Frame Rails Yet. Tying Wire Harness and Hose up out of way will be done later. The Wiring Schematic is shown in this book as a reference only, the wire harness will come to you assembled and ready to mount. The only wires that will have to be altered are the wires inside that connect to the existing Tractor Wires. These inside wires are intentionally left long so they can be cut as needed. None of the wires with the factory plugs will have to be cut. FIGURE 28 Servo Control Manifold Solenoid Plug 11. See the next two pages for Wiring Schematic, this is listed as reference only. Pin locations in schematic are actual pin locations in Plugs. Plugs are marked with the letters as shown. This schematic is listed to assist you in tracing wires through harness if needed. Do not change or modify the harness plugs in any way. Servo Control Manifold Solenoid FIGURE Alamo Group Inc. Section 7-10

73 Wht/Violet Ign Joystick Plug (Bottom of Joystick Console) Master Switch Grnd Dbl Trigger Switches Danfoss Command Circuit (Joystick) B J D C K + Positive B Z-Output Wht/Blk D B X X X 2 5 B Joystick w/ Push/Pull Motor Switch & Rocker Master Switch - Negatve Y-Output X-Output Wht/Red Violet Red Grey/Blk Rocker Switch 1 Org/Blk S 2 R Grn J D C K B T E G 3 Brn/Blk 4 N P 5 Yel 6 D 8 7 B FIGURE 30 Red X D Acc T Pwr Start Motor Relay Motor Push / Pull Switch With Momentary Start D 10 AMP Wide Notch (1) H J B K C L M Actual Pin Location IS SHOWN in this Illustration X W V G F A E D R P N Narrow Notch (2) U T S 2004 Alamo Group Inc. Section 7-11

74 Wire Harness (Joystick Console Plug to Valve) Actual Pin Location is Shown for Plug in this Illustration Narrow Notch (2) B (+) 12V D (-) Grnd K L Wire Harness Plug (New Style) J M Wide Notch (1) H C B N X D G A P W R E F V S U T FIGURE 31 Brn Brn T E G Start Solenoid Loop Piston Pump Solenoid H A R Blk Red Blk Blk Red Red Blk Red Blk Soleniod Lock Valve Red J L U C F V K M W R H S N X P Grnd Grnd Grnd Grnd Grnd SWING LIFT DIPPER TILT DOOR/ EXTEND 2004 Alamo Group Inc. Section 7-12

75 CONTROL VALVES: (See Figure 32) Control Valve - Electric / Hydraulic The Alamo A-Boom Optional Hydraulic Control Valve is an Electro-Hydraulic (Electric over Hydraulic) Valve. The Valve is designed to utilize Oil from the Tractors Hydraulic System. This is basically considered a Selector Valve. The Hydraulic Control Valve must be compatible with the type Tractor System being utilized. There is only one type System used, The Fixed Displacement (Open Center) Continuos Flow. Hydraulic Supply is from front Aux. Pump Pump Pressure Port Pressure Gauge Port 5 Spool Valve (Handles Shown as Illustration Only) FIGURE 32 P A A A A A B B B B B T Tank Return Port Inlet Section Swing Lift Dipper Tilt Door / Extend Starter Solenoid (Brown) Solenoid Lock Valve 1 H R Voltage Supply (Red) Ground (Black) Clamp Junction Box (Joystick) : Swing 2 : Lift 3 : Dipper 4 : Tilt 5 : Door / Extend Pump Solenoid Connector FIGURE Alamo Group Inc. Section 7-13

76 NOTES 2004 Alamo Group Inc. Section 7-14

77 Section 8 VERSA BOOM Head Installation (Optional Heads) John Deere Tractor JD 7220, 7320, 7420, 7520 Attention: Optional Versa Mower cannot be installed on Versa Boom without major frame modifications on JD 4 WD Models 2004 Alamo Group Inc. Section 8-1

