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Maverick/JD-6615,6715

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1. 58 Inch SPE 4 5 by 9 Heat Treated Alloy Blade Bar o ERR En otacked 3 Leaf Blade Bar Size 1 1 4 Thick X 5 Wide Ea Leaf Blade Bar Material EE T1 Steel bottom amp HRFB Steel top amp Middle Blade NN EE ET 360 Deg Swing PRE High Carbon Alloy Steel Cutter Weight Approximate w Rotary HeadQ 950 Ibs Cutter Deck Opening amp Closing Hyd Operated Door Recommended Hydraulic Oil ISO AW Hyd Oil See decal below Fluid Cleanliness level ee ISO 16 14 11 ATTENTION 10 F 30F_ 40F F 70 90 110 sover AWISOVGSa DIDA AW ISO VG 46 H AW mors VG AT OAWUSO VE TET VG 100 The correct hydraulic fluid is dependent upon ambient temperature Refer to chart when selecting proper grade 02982828 Maverick John Deere 6615 6715 Asy Man 02 05 O 2005 Alamo Group Inc Section 1 3 SPECIFICATIONS MAVERICK 2 BOOM SPECIFICATIONS Boom Reach 24 Foot Boom iii Out 24 Boom Reach 30 Foot Boom iii Out 30 FAIS EEE Manufactured Box Sections go RE ate ee ease gael ev teers Chrome Plated Alloy ESS AE CNN Greasable Weight 24 BOOM 1250 Ibs Weight 30 ODA 1450 Ibs PN Tractor Axle Mounted DOOm MOD Io SL ne ROPS or CAB Tractor Optional 3 FILTRATION Control Valve Functions Control functions include All Hydraulic Cylinders used to manipulate the Maverick Boom The boom and frame cylinders a
2. C 12 Hose Suction Hose No Plastic Tie CI nn F EE T D 12 Hose Red Plastic Tie Lam LII G 20 Hose Suction Hose No Plastic Tie A ft 8 Hose Red Plastic Tie i L Hose ND Blue Plastic Tie i LI mw pe AC F En J i a j ge Y H 12 Hose 90 Elbow Orange Plastic Tie D 12 Hose Red Plastic Tie B 4 8 Hose G 4 20 Hose Blue Plastic Tie Suction Hose No Plastic Tie 4 Hose amp Tee Tank Return Blue Plastic Tie H 12 Hose Orange Plastic Tie F 44 Hose Figure 2 E 4 Hose 90 Elbow 90 Elbow Red Plastic Tie Blue Plastic Tie NOTE Hoses are not shown in drawing above this is for clarity The hose routing is for the hoses which connect from one point to the other Use the instructions and hose description listed to follow hose routing Some hoses will be connected later Boom hoses and valve hoses Example Hose A connects to one end marked A and the other end of hose connects to the other item marked A This is done with the other letters as well the hose must connect to the same letter markings on each end as in drawing Some hose will be marked with a colored plastic tie Some hose will have a straight fitting or a 90 fitting This is to allow hoses to be routed to where they clear other items when connecting hose put
3. 6 DO NOT let anyone attempt any testing or repairs unless they are an experienced and qualified technician Technicians must have proper tools gauges meters etc to perform proper diagnosis and or repairs 7 DO NOT perform any repairs with dirty tools or in dirty area When working on hydraulic components keeping system clean and free of contamination is important 8 DO NOT start or engage systemiftheoillevelis not atthe proper level or condition Never start or run unit low or out of oil 9 DO NOT install add any oil unless you know it is the correct type and the container is clean Make certain the oil is not contaminated with dirt or any liquid Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 1 2 SPECIFICATIONS MAVERICK CUTTING CIRCUIT SPECIFICATIONS Hyd Pump Speed Front Aux PUMpP 1950 RPM Hyd Motor FN 1220 RPM Hyd Motor RAR cc 199 HP Hyd Motor Rotation as viewed f Top of the Deck CW Clockwise Relief Valve Setting At Motor 4000 PSI Relief Valve Setting At Pump 8 0 4500 PSI Hyd Pump Flow Front Pump 1950 RPM 25 3 GPM Hyd Oil Operating Temperature 100 F Ambient 155 165 F Hyd Oil Filtration Discharge f Charge Pump 10 Micron FIV LE Ta qe cele TOT 17 1 2 Gal Hyd Motor Start Stop Time Approximate 6 Seconds Cutting Diameter Rotary Headq
4. BOOM ARM MOWER Assembly Instruction Manual JOHN DEERE JD 6415 JD 6420 JD 6615 JD 6715 JD 7220 JD 7320 JD 7420 JD 7520 Cab 2 WD 4 WD Published 02 05 Part No 02982434 ASSEMBLY MANUAL INDUSTRIAL Rm ld i LIUM i d nd E 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 oeguin Texas 78155 MEMBER OF THE ra ALAMO GROUP 2 1 0 3 19 1 48 0 2005 Alamo Group Inc ALWAYS ON THE CUTTING EDGE 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 YOUSTART Read the safety messages on the implement and shown in your manual Observe the rules of safety and common sense FAILING TO FOLLOW SAFETY MESSAGES AND OPERATING INSTRUCTIONS CAN CAUSE SERIOUS BODILY INJURY OR EVEN DEATH TO OPERATOR AND OTHERS IN THE AREA 2 NO RIDERS 3 USE SAFETY SHOES 4 BLOCK UP SECURELY NO CHILDREN OPERATORS
5. Fo 1 Hose 4 Connects here w Tee Fitting Connect to Base End Stabilizer Cyl G 02981433 1 Hose 20FJX 12FJX 24 Lg Pump to Suction Filter H 02981462 1 Hose 12FJX 12FJX 90 20 Lg w Org Tie Valve Return to Tank JO 1 Hose 16 w Red Tie Pressure from Pump to Motor Bottom Port K 1 Hose 16 w Orange Tie Oil Return from Motor Top Port L 0 1 Hose w Blue Tie Oil Return from Oil Cooler to Tank Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 12 Section 10 MAVERICK Fill Oil Tank Electronic Controls Setting John Deere Tractor JD 6615 Hydraulic Oil Installation 2 WD amp 4 WD Hydraulic Tank Filling 1 Filling With Recommended Hydraulic Oil The oil used MUST MEET the requirements as to type and cleanliness level THIS IS A MUST The oil must be type ISO Grade Hydraulic Oil w protection wear grade based on abient temperature See Decal Figure 4 The grade of oil will vary with the ambient twmperature The Fluid Cleanliness level MUST BE ISO 16 14 11 rating MAKE CERTAIN that the oil you are using meets this requirement If Oil does not test to cleanleness reguirement it will have to be filtered to clean it before installing it into the maverick hydraulic system NEVER install or add Oil that does not meet these stadand requirenments 2 Remove the Filler Cap and fill the Hydraulic Tank Make certain
6. Grn Wht Tie Swivel Lift Sect n 02981830 1 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Yel Tie Ext n Lift Sectn 02981831 1 Y MJ Z FJX Hose 6 6Md 6FJX 76 Lg Yel Wht Tie Ext n Lift Sect n 02981832 1 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Red Tie Tilt Litt Sect n 02981833 1 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Red Wht Tie Tilt Lift Sect n 02981834 1 Y MJ O FJX Hose 6 6MJ 6FJX 96 Lg Blu Tie Dipper Dipper Sectn 02981835 1 Y MJ P FJX Hose 6 6MJ 6FJX 96 Lg Blu Wht Tie Dipper Dipper Sectn 02981836 1 Z MJ R FJX Hose 6 6MJ 6FJX 88 Lg Yel Tie Ext n Dipper Sect n 02981837 1 Z MJ Q FIX Hose 6 6MJ 6FJX 88 Lg Yel Wht Tie Ext n Dipper Sect n 02981838 1 Z MJ V FJX Hose 4 AMJ AFJX 176 Lg Yel Tie Door Dipper Sectn 02981839 1 Z MJ U FJX Hose 4 AMJ AFJX 176 Lg Yel Wht Tie Door Dipper Sect n 02981840 1 Z MJ X FJX Hose 4 AMJ 4FJX 176 Lg Grn Tie Swivel Dipper Sectn 02981841 1 ZW W FJX Hose 4 AMJ 4FJX 176 Lg Grn Wht Tie Swivel Dipper Sectn 02981842 1 Z MJ T FJX Hose 6 6MJ 6FJX 176 Lg Red Tie Tilt Dipper Sectn 02981843 1 Z MJ S FJX Hose 6 6MJ 6FJX 176 Lg Red Wht Tie Tilt Dipper Sect n 02981846 1 C FJX F FJX Hose 416 16FJX 16FJX90 102 Lg Red Tie Motor P Lift Sectn 02981847 1 A FJX D FJX Hose 416 16FJX 16FJX90 102 Lg Org Tie Motor R Litt
7. Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some are Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attached to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose Always Check Hose Size Color Code amp Part Number See Figure 4 Boom Cylinder Circuit Hoses Color Tie Code Hose Size P Diverter Hyd Function Green G SAE 6 A Swing Back Rod End Green White G W SAE 6 B Swing Forward Base End Orange OR SAE 6 A Lift Down Rod End Orange White OR W SAE 6 B Lift Up Base End Blue B SAE 6 A Dipper In Rod End Blue White B W SAE 6 B Dipper Out Base End Yellow Y SAE 6 A Telescope In Rod End Yellow White Y W SAE 6 B Telescope Out Base End Red R SAE 6 B Head Tilt Up Rod End Red White R W SAE 6 A Head Tilt Down Base End Green G SAE 4 A P2 Control Valve tor Diverter valve Green White G W SAE 4 B P1 Control Valve to Diverter Valve Green G SAE 4 C4 Swivel CW Rod End Green White G W SAE 4 C1 Swivel CCW Base End Yellow y SAE 4 es G3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Moto
8. 1 4 in order to maintain an equilibrium between the Joystick signal and the feedback signal 5 Reaction time from the time the Joystick is moved until the Spool moves is approximately 300 milliseconds Trigger Dipper Telescope Ny Trigger Swivel Door Joystick Functions Push Buttons Only ij Top Left Swivel CW Trigger e Top Right Swivel CCW Bottom Left TitUp Lift Dipper Tele Botom Right Tilt Down Down D Up Out Push Button amp Trigger Switch Top Left Door Open Lift Dipper Tele 4 Top Right Door Close Down ln Handle Movement Push Front Lift Down Pull Back Lift Up Push Right Dipper Up Push Left Dipper Down Rotate Right Swing Back Rotate Left Swing Forward Trigger amp Handle Movement Push Right Telescope Out FIGURE 18 Push Left Telescope In The Joystick is P N 02981374 The Plug in connections are marked with numbers on the plastic plug The wires are solid color or a color with a stripe The Plugs should not fit but one way and that is by matching the codes on the plugs Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 12 Install Front Pump amp Tank Cover Install Front Pump amp Tank Cover 1 Install The Front Pump Tank Cover The front cover and tank cover are a bolt on part The hinges are made onto the cover and the other half of the hinges are made on the tank mount bracket There are
9. LOCKNUT 3 4 NC WASHER 3 4 20 MM HARDENED BOLT HEX HEAD 3 4 NC X 2 1 2 PL GR8 FLATWASHER 1 1 32 X 2 3 16 X 22 HARDENED BOLT HEX HEAD 3 4 NC X 3 1 2 PL GR8 BOLT HEX HEAD 3 4 10UNC X 2 PL GR8 BOLT LAG 5 16 X 2 PL GR5 LOCKWASHER 5 16 PL STD LOCKWASHER M10 SPRING BOLT HEX HEAD M20 P2 5 X 80MM PL GH10 9 BOLT HEX HEAD 1 8NC X 11 1 2 PL GR8 BOLT HEX HEAD 3 4 NC X 3 PL GH8 BOLT HEX HEAD 3 4 NC X 2 1 4 PL GR8 BOLT HEX HEAD M16 P2 0 X 30MM PL GR10 9 FLATWASHER 5 8 HARDENED BOLT HEX HEAD M20 P2 5 X 60MM PL GR10 9 BOLT HEX HEAD M10 P1 5 X 35MM PL GH10 9 BOLT HEX HEAD M10 P1 5 X 25MM PL GHR8 8 LOCKWASHER 5 8 Bolt Bag P N 0298239 is in Component Box P N 02982396 which is in Mount Kit P N 02982395 02971789 Wheel Weight Kit Consist of the following Item No Item O TROND Part No 02971789 02970758 02971569 02971791 02979603 00012200 00012300 Qty CO CO CO Description WHEEL WEIGHT KIT ITEMS 1 THROUGH 6 WHEEL WEIGHT 1400 LBS WASHER WHEEL WEIGHT DRAWING WHEEL WEIGHT INSTALLATION BOLT HEX HEAD 7 8 NC X 16 PL GR 8 4 OF THREAD LOCKWASHER 7 8 PL STD NUT HEX 7 8 NC Wheel Weight Kit PIN 02971789 is in Mount Kit P N 02982395 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 8 Mounting Component ID 24 ft Cab amp 2wd 02976671 Auxillary Wheel Weight Kit Consist of the following Item No
10. Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 5 Frame Installation 5 Install Center Frame Weldment The Center Frame Weldment has a front and a back side LH amp RH side The Center frame must be installed with the two openings See Figure 26 toward the front of the tractor These openings are to allow for the movement of the swing cylinders when moving the boom to the boom rest position IMPORTANT NOTE When bolting the center frame up to the front and rear frame mounting rails the bolts on the RH turret side must have the bolts installed from the bottom with the bolt heads on bottom under center under frame and the nuts on top See Figure 27 showing nuts on top The reason the nuts must be on top is so the bolts will not hit the swing cylinders when the turret assembly has been mounted The Bolts that are used to mount center frame are not the same lentgh The 8 bolts for the rear fame bracts bolts that face the rear of the tractor will be 3 4 X 3 1 2 long The other twelve bolts will be 3 4 X 2 1 4 long All 20 Bolts that at are used to mount center frame MUST have hardened flat washers install on both sides one under Bolt Head and one under Nut See Figure 26 amp 27 Using floor jacks or Fork lift position the center frame weldment up under the tractor See Figure 27 The center frame weldment will bolt to the front and rear mounting rails on both sides Make Certain to use hardened flatw
11. Out Base End Yellow Y SAE 6 A Telescope In Rod End Yellow White Y W SAE 6 B Telescope Out Base End Red R SAE 6 B Head Tilt Up Rod End Red White R W SAE 6 A Head Tilt Down Base End Green G SAE 4 A P2 Control Valve tor Diverter valve Green White G W SAE 4 B P1 Control Valve to Diverter Valve Green G SAE 4 C4 Swivel CW Rod End Green White G W SAE 4 C1 Swivel CCW Base End Yellow Y SAE 4 C3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Motor Circuit Hoses to Boom Connections Listed as reference Color Tie Code Hose Size Hyd Function Red R SAE 16 Pressure Flow to Motor Orange OR SAE 16 Return Flow From Motor Blue B SAE 8 Case Flow From Motor to Boom Blue B SAE 12 Case Flow at Boom to Tank Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 5 6 Hydraulic Hose Connections HYDRAULIC LOCK VALVE Head Tilt Function An Electric Solenoid Operated Hydraulic Lock Valve Figure 4 is incorporated in the Head Tilt Function to prevent excessive Head Lift Cylinder leak down during storage or transportation The Solenoid which operates this valve is normally inthe Locked position until Head Lowering function is actuated at Joystick When Joystick is actuated to lower Head an electric signal is sent to solenoid to open Loc
12. This is the Return hose from the motor upper connec tion at pump See Figure 20 Third is the 16 Hose with the blue plastic tie the middle connection at the boom See Figure 17 which is the case drain from the motor This hose connects to the Oil Cooler Fan Assembly which is mounted under tractor bolster behind hydraulic tank See Figure 19 There is a short 16 hose See Figure 19 which will not have a plastic tie on it that will connect to the oil cooler and then goes to the tank to a return port See Figure 20 13 Pump Hose Routing at Tank The hose routing at tank is shown as reference to the Pump hose routing which most of will already be connected when the tank and pump assembly is shipped from the factory All hoses that you must disconnect and re connect during pump and or tank assembly refer to this figure for the correct location of hose See Figure 21 DO NOT start tractor before all steps of the installation is completed if tractor is started damage to the hydraulic system will occur leeving Material for Hoses Hose From Boor Motor cena s Blue Pl ti Hose From Oil Cooler to Tank return No Plast E Jj fom RH Side G j E Tractor 47 No Tie oi Cooler to Tank Figure 20 amp Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 10 Hydraulic Tank Hose Routing J 16 Hose B 8 Hose Red Plastic Tie
13. bolts See Pump Schematic at beginning of this section Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 4 8 Section 5 MAVERICK Hydraulic Tank amp Control Valve Installation John Deere Tractor JD 6615 6715 Hydraulic Tank amp Control Valve Installation Hydraulic Tank and Control Valve installation This Section covers the installation of the Hydraulic Tank and Control Valve Assembly The Tank and valve are shipped as an assembly 1 Locate Tank and Valve Assembly this will need to be lifted with a hoist the front bumper weldment is welded to the front of the tank from the factory 2 All Tools Work Area Components and Workers Hands must remain Clean when working on any part of the Hydraulic System All hoses and fittings should remain plugged till ready to install them to keep them clean 3 All components should be rechecked for tightness and Hose routing also double checked Install Hydraulic Tank to Front of Tractor 1 Hydraulic Tank and Valve Assembly The Hydraulic Tank Control Valve and Pump are shipped together See Figure 1 The Pump should have already been mounted 2 Install Hydraulic Tank amp Control Valve Assembly Toinstallthe tank and valve assembly you should use an over head hoist to lift Tank and Valve Assembly as it is heavy and can be dam aged if dropped The hoist will also assist when aligning the mounting holes There are three mounting
14. ltem AOUN Part No 02976671 00012200 00012300 00760266 02976644 Qty 2 2 Description AUXILLIARY WHEEL WEIGHT KIT ITEMS 1 THROUGH 4 LOCKWASHER 7 8 PL STD NUT HEX 7 8 NC BOLT HEAX HEAD 7 8 NC X 5 1 2 GR8 PLATE WHEEL WELDMENT Auxilary Wheel Weight Kit P N 02976671 is in Mount Kit P N 02982395 02982431 Front Axle Staibilizer Kit Consist of the following Item No T 3 oe c OD eS YS Part No 02982431 02981316 02981896 02965166 02960018 02960054 001845 7B101128 00695100 00001800 02971158 02975738 5312316 02972846 00756077 00010300 00759635 02892000 Qty ro BR PO VPN P PO ND AH AH d Ss Description FRONT AXLE STABILIZER KIT ITEMS 1 THROUGH 17 CYLINDER ASSEMBLY ADAPTER HYD REDUCER 6FJX 4MJ ADAPTER HYD TEE 6MJ 6MJ 6FJX ADAPTER HYD ELBOW 4MB 4MJ90 PLUG 4MB W T VENT amp O RING HOSE 4 AFJX 4FJX90 70 LG BOLT HEX HEAD 5 8 NC X 3 1 2 PLGR8 LOCKNUT TOPLOCK 5 8 NC LOCKNUT TOPLOCK 1 2 NC PLB LOCKWASHER 20MM BOLT HEX HEAD M20 P2 5 X 70MM PL GH10 9 WASHER 3 4 HARDENED BOLT HEX HEAD M16 P2 0 X 40MM PLGR10 9 WASHER 5 8 HARDENED LOCKWASHER 5 8 FLATWASHER 1 2 HARDENED NON PLTD BOLT HEX HEAD 1 2 13NC X 1 1 2 PL GR8 Auxilary Wheel Weight Kit P N 02976671 is in Mount Kit P N 02982395 02982412 Lexan Door Kit Consist of the following Item No Part No 02982412 02982398 02982417 02982418 Qty Description