78 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 boom Weldment with the Flail Axe Head Hitch Post. Insert special bolts (item 1 p/n and item 2 p/n ) into Boom Weldment and Hitch Post. Attach nuts (item 3 p/n and item 4 p/n ) to bolt and tighten securely. Note: Additional support may be needed at the end of the Boom to aid in installation. 2. Install Hoses p/n (#1) and p/n (#2) in positions shown. Fully extend and retract tilt cylinder and insure hoses do not bind or kink then secure fittings. Tighten any leaking Hydraulic Fittings. If fluid still leaks, loosen the fitting, apply a pipe thread compound to the end threads and tighten. Care must be taken when tightening can cause the fittings to crack and require replacement fittings. Use recommened hose end and torque values found in chart on page Warning, Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and mozzles which eject fluids under high pressure. Use a piece of cardboard to search for leaks. If any fluid under pressure is injected into the skin, it must be surgically removed withing a few hours by a doctor familiar with this type injury or gangrene may result. 4. Hoses should not interfere with mower operation such as being pinched, kinked or entering the cutter housing. The hoses may be twisted slightly. To hold them up and/or inward tighten the fitting once the proper location is found. * Note the position of hoses and fittings. It is important that they are installed as shown. Figure 1 Hose #1 45 Elbow ( ) Figure 2 Hose #1 ( ) Hose #2 ( ) Figure 3 Hose #1 Hose #2 90 Tube Elbow ( ) Hose # Alamo Group Inc. Section 8-2

79 Attaching Flail Head: Optional Mower Head Installation 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 and item 2 p/n ) into Boom Weldment and Hitch Post. Attach nuts (item 3 p/n and item 4 p/n ) to bolt and tighten securely. Note: Additional support may be needed at the end of the Boom to aid in installation. 2. Install Hoses Female - JX in position as shown, hand tighten. DO NOT start Tractor untill after filling Hyd Tank with Oil (See Filling Hyd Tank Section). Fully extend and retract tilt cylinder and insure hoses do not bind or kink then secure fittings. Tighten any leaking Hydraulic Fittings. If fluid still leaks, loosen the fitting, apply a pipe thread compound to the end threads and tighten (Do not allow Thread compond to get into Hydraulic system). Care must be taken when tightening, over tightening can cause the fittings to crack and require replacement fittings. Use recommened hose end and torque values found in chart in operators manual. 3. Warning, Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and mozzles which eject fluids under high pressure. Use a piece of cardboard to search for leaks. If any fluid under pressure is injected into the skin, it must be surgically removed withing a few hours by a doctor familiar with this type injury or gangrene may result. 4. Hoses should not interfere with mower operation such as being pinched, kinked or entering the cutter housing. The hoses may be twisted slightly. To hold them up and/or inward tighten the fitting once the proper location is found. * Note the position of hoses and fittings. It is important that they are installed as shown. Boom View "A" Female - JX & Male JX90 deg. Elbow # deg. Boom deg View "A" Figure Alamo Group Inc. Section 8-3

80 Optional Mower Head Installation Attaching Ditcher Head: 1. With a forklift or hoist, lower the Boom Weldment down in the Ditcher Head. Align the Boom Weldment with the Ditcher Head Hitch Post together. Insert special pins p/n into Boom Weldment and Hitch Post. Attach with washer P/N and roll pin P/N NOTE: Additional support may be needed at the end of the Boom to aid in installation. (See Figure 5). 2. Attach Hydraulic Hoses as illustrated (See Figure 69). Tighten all Hydraulic Fittings. Care must be taken when tightening Hydraulic Fittings. Over tightening can cause the fittings to crack and require replacement. Use recommended hose end torque values found in chart in operators manual.. 3. The motor for the Ditcher will operate in both directions. It is important to plumb the motor so that it rotates to deposit the spoil properly. The direction of rotation can be observed by standing behind the Ditcher Head, beside the right rear tire. If the Ditcher rotates 'clockwise' it is plumbed for forward rotation and the spoil will be deposited away from the tractor. If the Ditcher is the reverse design then the proper rotation is counter-clockwise when observed from the rear. Do Not try to reverse Ditcher from Rotation it was designed for, it will not work. The Forward and reverse Rotation Models do not use the same Blade Assembly. 4. Note: The two hoses (P/N ) connecting the main boom to dipper arm are used to connect the Ditcher motor. The 90 degree fittings attach to the fittings on the main boom and the straight fittings attach to the 90 degree fittings on the hydraulic motor. See Figure 69 below. See Note Figure 5 WARNING Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and mozzles which eject fluids under high pressure. Use a piece of cardboard to search for leaks. If ANY fluid under pressure is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Alamo Group Inc. Section 8-4