15. 15 6 GPM Low Pressure Standby 250 PSI High Pressure OOM Din 2 3000 PSI Horse Power at 1850 RPM Engine Speed 28 5 HP 5 HYDRAULIC HOSE CODES Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some have a Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attachted to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose __ Always Check Hose Size Color Code amp Part Number Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 1 4 SPECIFICATIONS MAVERICK Boom Cylinder Circuit Hoses Color Tie Code Green G Green White G W Orange OR Orange White OR W Blue B Blue White B W Yellow Y Yellow White Y W Hed H Hed White R W Green G Green White G W Yellow Y Yellow White Y W Motor Circuit Hoses Color Tie Code Red R Orange OR Blue B Blue B Hose Size SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 4 SAE 4 SAE 4 SAE 4 Hose Size SAE 16 SAE 16 SAE 8 SAE 12 Hyd Function Swing Back Rod End Swing Forward Base End Lift Down Rod End Lift Up Base End Dipper In Rod End Dipper Out Base End Telescope I
16. 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 6 CONTROL VALVE ELECTRONIC NETWORK Maverick Electronic Network continued The XP2 The XP2 is a controller module that is mounted at the front of the tractor next to the maverick control valve The function of this compo nent is to provide a gateway for incoming and outgo ing information Information is sent via the network to this module in order to provide control of the sole noids for valve operation See Figure 9 REFER ENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANU FACTURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com The XT2 The XI2 is also a controller mod ule that is mounted at the front of the tractor on the side of the tank The function of this component is to provide a gateway for incoming and outgoing infor mation This module receives input from instrumen tation then provides that information to the network for further utilization See Figure 10 REFER ENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANU FACTURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com The XS The XS is expansion module that provides extra input and output capabilities in order to gain more flexib
17. 90 Elbow en Blue Plastic Tie A 8 Hose E m4 IUBE K 46 Hose 90 Elbow Red Plastic Tie Orange Plastic Tie Red Plastic Tie C 12 Hose Suction Hose N No Plastic Tie ee TEIT i D 12 Hose Red Plastic Tie a IL ee G 4 20 Hose Suction Hose No Plastic Tie p w Cd wi JE eee Ee a M Ira pe AS A 8 Hose AICHE Red Plastic Tie s CH v H 12 Hose L Hose SS s 90 Elbow Blue Plastic Tie Orange Plastic Tie D 12 Hose Red Plastic Tie B 4 8 Hose Blue Plastic Tie G 20 Hose Suction Hose No Plastic Tie F 4 Hose amp Tee Tank Return Blue Plastic Tie H 12 Hose Orange Plastic Tie F 4 4 Hose Figure 21 E 4 Hose 90 Elbow 90 Elbow Red Plastic Tie Blue Plastic Tie NOTE Hoses are not shown in drawing above this is for clarity The hose routing is for the hoses which connect from one point to the other Use the instructions and hose description listed to follow hose routing Example Hose A connects to one end marked A and the other end of hose connects to the other item marked A This is done with the other letters as well the hose must connect to the same letter markings on each end as in drawing Some hose will be marked with a colored plastic tie Some hose will have a straight fitting or a 90 fitting
18. AE ie E FIGURE 29 29 ui 14 Diverter Valve Wiring Connection The plug for the diverter valve is at the end of the exterior wiring harness and will be marked with code BB The plug and wire will run down the LH side of tractor from the front mounted hydraulic pump Tank The diverter valve is bolted the the LH front Frame Mount bracket The holes are already in the bracket and the diverter valve should have already been mounted If valve has not been mounted it can be mounted now See Figure 27 28 31 amp 38 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 13 Exterior Wire Harness Schematic P N 02981375A Diverter Valve Wire Harness Connection BB of exterior harness connects here Diverter Valve Diverter Valve C1 Port to Swivel Cyl Base End Port G W Tie Valve B Port to Diverter valve P1 Port Diverter Valve C4 Port G W Tie to Swivel Cyl Rod End Port G Tie 4 E kr are Diverter Valve C2 Port mounting holes to Door Cyl Base End Port Y W Tie Valve A Port to Diverter valve P2 Port G Tie Diverter Valve C3 Port to Door Cyl Rod End FIGURE 31 Port Y Tie Connecting Oil Cooler And Fan Assembly to Ex terior Wire Harness 15 Oil Cooler Fan As sembly The Oil cooler fan assembly is for cooling the oil being returned from the Motor Case Drain The fan is con nected to the control box and is turned on amp off automati cally Itsetto run on a program
19. Bolts 2000 ft Ibs Blade Bar to Spindle BOIS sieheritedancarecedsntacesioaarostedencutevsesuteetale 400 ft lbs AS BON EE EE 400 ft lbs Ni LOT B ad LE EE See Set Up Instructions 11 TORQUE VALU ES BOLTS Recommended Torque Ft Ibs amp Nm IMPORTANT Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE Component Application Torque will vary depending on what is bolted down and the type material Metal that is being bolted together Thread condition and lubrication will vary Torque settings ALWAYS CHECK MARKINGS ON TOP OF BOLT HEAD OR OTHER BOLT DESCRIPTIONS Inche Sizes Metric Sizes 2 B D Plain Head 3 Dashes ft Ibs N M Not Used Not Used Not Used 35 47 55179 75 102 875 1186 1200 1627 800 1084 1600 2169 900 1220 2100 2847 910 1234 1250 1695 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 1 7 NOTES Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 1 8 Section 2 Maverick Boom Tractor Preparation John Deere Tractor JD 6615 6715 verick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 2 1 General Information Installation Requirements FEE EEE EEE EEE GENERAL INFORMATION The tools you will need at the assembly site are as follows Impact wrench or socket and ratchet set Rubber mallet Box end Allen a
20. DO NOT reconnect battery cables at this time rie the electrical wiring is NOT done IGUR Display Control Box Bent Here to bolt to cab corner post Mount Plate Iqan Display Control Box Mount FIGURE 23 FIGURE 24 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 10 Exterior Wire Harness Schematic P N 02981375A 13 Exterior Wire Harness The exterior wire harness will run from the cab of the tractor to the front It will include the wiring for the sensors at the pump The connections for the valve actuator assemblies The electronic modules that are mounted to the right side of the tank and the module on the front of the valve The plugs have codes labeled on them there is a matching code on them where the plugs are connected Some plugs have instructions and or color codes Read the next pages of this manual to become familiar with the wire harness connections There are two electronic modules bolt on the tank assembly inthe front of the tractor The XT2 module bolted on the right hand side of the tank and the XP2 bolt on the LH side in front of the 6 spool valve See Figure 25 27 amp 28 The exterior wiring harness should be laid out and connections need to be start at the first connection coming from the tractor cab connection this allows the harness to be moved around and under components as needed NOTE V1 Pump Solenoid 2 is only used when the Timbercat Head is installed and
21. Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 12 Mounting Component ID Under Mnt Frame Asy 24 30 Under Mount Frame Asy 24 amp 30 ft are the same except for the LH weight 30 ft model on model only LH Counter Weight Turret Asy Machined Turret Boom Mount Pin ae Weight Attaching Pin Long Pin Boom Mount Attaching Pin Long Pin Turret Cylinder Link Center Section Frame Weldment Boom Mount Attaching Pin Medium Pin Boom Mount Machined Boom Mount Attaching Pin Short Pin Swing Cylinders Swing Cylinder Pivot Bushings Swing Cylinder Trunnion Mount Weldment Swing Cylinder Cover Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 13 Mounting Component ID Hyd Hose Connections 24 FT Boom Z Hole In Side of Lift NES KK i A ADS VEN DU RU hi if SSR vi v mo x a SF AA n Do n m b ie MB Sell P Gr dn T Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 14 Mounting Component ID Hyd Hose Connections 24 FT Boom Part No Qty End 1 End 2 Description 02981823 1 Y MJ Z FJX Hose 4 4Md 4FJX 76 Lg Yel Tie Door Lift Sectn 02981824 1 Y MJ Z FJX Hose 4 AMJ 4FJX 76 Lg Yel Wht Tie Door Lift Sect n 02981828 1 Y MJ Z FJX Hose 4 AMJ 4FJX 76 Lg Grn Tie Swivel Lift Sect n 02981829 1 Y MJ Z FJX Hose 4 AMJ 4FJX 76 Lg
22. Hose 12FJX 12FJX 23 Lg Pump to Suction Filter hose under pump and cannot be seen in drawing D 02981430 1 Hose 12FJX 12FJX 31 Lg w Red Tie Pressure Filter to Supply E 02981431 1 Hose 4FJX 4FJX 90 35 Lg w Red Tie Pump Load Sense to Valve PX F 02981432 1 Hose 4FJX AFJX 90 20 Lg w Blu Tie Pump Regulator to Tank F 1 Hose 4 Hose f Base end of Stabilizer Cyl to Tank port Via a Tee fitting G 02981433 1 Hose 20FJX 12FJX 24 Lg Pump to Suction Filter H 02981462 1 Hose 12FJX 12FJX 90 20 Lg w Org Tie Valve Return to Tank NOTE Hoses are not shown in drawing above this is for clarity The hose routing is for the hoses which connect from one point to the other Use the instructions and hose description listed to follow hose routing Example Hose A connects to one end marked A and the other end of hose connects to the other item marked A This is done with the other letters as well the hose must connect to the same letter markings on each end as in drawing Some hose will be marked with a colored plastic tie Some hose will have a straight fitting or a 90 fitting This is to allow hoses to be routed to where they clear other items when connecting hose put the end on that has the correct fitting as noted in drawing with 909 or the straight fitting if note marked hose routing that is to make hoses clear other items Do Not connect hose to different letter items all hose end mu
23. Hose Cylinders Tank must be kept plugged at all times No part of the Hydraulic System can be left open at any time during mounting process this will keep system clean 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 Install Crankshaft Pulley Adapter Driveshaft amp Pump Mount Plate 1 Remove Plate from the front of the Tractor On front of the tractor there is a plate that must be removed itis retained with two Allen head bolts that can be seen from the outside See Figure 1 Remove these two bolts and remove the cover this cover will not be used See Figure 2 There is already a hole through the front bolster that will allow the driveshaft to be run through it 2 Install Pulley Adapter The Pulley adapter P N 02979790 is around plate with 4 threaded holes and four non threaded holes init Notice this pulley adapter will not have a center hole in it See Figure 3 The four non threaded holes are used to mount the Adapter to the Crankshaft Pulley using bolts P N 02980967 12 mm X 60 mm long and lockwashers P N 00754566 12 mm thatare supplied in mountkit The four threaded holes are used to install the flange yoke of driveline to pulley adapter Do notuse longer bolts to mount Pulley Adapter to Pulley or Flange yoke to adapterthan are supplied wit
24. INST MAVERICK HARNESS 02982340 1 ASY MDM MODULE amp PROGRAM 19 02981517 2 BOLT EYE TURNED 1 4 NC20 X 1 20 02976531 10 ADAPTER HYD ELBOW 6FJX 6FJX45 21 02981953 5 HOSE HANGER FORMED 22 02981787 1 BOLT HEX HEAD 3 4 NC X 1 1 2 PL GR8 23 02981988 2 DECAL JOYSTICK OPERATION 24 02981992A 1 OPERATORS MANUAL amp PARTS MANUAL ASSEMBLY 25 02918600 6 BOLT HEX HEAD 3 4 10NC X 2 PLGR8 26 00011400 4 BOLT HEX HEAD 3 8 NC X 1 27 00023100 4 BOLT HEX HEAD 3 8 NC X 1 1 2 PLGR5 28 00017000 2 LOCKWASHER 1 4 PLSTD 29 00776031 1 CANISTER F MANUALS 30 00776481 1 DEGAL SHEET CANNISTER MANUAL c 02977417 1 DECAL OPERATORS MANUAL INSIDE 32 107079 1 WIRE BLACK 14 GA X 24 LONG 33 02982339 2 OVAL SLEEVE 5 32 DIA 34 D377 1 BOOKLET DECAL BOOM MOWER 35 02981822 1 HOSE BRACKET WELDMENT 36 00019600 1 LOCKWASHER 1 2 HEAVY PL of 02892000 1 BOLT HEX HEAD 1 2 13NC X 1 1 2 PL GR8 38 02981992CA 1 MANUAL CANNISTER ASSEMBLY Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 5 Mounting Component ID 30 ft Cab 4 wd IMPORTANT NOTICE The following Part Assembly Numbers are for reference and should not be ordered as replacement parts unless all the components in that assembly are wanted These will break down to bills of material of the components Some of numbers listed are NO individual Parts but complete assemblies and or box of assemblies Check before ordering 30
25. Inputs Prop Outputs Digital Inputs Digital Outputs 1 Freq Inputs E Gas Item A Maverick Electronic Network Figure 8 Electronic Network The electronic network is the control and communication network that receives and transmits data to certain components in the boom control system Its purpose is to manage the incoming and outgoing information There are five main components The MDM is an operator Display that is located in the cab The purpose of the display is to house the programming software for the system control and provide an interface between the operator and the Maverick Boom The interface is utilized through a multi screen function that allows the operator to set individual parameters for customized control functions The display also provides tools such as an on board measurement device useful for determin ing short circuits component loss and or power supply issues REFERENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAIL ABLE FROM THE MANUFACTURER ON THE INTERNET AT www iqan com viewable and print able with ADOBE ACROBAT READER If you do MDM Master Display Mini not have Adobe Acrobat Reader it can be ob Eid P Dig aa 1 tained at www adobe com Freq Inputs E Gas Make certainto view the MDM section as this Op 109 is the type used on the maverick boom there are listings at the web site that will not apply to the FIGURE 8 maverick boom Maverick John Deere 6615
26. LEXAN DOOR KIT ITEMS 1 THROUGH 3 LEXAN DOOR JD6020 TRIM PUSH ON WEATHER SEAL 168 TRIM PUSH ON WEATHER SEAL 96 exan Door Kit P N 02982412 is in Mount Kit P N 02982395 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 9 Mounting Component ID Control Valve Fittings 2 Item Part No Qty Description 02981888 Valve amp Fittings Asy 6 Spool 1 02981370 1 Valve Asy w o Fittings 2 02090800 2 Adapter Hyd Elbow 12MB 12MJ 90 3 02972177 11 Adapter Hyd Straight 10MB 6MJ 4 03200284 1 Adapter Hyd Straight 6MB 4MJ 5 02981889 1 Adapter Hyd Straight 10MB 6MJ 6 02972208 1 Valve Solenoid Asy 7 02975438 1 Adapter Hyd Straight 8MB 8FJX 8 02981890 1 Adapter Hyd Straight 8MB 6MJ Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 10 Mounting Component ID Hydraulic Lock Valve FN 2 C2 4 4 5 Item Part No Qty Description 02972208 Solenoid Valve Asy 1 02971425 1 Seal Kit f solenoid Valve 2 02975198 1 Coil 12V DC w Dual 8 32NF Studs 3 02975199 1 Cartridge Solenoid Valve 4 02975438 1 Adapter Hyd Straight 8MB 6FJX 5 02981890 1 Adapter Hyd Straight 5MB 6MJ Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 11 Mounting Component ID DIVERTER VALVE Door Swing Cylinder Diverter Valve Asy P N 02977622 The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be sha
27. Section 9 5 2005 Alamo Group Inc Ee cc al OQ UT EN RICO7 CES ETES Motor Tank Return Me 16 Hose eg Orange Tie Motor Pressure ER 16Hose M diis Me Cyl 4 Hose alaa Tie Head Lift Link Pin Hole Head Mount Pin Hole 50 Inch Head w o Swivel Hitch Mount Boom Valve Hydraulic Schematic ees into Lift 5 Port S Hose No Plastic Tie Figure 11 _ 4 Hose 20 mile e F cE 8 o 9 6 Spool Control Valve ium Oo 513 gt 2 SG Returns to same port on E tan as Oil cooler Hose ANA O IB QUE g E TankReturn B Ports f D 9 Orange Tie e A Ports Y e A Pressure Supply Y Red Tie E No Colored Ties only H E O Lolore les only Hose A N Bands P N 02981825 L N Diverter Valve 6 Hose Q P1 C2G C1 E Swing Cyl i __ pt f O Boom Lift Cyl f Dipper Cyl E O eT 1o 6 Hose veliow I White aie f i e 5 2 49 ll 1S 2 2 Telescope Gi 22 EG elescope Cy c QO 3 z D O O it 6 Hose O J D O nod White TE ar D L a ned l O amp Head Tilt Cyl C EE O Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 6 Boom Head Installation 11 Routing Cylinder Hoses from Boom to Valve The Hose from the boom to the valve will be split the four hoses to the door cylinder and swivel cylinder will run together through a section of slee