81 Attaching Timber Cat Head: Optional Mower Head Installation 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 inserting the pins. Attach the 90 elbow (Item 1) to the front port of the boom and position it so that it faces down. Attach the 90 end of the return hose (P/N ) to the fitting and attach the straight end to the 90 fitting (Item 2) on the flow divider (if it is not already connected). Attach the pressure hose (P/N ) to the rear port of the boom and attach the other end to the 90 elbow (Item 3) on the flow divider (if it is not already attached). (See Figure 6.) 2. Be sure the hoses are routed as shown in the figure and securly tighten all connections. Stop here and go to Hydraulic Oil Tank fill setion, DO NOT Start Tractor untill Hydraulic tank has been filled. Start tractor and move the head tilt through its motions and check for excessive twisting and bending. It may require many attempts to obtain the optimum hose connection position. Once achieved, start the tractor and position the head in a safe area for operation, if necessary, baracade the head to prevent any contact while it is being operated. This unit is dangerous - STAY AWAY - anytime the tractor is in operation! Turn on the head and bring the tractor engine up to normal operating speed (540 PTO RPM). Tighten any leaking hydraulic fittings. Caution, too much tightening can cause the fittings to crack and require replacement. Use recommended hose end torque valves found in the Maintenance Section. WARNING Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and mozzles which eject fluids under high pressure. Use a piece of cardboard to search for leaks. If ANY fluid under pressure is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Pressure Hose Boom 1 Return Hose 2 Flow Divider 3 Figure Alamo Group Inc. Section 8-5

82 Optional Mower Head Installation X-Frame Square Head Attachment: FIGURE With a forklift or hoist, lower the Boom Weldment down on the X-Frame Square Head. Align the Boom Weldment with the X-Frame Square Head Hitch Post. Insert special bolts 1" x 9" (item 1) and item 2, 3/4" x 5-1/2" into Boom Weldment and Hitch Post. Attach nuts 1" (item 3) and item 4, 3/4" to bolt and tighten securely. Note: Additional support may be needed at the end of the Boom to aid in installation. Figure 7. Figure 7 1,3 2,4 2. Connect the Pivot Hitch tomower as shown in Parts and Assembvly Manuals. (See Figure 8) 3. Connect Hoses to Mower Head. Connect Hoses as shown (See Figure 8 & 9) Boom to Mowers, Do Not Start tractor untill the hydraulic Tank has been filled, Go to Hydraulic Tank Fill Section now. After Oil has been fill Start Tractor and run the Hydraulic System through its funtions as outlined in the Oil Fill Section. NEVER Start Tractor without Oil in system (Oil level to Sight Glass) it will damage the Hydraulic System if you do. Figure 8 Figure 8 Figure Alamo Group Inc. Section 8-6

83 Section 9 VERSA BOOM Fill Hydraulic Tank John Deere Tractor JD 7220, 7320, 7420, Alamo Group Inc. Section 9-1

84 Fill Hydraulic Tank with Oil: Fill Hydraulic Tank 1. DO NOT START TRACTOR until you have filled Hydraulic Oil Tank to a level as shown in Sight Glass gauge and fill the Suction Hose to Pump with Oil (See Figure 6). 2. Remove Filler Cap. Remove Filler cap only when ready to fill hydraulic Tank with Oil. Do Not leave the Cap off and the system Open, always keep sytem closed when possible. Avoid any oil contamiantion. (See Figure 1) 3. Avoid Hydraulic Contamination by filtering the Hydraulic Oil while filling the Hydraulic Tank. Filter buggies or carts are commercially available for Hydraulic system clean-up and Oil transfer. These consist of high capacity filter, a Circulating Pump, a Drive Motor and hoses for connecting to the units hydraulic system. When adding Oil always use Clean new Oil from a sealed container, If you suspect the Oil of being contaminated don't use it. (See Figure 2 & 3). It is best to always use a filter system when adding even new oil. 4. When adding Oil in the field keeping it clean is critical, do not use dirting funnels or hoses. Do Not open Hydraulic tank or any contaners unless the openings have been cleaned first. The outside of the containers must be clean. If a windy dusty day do not fill and allow dirt to blow into oil. Always add Oil using a pump systemwith at least a 10 Micron filter system. (See Figure 4) FIGURE 1 FIGURE 2 FIGURE 3 FIGURE Alamo Group Inc. Section 9-2

85 Fill Hydraulic Tank Fill Hydraulic Tank with Oil: 5. Fill Tank. Fill the Hydraulic Tank (See Figure 4) Fill tank till the Oil is visable in the sight Gauge (See Figure 5 & 8). This will fill tank for the start but it will have to filled again later. 6. Fill Suction Hose with Oil. Remove the Suction Hose at the Tank (See Figure 6) and fill the hose with clean oil, THIS IS A MUST DO. The Suction Hose must be filled with Oil to prevent Dry strat up of Pump. Dry start up of PUMP will damage the Pump. After filling suction Hose reinstall it and tighten down Hose Clamp. (See Figure 7) Pressure Gauge Sight Gauge FIGURE 5 FIGURE 6 FIGURE 7 Sight Gauge Return Pressure Gauge Return Filter Suction Line Filler Cap FIGURE 8 FIGURE Alamo Group Inc. Section 9-3

86 NOTES 2004 Alamo Group Inc. Section 9-4

87 Section 10 VERSA BOOM Hydraulic Start-Up Procedures John Deere Tractor JD 7220, 7320, 7420, Alamo Group Inc. Section 10-1

88 Start-Up Procedures Start-up Instructions: 1. Read all safety instructions. Decals on the A-Boom warn you of particular and multiple Hazards. Many decals are attached close to part of the A-Boom where there is a possible hazard. Read and make sure you understand the safety messages before you operate the A- Boom. Keep all decals clean and readable. Replace lost or damaged decals. 2. Before operating, read all the safety and operating instructions in the Operator's Manuals for both the tractor and mower. 3. When the hydraulic tank has been filled, The Pump Suction Hose filled with Hydraulic Oil and the mower unit (Head) properly assembled, the unit should be started up. NOTE: Make sure that no materials, tools, or jacks have been left under the mower head. Make sure the front and rear of the mower are properly guarded to prevent any foreign objects from being thrown by the mower. All other workers should be kept a safe distance from the unit before the mower is started. 4. Start the tractor and idle at a slow engine speed until oil is being pumped. Check for any leaks, this is easiest with an assistant watching for leaks. Do not run if Oil is leaking. 5. Bleed the air out of all hydraulic cylinders one at a time by extending them to their full length. DO NOT SWING THE BOOM till last and you have gone to the Rest Stop and Support Section for instructions. 6. Engage the Cutter Control Valve at low engine rpm and run the mower slowly for a short period until all air is removed from the hoses. Keep all persons WELL CLEAR of mower since Blades can THROW OBJECTS with great velocity for a considerable distance! KEEP CLEAR! 7. Run the mower at a low tractor engine speed until the mower Hydraulic System gets the Air out off it. Operate at an engine speed that keeps the filter restriction gauge reading in the "Green Zone". With the hydraulic warm, bring the tractor speed up to normal operating speed. If the filter gauge reads in the red zone, stop the unit, release all hydraulic oil pressure, and Check the filter element in the tank mounted filter or any Hose that may be kinked. Restart the tractor and mower unit and again check the filter gauge (oil must still be hot). 8. If the filter gauge reads in the red when first started and does not drop as oil warms, then something is wrong, contaminants have been introduced into the hydraulic system or some thing connected wrong. You may need to repeat previous steps again until the gauge reads in the green. 9. Check the fluid level in the Hydraulic Tank and add oil if required. As the air has been forced out of the Cylinders and Hoses, it goes into the Hydraulic Tank and reduces the oil level. The Hydraulic Oil must be at least at the level of the Sight Gauge on the side of the Tank. 10. Basic trouble shooting guide for first start up. A. Electrical solenoid valve does not work - check wiring, possible faulty switch, possible faulty solenoid. B. Pump is making noise - check for obstruction in suction hose and tank suction assembly, check alignment of pump driveshaft. C. Cylinders will not raise - hoses from cylinder incorrectly connected to valve bank, pump not suppling oil. D. Cylinder rises slowly - hoses from cylinder incorrectly connected to valve bank, work port reliefs on valve bank set too low - replace as required. E. Filter reads in red - viscosity of oil too high - wait until oil heats up before checking filter gauge. If gauge reads in red even after unit is hot, then the filter must be replaced. 11. DO NOT put Boom in transport position without using extreme caution as the Boom Stop has not been installed. It cannot be installed until after the start-up has been done (See Next Section). Versa Boom (7220, 7320, 7420, 7520 Asy. Man.) 12/ Alamo Group Inc. Section 10-2