28. The boom must be working smoothly Slowly with low engin RPM with some one guiding you swing boom inward towardl P Bottom cab until the boom rest lug is aligned with the boom rest pin Turret See Figure 26 Set boom securely down over pin Ei Cover 4 Final Swing Stop Adjustment Unscrew the stop bolt MM See Figure 27 until the head is against the swing stop lug of M the turret cylinder link weldment See Figure 27 Hold the M bolt so it won t turn tighten the locking nut down against the T turret stop swing lug Recheck to make certain the boom will not hit the cab of the tractor It will stop at the turret RID lug when properly Swing 3 adjusted This Cvlind ylinde may haveto be NS adjusted more than once NEVER allow unit to be run if Boom will hit the cab this will damage cab Figure 25 E 7 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 14 Adjust Boom Swing Stop Turret Assembly as seen from the bottom Swing Stop Lug Built onto the Turret Cylinder Link Weldment Turret Swing Stop Lug with Adjusting Bolt amp Locking Nut Swing Cylinders Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 15 NOTES Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 16 Gection 11 Maverick Mounting Specifications John Deere Tractor JD 6615 6715 Mounti
29. align Installthe long upper retaining pin and then the two small front and rear pins The long upper pin is retained with two cotter pins that need to be bent over on the ends The short pins are retained with nuts and bolts See Figure 36 amp 38 Figure 37 JR 4 Turret Assembly Grease Fittings The turret assembly has three grease fittings around the OD of it The grease fittings are 120 apart this is to make certain that the bearing will be greased all the way around because of the large diameter of the bearing This bearing must be greased before unit is put into service It is easier to get to grease fittings now than after boom has been installed On the under side of the turret assembly are the grease fittings for the swing cylinder pivot mounts these need to be greased before operating the unit Also there is a bolt on cover on the under side of turret that will be installed See Figure 40 atalatertime Greasing the cylinder pivots will need to be done before the cover is installed See Figure 39 and the boom swing stop will need to be adjusted but this cannot be done until a later time making it best to leave this cover of until then After greasing components at assembly of unit operator should consult the operators manual for maintenance requirements w La SEU E i pre Ti 2 F 1 ET 1 s A Elia e 7 1 E e P 1 p M tas EFE T Mn keg Du mou Phi 2 A ig disi E gt sub ere 7 Ls dh LED RE
30. be sticking up through the turret mount weldment between turret and tractor The hoses will need to be connected there and routed to the hydraulic control valve One hose will have a Green Tie and one a green and white tie where the come up throught the turret mount weldment See Figure 3 2 Booms Are recieved from the factory with or the Sections of Boom Assmebled to together s The Boom Sections are assembled with the hy Figure Rear gle draulic lines and cylinder connected The hose will be connected to the boom that are routed to the control valve and diverter valve and bundled together See Figure 4 The Boom Hoses are Lifting protruding out the turret mount end of the boom Point The Hose connections on the head end will be shipped with metal caps on them these are to protect the lines from contamination and should not be removed until the hoses are being in stalled See Figure 5 The hose that attaches to the boom are sent installed on the head assem bly and the hose will also have plugs in them 3 Boom Lift Cylinder The boom lift cylinder pum will be connected to the boom at the rod end of Figure 2 the cylinder See Figure 2 amp 4 when it is shipped from factory The hoses will also be connected to the cylinder The retaining pin for the lift cylinder will be located in the turret assembly The Lift Cylinder will be fastened to boom with tie wire It will not be required to remove this tie wire before mounti
31. mounted on to the tank top The fluid returning from the cylinder control valve is filtered before returning to tank at this loca tion See Figure 15 The sensor monitors back pressure created by the filter assembly while cylin der circuit is in operation When the back pressure reaches 25 psi the switch will trigger and prompt the operator for a filter element change WARNING This filter does not have a by pass The element must be changed at the FIGURE 15 appropriate time to avoid element damage and FIGURE 15 system contamination Maverick Operator Interface The Operator Interface The operator selects parameters provided by a menu system in the MDM display control box The parameters are usedto establish how the boom unit functions The menu system is comprised of two sections The first section is setup the second section powers up the boom control circuit and cutter head circuit The following steps outline how to successfully page through the menu system to execute operation See the end of this section for Joystick control operation after start up procedure is completed Executing Set Up The following representations will outline the steps necessary to execute set up Key Escape or back at anytime to revert to the previous Alamo Industrial Boom Meru Key FL For Setup Key F 1 to access the set up menu Select Boom peratina Speed a Hich Key the corresponding F key to establish the desired boom sp
32. power supply DO NOT connect the power supply wire CC1 to an other power supply as it could cause interference with the electronic components due to a power surge 10 Tractor RH Side Panel reinstalled When the tractor side panel is reinstalled the plugs 2 Plugs K3 amp X1 for the Display control box will be sticking up out from be hind the panel See Figure 21 Run the wiring harness in from behind panel use caution to not let wire harness interfere with or be in a position to damage or be damaged by other tractor components behind panel 11 Install Display Control Box Mount Bracket The display mount control box mount to the Rh rear cab post See Figure 22 amp 23 There are two plastic plugs in the plastic cover over cab post Remove these two plug to expose two 10 mm bolt holes in cab post Position the mounting bracket with the bent end atthe post and using the 10 mm bolts furnished bolt the bracket to the post 12 Install Display Control Box The display control box will bolt to the mount plate thatis mounted to the RH Rear Cab corner post See Figure 22 23 amp 24 There y is a wire setion on disply control box that will pug into the LE Mount Plate two plugs on the interior harness plug KS amp X1 See 3 Iqan Display Figure 21 amp 22 Thedisplay control box cannot be tested until the interior and exterior wiring harness installation has been com pleted and all the other installations of unit have been done
33. read it thoroughly These mount kits are made for selected tractors with standard configurations Only the noted options and tire sizes listed in the Mounting Specifications will work with these mount kits Other options front axles or different tire sizes may prevent the mount kit from fitting your nonstandard tractor Alamo Group cannot take responsibility for these problems or any modifications made to the unit 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 forward always DANGER A signal word DANGER WARNING or CAUTION is used with the Safety Alert symbol DANGER identifies the most serious hazards Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 2 2 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 and safe operating practices General Information Installation Requirements WARNING Safety signs with signal word WARNING are typically used to point out more serious hazards CAUTION General precautions are listed on CAUTION safety sign CAUTION also calls attention to safety messages in these instructions CRUSHING AND PINCH POINTS RES MOVING MACHINERY PARTS CAN PINCH OR CRUSH OR FALL WHICH MAY CAUSE