89 Post-Assembly Check List: 1. Is oil level in the tank even with the sight gauge on the tank? 2. Has the proper oil been used in the system? Proper oil is Universal Tractor Hydraulic. 3. Does Boom machine movement match operation decal - Swing, Lift, Dipper, Tilt? 4. Is control valve free and does not stick? 5. Are all hoses tight and do not leak? 6. Are all decals in place? See Safety Section in Manual for decal description and placement. 7. Does tractor pass Alamo Group Mower Stability Test? 8. Have all grease points been adequately greased? 9. Are all bolts tight? Post-Assembly Check List 10. Have all hoses been properly routed so that hoses do not kink or bend when boom is articulated through all motions? 11. Does starter lockout device work correctly on machine? Tractor should not start if mower switch is on. 12. Is swing cylinder pinned in correct hole? On rear-swing type machine cylinder should be pinned to outside hole. On front-swing type machine cylinder should be pinned in inside hole. 13. Is machine equipped with proper operator protection? Must have cage or cage panels. 14. Does mower operate when on/off switch is on? Stop when switch is off? 15. Is head rotation correct? On rotary heads (looking from the top of the deck) rotation should be clockwise so that debris will be thrown away from the tractor. On flails, rotation can be forward or reverse, but forward rotation is standard. 16. If furnishing a square head, are spindle housing bolts tight? Is spindle assembly tight? Are bolts that hold blade bar to spindle tight? Checked the lube level in spindle housing? 17. Does head operate smoothly at normal operating speed? Head should not vibrate excessively Alamo Group Inc. Section 10-3

90 NOTES Versa Boom (7220, 7320, 7420, 7520 Asy. Man.) 12/ Alamo Group Inc. Section 10-4

91 Section 11 VERSA BOOM Boom Rest & Swing Stop Installation John Deere Tractor JD 7220, 7320, 7420, Alamo Group Inc. Section 11-1

92 Boom Rest Boom Rest installation: 1. Boom rest Mounted. Boom rest should already be mounted and tighten down to Tractor from earlier assembly section (See Figure 1). At the top of the Boom rest there will be a Boom rest Plate bolted to Boom rest, this should be mounted out to the Far right side. (See Figure 2) 2. Boom Rest Transport Plate. There is a Boom Rest Hook plate welded to the boom from the factory. (See Figure 3). 3. Swinging Boom. Extreme caution must be used when swinging Boom, There is NO BOOM STOP INSTALLED and can not be installed till later. Slowly swing boom Up and back watching the Cab so as not to hit it with the Boom. Do nor raise Boom higher than the inner stop om Boom rest plate bolted to the top of the Boom rest. Swing Boom till it is aligned in Boom Rest. The Head should be in the folded position as you lower Boom (See Figure 3). 4. Slowly lower the Boom down into Boom Rest. You will need to take measurement on the Boom (See Figure 4) here and Mark the Boom so you can weld on the stop plate to Boom. The Height of the Boom when in the Boom Rest should not exceed 12 ft. 9 in. max. (See Figure 3). 5. Boom Swing Stop cannot be installed untill the boom is setting in the boom rest (See Figure 3). The Boom Stop will have to be welded on the versa frame behind the Lift Cylinder Lug on the king post. the purpose of this stop is to prevent the boom from hitting the cab when moving boom to transport position. Figure 1 Figure 2 Figure Alamo Group Inc. Section 11-2

93 Boom Swing Stop installation: Boom Swing Stop Installation 1. Position Boom Swing Stop Lug. BoomSwing Stop Log is used to prevent Boom from swinging back to far and hitting Cab. With Boom folded and restin on Boom Hook in Boom Rest Plate. Position the BoomSwing Stop on King Post Mount behond the Lift Cylinder Lug. (See Figure 10) This can be difficult to hold heare while you tack it, it is important that it be square and touch the Cylinder lug as shown. (See Figure 10). 2. Tack Weld Boom Swing Stop Lug. Tack Weld the Boom Swing Stop Lug to the King Post Mount (DO Not Weld to the King Post). (See Figure 11) Tack Wled the Lug secure enough that the Boom can be swung out to the side, this gives you more rome to weld on the Boom Swing Stop Lug completly(see Figure 12) 3. Weld Boom Swing Stop Lug Solid. After the Boom is swung out 90 deg. from tractor completly weld the Stop Lug to the King Post Mount on High frame (See Figure 12). Slowly swing th Boom inward to the Boom rest and make sure tha Boom cannot be swung in so far that it will hit the cab of tractor. This is a very critical step and must be done with extreme caution so as not to damage Cab of tractor. Boom Swing Stop Lug High Frame FIGURE 10 Tack Weld Boom Swing Stop King Post Lift Cyl Lug FIGURE 11 FIGURE 12 FIGURE Alamo Group Inc. Section 11-3

94 NOTES 2004 Alamo Group Inc. Section 11-4

95 Section 12 VERSA MOWER Component Identification John Deere Tractor JD 7220, 7320, 7420, 7520 NOTE: Parts listed in the hydraulic schematic pages are mosetly parts contained in other assemblies which may be components in mount kit or components in the basic boom assembly. If in doubt check Bills of Material listing for mount kits or the standard parts manual for basic components Alamo Group Inc. Section 12-1

96 Mount Kit / Tractor Specification John Deere 7220/7320/7420/7520 Cab/2&4wd Max Front Tire Efective Date: Max Rear Tire Mount Kits Versa-Boom Mt Kit (Cable Remote) Versa-Boom Mt Kit (Joystick Remote) Wheel Weight Adapters: 34" Flanged Rim " Flanged Rim " Rack & Pinion Rim Options: Lexan Door Kit Side Screen Kit Rear Screen Kit Pump Guard Kit Restriction Notes: 1. Mount kit designed for right hand, thru-hood exhaust. A-post exhausts may interfere with the boom and must be modified at the dealer/customer s expense. 2. Optional Electrohydraulic mount kit does not include a seat-mounted joystick due to the complicated seat design and/or multiple seat options. Instead, a bracket mounts on the corner post and positions the joystick comfortably near the seat and console. 3. If an optional wheel weight is desired, the order must include one of the wheel weight adapters above. 4. Notice that these mount kits can also be used on the John Deere 6615/ A Lexan window insert can not be installed with the rear screen due to the glass curvature. 6. The Versa side mount kit is rated for 2wd tractors only. It can only be utilized on a 4wd if the frame is shifted at least six inches to the right to allow head clearance with the front tire. This alteration would also necessitate the use of a frame extension on the left for proper oil reservoir installation. 7. The Right Hand Light will need to be removed and relocated to clear the boom when in the transprot position. Becasue of the different mounting on tractors this will need to be done by the dealer and/or customer at their exspense. Note some tractors do not have functioning RH doors from tractor manufacturer. If this the case the door lock fastener will be mounted with the same bollts as the lifght, if so this fastener will have to reinstalled to keep door secured. 8. Driveline must be installed with the universal joints timed to ensure long driveshaft life Alamo Group Inc. Section 12-2

97 Mount Kit / Tractor Specification See Note 1 See Note 1 RH Side Tractor Light See Note 3 See Note 7 Door Lock Bracket Light Bracket Time Universal Joints on Driveline See Note 7 See Note Alamo Group Inc. Section 12-3