34. tabs in the rear of the tank Mount the three rear bolts Three on each side The hydrau lic tank slide under pump and between the LH amp RH Tankrails Do not remove from hoist until tank has been bolted on and bolts tightened 3 Rotate Fittings to make better access to Valve and tank connections The fittings in the pump and valve may have to be rotated to make it more accessible when connecting the hoses 4 Tighten Bolts Mounting Tank Rails After the bolts that attach the tank to the tank rails are installed tighten the bolts that mount the tank rails to the tractor these were left loose to make it easier to install the tank to them Tighten the six bolts mounting tank to the rails See Figure 2 5 Reconnect Hose to Tank The hose to the tank that were disconnected so the pump could be installed earlier will need to be reconnected now make certain that any plugs used to cover hoses and pump fitting are removed before con necting hoses Make Certain that all hoses are reconnected to the correct place see the hydrau Figure 1A b lic hose illustration in this section See Figure 1A Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 5 2 Hydraulic Tank amp Control Valve Installation J 16 Hose B 8 Hose Red Plastic Tie 90 Elbow umi Blue Plastic Tie A 8 Hose up Ne K 46 Hose 90 Elbow Red Plastic Tie Orange Plastic Tie Red Plastic Tie
35. that will run the fan in the cool Exterior wire ing rotation for a designated harness connec time then stop reverse the tion marked R1 rotation cycle to clean debris off of cooler then stop and reverse the fan again and be a gin the cycle all over again j The connection to the cooler onthe exterior wire har ness is marked with code H1 The connection from the fan will have two wires a Blue connection and a black con nection See Figure 32 connects here Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 14 Exterior Wire Harness Schematic P N 02981375A Maverick Sensor Connections 1 Instrumentation The Maverick Boom utilizes instrumentation for certain decision making activi ties Listed below are the sensors included on this unit Tank Temperature Sensor Charge Pressure Filter Switch Valve Pressure Filter Switch and Re turn Filter Switch 2 Tank Temperature Sensor The tank tem perature sensor monitors the fluid temperature in the area of the pump suction screens the tempera ture is real time and is used on the network to accomplish certain objectives The first is to display on the interface while the cutter circuit is operating The second is to be used to control the electric fan on the hydraulic cooler At any time the fluid level reaches 150 F the fan is activated and remains activated until fluid temperature drops to or below the desired temperat
36. the long mounting pin The front and rear pin holes should be aligned install the short pins front and rear The short pins are retained using a nut and bolt The long pin uses two large cotter pins install cotter pins and bend end of them to secure them See Figure 32 33 34 amp 34A Counter Weight willl mount under tractors factory fuel tank See Figure 24A 2 Additional Counter Weight CWT Installation The 30 foot boom model has an additional bolt on weight at the counter weight This additional weight bolts to the weight weldment on the 30 foot model only See Figure 32 Weight Attaching Pin LH Counter Weight 24 or Short Pin Rear side 30 Foot Boom Weight Mount Attaching Pin Long Pin Center Section Under Frame Weldment 2 AP Bre en e HA j Fw Qr E Additional bolt on Weight Used PH 30 ft boom models only Fiaure 32 P Weight Attaching Pin on pd Short Pin front side 3 Wheel Counter Weight CWT Installation The Wheel counter weight is in addition to the frame mounted counter weight they both must be used together the 30 foot boom will have an additional frame mounted counter weight bolted on See Figure 32 33 amp 34 Allthese weight are in addition to adding liquid weight into the Left rear tire The proper amount of counter weight is not complete until all these weight have been installed Turret Assembly Installation 24 amp 30 Foot Boom 1 Turret Assembly Theturret assembly is shipped assem
37. top of the right hand side panel See Figure 16 17 18 amp 19 When the small cover is replaced the plugs and wires need to be moved to the back of the panel near the RH rear cab post See Figure 17 amp 18 Cuta notch in the panel at the rear so the cover will fit down around the wire harness plugs See Figure 17 amp 18 Also the rear tractor panel will need a notch cut in it to allow the wire harness to be installed between the side and rear panel Cut this notch near the bottom of the rear panel See Figure 19 Cut Notch in Small cover panel to allow harness to fit through Display Control Box Connections FIGURE 19 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 8 Interior Wire Harness Schematic P N 02981375B CAN 1 XS ES MODULE i d CAN 2 TE XS MODULE i NOTE See Figure 14 for J2 listing of Code Locations K3 i 4 ve M1 X1 ___ CC1 Must connect to Key switch wire CC2 G1 Eu i lif Gi HT FIGURE 20 Maverick John Deere 6615 6715 Asy Man 02 05 O 2005 Alamo Group Inc Section 8 9 Interior XS Module amp Display Control Box 9 Connect Wires to Key Switch There are two wires on the interior Harness that connects to the key switch Wires CC1 and CC2 these need to be routed under floor mat and in behind dash panels CAUTION The positeve wire CCl MUST be connected to the wire from the key ignition switch of tractor for an electrical
38. two bolts one each hinge that bolt the two hinge halves together The is a safety cable that will bolt to the cover and the tank mount bracket this is to prevent the cover from opening to far forward and hitting the ground There are retaining latches that will bolt to the tank mount bracket and the cover The holes for the fasteners will have to drilled by the installation technician in the tank mount brackets and the front cover See Figure 19 20 21 amp 22 an LL FIGURE 19 3 FIGURE 21 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 13 Adjust Boom Swing Stop Boom Swing Adjustment 1 Boom Swing Stop Location The boom Stop adjust Turret ment cannot be seen from the top of the turret assembly See Assembly Figure 23 If the bottom cover plate See Item 24 is not already removed it will need to be it is bolted on from the under side of the turret assembly From the under side you will see the swing cylinders and cylinder pivot mounts See Figure 25 2 The Swing Stop Lug which is part of the Turret Cylinder Link Weldment See Figure 27 On the side toward the rear there will be a lug with a bolt and locking nut in it See Figure 27 Loosen the bolt and locking nut turn the bolt outward 3 Swinging Boom DO NOT Swing Boom until the UM boom has been run with it sticking out away from tractor and all electronic control adjustments have been done
39. you are using It is also recommended that a trained person installs the calcium Chloride Calcium Chloride must be added in addition to the Steel Wheel Weight 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 Chloride Water mixture provides antifreeze to approx 50 deg F below O Rotate Washer to Match Bolt Circle dia and Washer fits into 4 Wheel Weight Slot gt Bolt is shown extra long in drawing for illustration only Item Part No Qty Description 1 02979603 3 Hex Head Bolt 7 8 NC X 16 2 02971569 3 Wheel Weight Washer Special 3 02970758 1 Wheel Weight Casting 1400 Ibs 4 5JRC1490 3 Locknut Top Lock 7 8 NC Note some Older Units used a All Thread Rod with Hex Nuts Lock Nuts with Flat Washer and Lock washer This was replaced with the Bolt Type shown above These Bolt and Nut combinations will replace the old All Thread type Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 7 2 Rear Wheel Counter Weight Installing Wheel Weight 1 This Wheel Weight is 1400 los 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 moun
40. 0 ft Cab 4 wd 02982157 Hose Bundle Consist of the following Item No Item Part No Qty Description 02982157 HOSE BUNDLE ASSEMBLY ITEMS 1 THROUGH 6 02982158 1 ASY POWER HOSES IN SLEEVE includes next 5 Items 02982142 1 HOSE 16 16FJX 16FJX90 146 LG RED TIE 02982143 1 HOSE 16 16FJX 16FJX90 146 LG ORANGE TIE 02982144 1 HOSE 12 12FJX 12FJX90 144 LG BLUE TIE 000859 2 PLASTIC TIE 00999588 1 CORDURA SLEEVING BLACK 3 66 ID X12 5 FT LG 02982159 1 ASY SWING HOSES IN SLEEVE Includes next 4 Items 02982145 1 HOSE 6 6FJX 6FJX90 140 LG GREEN TIE 02982146 1 HOSE 6 6FJX 6FJX90 140 LG GREEN WHITE TIE 000859 2 PLASTIC TIE 00900913 1 CORDURA SLEEVING BLACK 2 54 ID X 10 FT LG 02982160 1 ASY LIFT HOSES IN SLEEVE Includes next 4 Items 02982147 1 HOSE 6 6FJX 6FJX 179 LG ORANGE TIE 02982148 1 HOSE 6 6FJX 6FJX 179 LG ORANGE WHITE TIE 000859 2 PLASTIC TIE 00900913 1 CORDURA SLEEVING BLACK 2 54 ID X 14 5 FT LG 02982161 1 ASY DIP TELE TILT HOSES IN SLEEVE includes next 8 Items 02982149 1 HOSE 46 6FJX 6FJX 147LG BLUE TIE 02982150 1 HOSE Z6 6FJX 6FJX 147LG BLUE WHITE TIE 02982151 1 HOSE 46 6FJX 6FJX 152LG YELLOW TIE 02982152 1 HOSE 6 6FJX 6FJX 152LG YELLOW WHITE TIE 02982153 1 HOSE 6 6FJX 6FUX 152LG RED TIE 02982154 1 HOSE 36 6FJX 6FJX 152L G RED WHITE TIE 000859 2 PLASTIC TIE 00999588 1 CORDURA SLEEVING 3 66 ID X 12 FT LG 02982162 1 ASY DI
41. 001800 02981436 02981463 02981468 00002700 00001300 02892000 02968923 63042700 03200587 02981372 02822700 02968167 02981435 02043600 02981369 02978986 02981388 QTY 7 1 1 1 2 6 o dv t ND nm nm mm mm mm D RD HSH h m VN OND ODD ND OO NN 2 0 NO DESCRITION LOCKNUT TOPLOCK 3 4 NC PUMP COVER ASSEMBLY LOCKNUT TOPLOCK 1 4 NC PLB BOLT HEX HEAD 1 4 NC X 1 PLGR5 KNOB CR30 X 1 1 2 STUD FLATWASHER 1 4 PLSTD CABLE 1 4 AIRCRAFT 7X19 CABLE CLAMP OIL COOLER ASY W FAN LOCKNUT TOPLOCK 3 8 NC FLATWASHER 3 8 STD COOLER MOUNT RH COOLER MOUNT LH ADAPTER HYD ELBOW 12MB 12MJ90 ADAPTER HYD STRAIGHT DIVERTER SOLENOID VALVE VALVE AND HYD TANK ASY Includes the Next 47 Items INDICATOR ELEC W PACKARD MOUNT MODULE ADAPTER HYD ELBOW 6MB 4MJ 90 ADAPTER HYD STRAIGHT LOCKNUT TOPLOCK 3 8 FLATWASHER 3 8 STD BOLT HEX HEAD 3 8 NC X 1 1 4 PL GR5 ADAPTER HYD STRAIGHT ADAPTER HYD ELBOW 12MB 12MJ90 FILTER MEDIUM PRESSURE LOCKNUT TOPLOCK 1 2 NC PLB KIT FLANGE 20 CODE 61 ADAPTER FLANGE 1 1 4 X 20MJ 45 BRACKET SHIPPING ONLY FLATWASHER 1 2 PLSTD LOCKWASHER 1 2 BOLT HEX HEAD 1 2 13 NC X 1 1 2 PL GR8 FILTER ASY PRES ELEMENT ADAPTER HYD STRAIGHT PLUG HEX HEAD 8MB FILTER HEAD W IND PORT ADAPTER HYD ELBOW ADAPTER HYD STRAIGHT 16MB 8MJ ADAPTER HYD 10MB 10 FJX90 ST ADAPTER HYD ELBOW 16MB 16MJ45
42. 1 Hose Hyd Pressure f Door Swivel B Port on Control Valve Green White Tie P2 Hose Hyd Return to Door Swivel A Port on Control Valve Green Tie C1 Hose to Head Swivel Cylinder Base End Green White Tie C2 Hose to Door Cylinder Base End Yellow White Tie C3 Hose to Door Cylinder Rod End Yellow Tie C4 Hose to Head Swivel Cylinder Rod End Green Tie Maverick John Deere 6615 6715 Asy Manl 02 05 2005 Alamo Group Inc Section 5 7 Hydraulic Hose Connections OD Six Spool Control Valve eS 40 ko External Wire Connec D tions for valve are marked gt A and B on Valve amp a D AA1 thru AA12 on wire OD harness connections a O p Pressure Supply Port P Diverter Valve C1 Port to Swivel Cyl Base End Port G W Tie Valve B Port to Diverter valve P1 Port G W Tie Diverter Valve C4 Port to Swivel Cyl Rod End Port G Tie 4 Through holes are mounting holes Diverter Valve C2 Port to Door Cyl Base End Port Y W Tie Diverter Valve C3 Port to Door Cyl Rod End Port Y Tie Valve A Port to Diverter valve P2 Port Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 5 8 Oil Cooler Fan Assembly Connecting Oil Cooler And Fan As sembly 1 Oil Cooler Fan Assembly The Oil Cooler and Fan Assembly connects to the two tank mounting rails behind the tank The mount ing holes are already in the tank m
43. 12FJX 90 20 Lg w Org Tie Valve Return to Tank J 1 Hose 16 w Red Tie Pressure from Pump to Motor Bottom Port K 1 Hose 16 w Orange Tie Oil Return from Motor Top Port Lo 1 Hose w Blue Tie Oil Return from Oil Cooler to Tank Hose Connections Hydraulic Valve See Figure 3 1 Fittings and Hose Connections to Valve The fittings are installed in the valve when it is shipped from the factory the Valve is mounted to the tank when it is shipped from the factory The fittings will have caps and or plugs covering all the openings to keep contamination out of the system DO NOT remove any caps or plugs at this time The valve is ONLY listed here to show which fittings are installed where on the valve The hoses to the valve with the exception of the pressure supply from pump to valve will not be connected until later after Boom has been installed See Boom Head Installation section Valve Fittings and Location See Figure 3 Item Part No Qty Description 02981888 Valve amp Fittings Assembly 6 Spool 1 02981370 1 Valve Assembly w o Fittings 2 02090800 2 Adapter Hydraulic Elbow 12MB 12MJ 90 3 02972177 11 Adapter Hydraulic Straight 10MB 6MJ 4 03200284 1 Adapter Hydraulic Straight 6MB 4MJ 5 02981889 1 Adapter Hydraulic Straight 10MB 6MJ 6 02972208 1 Valve Solenoid Assembly 7 02975438 1 Adapter Hydraulic Straight 8MB 8FJX 8 02981890 1 Adapter Hydraulic St
44. 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 4 SAE 4 SAE 4 SAE 4 Valve Pressure Filter Switch Port WU gt PW gt WP gt UWUUWP gt P gt UWUW gt Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc i Hyd Function Swing Back Rod End Swing Forward Base End Lift Down Rod End Lift Up Base End Dipper In Rod End Dipper Out Base End Telescope In Rod End Telescope Out Base End Head Tilt Up RodEnd Head Tilt Down Base End Swivel CW Rod End Swivel CCW Base End Door Open Rod End Door Closed Base End Component Identification XP2 Expansion Power Analog Inputs 4 Prop Output 4x2 Digital Inputs 4 Digital Outputs 4 Freq Inputs 2 E Gas Igan Display Unit XP2 Expansion Power XT2 Expansion Transmission Analog Inputs 10 Prop Outputs 2x J1909 CAN hub 4 Digital Outputs 6 Freq Inputs 3 E Gas 1 XS expansion signal XT2 Expansion Transmission XS Expansion Signal Tank Temperature Sensor Charge Pressure Filter Switch Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 22 Component Identification RH Side Install with these openings to front p mn FAE JE eee of tractor Front of zi Side of Tractor ractor Hear View o el dle o FG LO o oll 1 lo o QJ P N 02981168 Center Section Under Mount Frame Wldmnt P N 0297
45. 6FJX 16FJX90 140 Lg Red Tie Motor P Litt Sectn 02981874 1 A FJX D FJX Hose 416 16FJX 16FJX90 140 Lg Org Tie Motor R Lift Sectn 02981875 1 K FJX L FJX Hose 16 16FJX 16FJX 94 Lg Red Tie Motor P Dipper Sect n 02981876 1 H FJX N FJX Hose 416 16FJX 16FJX 98 Lg Org Tie Motor R Dipper Sectn 02981877 1 B FJX E FJX Hose 12 12FJX 12FJX90 140 Lg Blu Tie Case Drain Lift Sect 02981878 1 J FJX M FJX Hose 12 12FJX 12FJX 96 Lg Blu Tie Case Drain Dipper Sect n NOTE 1 Hose End 1 amp End 2 these are where the ends of that hose connect the letter shows location of that end and show type hose fitting at that end NOTE 2 The hoses have plastic ties on the to show which hose is which The colors are abreviated to YEL Yellow YEL W Yellow with Whiter stripe GRN Green GRN W Green with White Stripe RED Red RED W Red with White Stripe BLU Blue BLU W Blue with White Stripe ORG Orange ORG W Orange with White Stripe NOTE 3 Sect n Location where hose is located on boom Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 17 Mounting Component ID Motor amp Boom Pump Hose B 90 C A A 90 D Seo iK RH m GBESE EE CUT ae OO SM oeMelllcaB o H 90 Item PartNo Qty Description A 02981427 1 Hose 8FJX 8FJX 90 24 Lg w Red Tie Charge Filter to Pump B 02981428 1 Hose 8FJX 8FJX 90 21 Lg w Blu Tie Case Drain to Tank C 02981429 1
46. 8480 Pump Mount Plate Spacer P N 029747704 LH Rear Axle Strap two required Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 23 Component Identification Q a P N 02981382 Tank Mount Plate Arm Rest Controller Mount Weldment RH amp LH use same part RH amp LH Side are the Tractor End same part P N 02982388 Rail Weldment PIN 02982390 Rail Weldment RH Rear LH Rear P N 02982380 Rail P N 02982383 Rail Weldment RH Front Weldment LH Front Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 24 Component Identification Lo xo Front Axle Stabilizer Rear Bracket Weldment Included in Front Axle Stabilizer Kit Only P N 02982392 for 30ft Boom Rest Weldment Front Axle Stabilizer Front Bracket Weldment Included in Front Axle Stabilizer Kit Only Send Here Mount Plate Iqan Display Mount Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 25 Component Identification Boom Rest Stabilizer Wldmnt Two Wires in plug BS 1 Blue Wire Connection S 1 Black Wire Connection Connecte to R1 Connec tion of Exterior Wire Harness Oil Cooler Fan Assembly P N 02591841 TE Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 26 Section 12 MAVERICK PRE DELIVERY INSPECTION CHECKLIST John Deere Tractor JD 6615 6715 MAVERICK PRE DELIVERY INSPECTION
47. 982434 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc
48. CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See Bolt torque chart for bolt torque specifications Saftey Equipment Operators Manual is with Unit The Safety Decals are installed as listed in the Assembly Manual Valve operation plate is installed Operators cage or Tractor Cab is in place Deflectors are installed on the Mower Head Tractor Rops or Cab with seatbels installed properly Frame and Boom JD 6615 amp 6715 Axle Plate Bolts are torqued to 355 ft Ibs Boom Rest Axle Plate Bolts are torqued to 355 ft Ibs Front Rail Bolts are torqued to 425 ft Ibs Front Support Bolts at tractor are torqued to 425 ft Ibs Rear rail Bolts torque to 425 ft Ibs Rotator bolts torque to 120 ft Ibs All Welds inspected toinsure proper welds and locations Hydraulic System see Oil Level in Hydraulic Tank is within the sight gauge Hose connections are tight Hoses do not have any kinks or twist in them Front Pump Shaft adapter bolts are tight Front Pump Shaft Coupler Drive Shaft is lubricated and has an anti seize compound on the Splines of Pump and Shafts The Pump Drive Shaft has correct alignment Suction Hose has no leaks or kinks Rotary Mower Head Skid Shoe Bolts are torqued to 120 ft Ibs Spindle
49. HARD HAT SAFETY BEFORE WORKING GLASSES SEAT UNDER BELTS amp ROPS 1 Sudy andundersand operators manus safety signa and Insinictienal decals for tractor and Implement lagreven meuse bye and accidents Leann how 6 slep engine suddenly la 8 emergency Be alert f r passerby and especialy chi dren i Allow no children on onen Implement or bractor Ad own onders on tractor andimplem ent Falingofl maycouse senou sinjury or deaf from being run Svar by rector or outer or conkad wih reiting blades 4 Opergie oniywilh racio heving oil Over Protective Sructure HOP an dwilh sea belt fasten ed securely and snug y bo preventimjury and pode death from felling aff or tractor overtar Personal Protective Equipment sich az Hard Hat Safety Glasses Safety Shoes and Ear Flags are Recommended 4 Elocik up or support raised machine and allimted components se cureby before putting hands ar te et under or working underneath a ny Med components bo prevent crushing Injury or death from sudden dropping or inadvertent operation of controls Make certain aman clear beiore owerningormolding Beforetransponting put Lift Lever in detent or full posin Secure e implement for Eransp ort by installing Cynder Stops or Transport Fin on Pull hig implement center axle and Ving Transpeost Locks on fokdigimplemaents e Sach Safety Chanto cuter and bring unit secunehy Ser Operators Manual i Maine certain that the SKY sign Vaming Lights and Refectors are dea
50. Housing Bolts are torqued to 400 ft Ibs The Spindle Housing is properly lubricated Motor Bolts are torqued to 120 ft Ibs Blade Carrier Bar Bolts torque to 400 ft lbs Blade Bolts are torqued and the retainings Pins are in place Blades Swing freely Boom Boom Telesoping Bearings Adjusted completely inward All Hoses tightened and no leaks All hoses secured to where they will not rub get pinched or hanging down where they may catch on something All Decals installed Pump Primed and Pressure adjusted if needed only applys to Pump for Cylinder control Maverick John Deere 6615 6715 Asy Manl 02 05 2005 Alamo Group Inc Section 12 2 MAVERICK PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component location Flail Mower Head Skid Shoe Bolts are torqued to 120 ft lbs Motor Bolts are torqued to 120 ft lbs Belt Alignment amp tension adjustment is correct Cutter shaft bearings are properly lubricated Roller bearings are properly lubricated Blades swing freely Tractor Mower Operation Inspection Using all Safety precautions operate the Tractor and Mower unit for 30 minutes and while the unit is running check the following items Note Only make adjustments after the mower has been turned off and all motion has stopp
51. INJURY OR DEATH 02962765 GENERAL INFORMATION The tools you will need at the assembly site are as follows Welding equipment including correct head gear eye shields and protective clothing Impact wrench or socket and ratchet set Rubber mallet Box end Allen and crescent wrenches Alignment pins Phillips and plain head screwdrivers Forklift or hydraulic floor jacks with rolling back boards Over head hoist and floor jacks Jack Stands and or other support devices that are strong enough to support tractor and components 10 Multidirectional Levels 11 Paint Scraper 12 Hydraulic Filter Buggy or Cart 13 Safety shoes safety glasses and gloves A hard hat should be worn by anyone working under any raised component OS cO OL oo Ir e 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 An uncluttered assembly area and a crew that is sensitive to the hazards involved in putting this implement together will help prevent accidents Keep all unauthorized personnel from the area 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 assisting with the assembly Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 2 3 General Informati
52. JX Hose 4 AMJ 4FJX 115 Lg Grn Tie Swivel Lift Sect n 02981856 1 Y MJ Z FJX Hose 4 AMJ 4FJX 115 Lg Grn Wht Tie Swivel Lift Sect n 02981857 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Yel Tie Ext n Lift Sect n 02981858 1 Y MJ Z FJX Hose 6 6Md 6FJX 115 Lg Yel Wht Tie Ext n Lift Sect n 02981859 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Red Tie Tilt Litt Sect n 02981860 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Red Wht Tie Tilt Lift Sect n 02981861 1 Y MJ O FJX Hose 6 6MJ 6FJX 135 Lg Blu Tie Dipper Dipper Sect n 02981862 1 Y MJ P FJX Hose 6 6MJ 6FJX 135 Lg Blu Wht Tie Dipper Dipper Sect n 02981863 1 Z MJ R FJX Hose 6 6MJ 6FJX 125 Lg Yel Tie Ext n Dipper Sectn 02981864 1 Z MJ QX FJX Hose 6 6MJ 6FJX 125 Lg Yel Wht Tie Ext n Dipper Sectn 02981865 1 Z MJ V FJX Hose 4 AMJ AFJX 214 Lg Yel Tie Door Dipper Sect n 02981866 1 Z MJ U FJX Hose 4 AMJ AFJX 214 Lg Yel Wht Tie Door Dipper Sect n 02981867 1 Z MJ X FJX Hose 4 AMJ 4FJX 214 Lg Grn Tie Swivel Dipper Sectn 02981868 1 Z MJ W FJX Hose 4 AMJ 4FJX 214 Lg Grn Wht Tie Swivel Dipper Sectn 02981869 1 Z MJ T FJX Hose 6 6MJ 6FJX 214 Lg Red Tie Tilt Dipper Sectn 02981870 1 ZW S FJX Hose 6 6MJ 6FJX 214 Lg Red Wht Tie Tilt Dipper Sect n 02981873 1 C FJX F FJX Hose 416 1
53. Li EC m L 1 1 T ad e m Le e U 1 mm i s i c EE ite dem 7 Figure 39 NM Figure 40 E Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 10 Front Axle Stabilizer Installation Front Axle Stabilizer Kit Installation 1 Install Front Axle Stabilizer Kit The front axle stabilizer kit will consist of all brackets and hardware to install to front RH side of 4 wheel drive axle and RH side of tractor frame This kit is tied to the oil supply from the Lift Cylinder for the boom the pressure supply hose Is tee d to the B port of valve for the lift cylinder and connected to the rod end of the stabilizer cylinder Install the cylinder with the rod end toward the axle and the base end of cylinder up to the bracket See Figure 41 bolted to tractor frame The hose connects at base end of stabilizer cylinder will connect with a tee to the tank return port for the Pump regulator it is a Number 4 hose with a blue plastic tie at the front side of tank The Brackets bolt to the tractor axle and form a clamp around front axle housing See Figure 42 The Stabilizer cylinder is charged only when the boom lift cylinder is activated and is controlled auto matically with the boom lift controls The three axle brackets are as follows Item PartNo Qty Description 1 Rear of Axle Bracket D 1 Front of Axle Bracket 3 1 Stabilize
54. PUMP LS VARIABLE DISP PUMP MED DUTY HYDROSTAT TANK ASY HYDRAULIC Continued Next Page Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 4 Common Box Component List 02981781 Common box Consist of the Following Items Contiuned from previous page ITEM PART NO QTY DESCRITION 02981427 1 HOSE 8 8FJX 8FJX90 24 LG 02981428 1 HOSE 8 8FJX 8FJX90 21 LG 02981429 1 HOSE 12 12FJX 12FJX 23 LG 02981430 1 HOSE 12 12FJX 12FJX 31 LG 02981431 1 HOSE 4 4FJX AFJX90 35 LG 02981432 1 HOSE 4 4FJX 4FJX90 20 LG 02981433 1 HOSE 20 20FJX 20FJX 24 LG 02981462 1 HOSE 12 12FJX 12FJX90 20 LG 02981986 1 DECAL HOSE amp ELEC CONNECTION 02979473 1 DECAL AW ISO VG 100 02971123 1 DECAL WARNING PRESSURIZED TANK 02965262 1 DECAL WARNING HOSE BURST 02971943 1 DECAL ALAMO IND YELLOW 02981888 1 ASY VALVE amp FITTINGS 02968896 1 PLASTIC TIE ORANGE 11LG 02968894 1 PLASTIC TIE RED 11LG 02971943 1 DECAL ALAMO IND YELLOW 02982347 1 ADAPTER HYD 16MB 10MJ STRAIGHT 02972064 1 ADAPTER HYD ELBOW 16MB 8MJIC 90 18 02981805 1 ELECTRONIC KIT includes the following 9 items 02981374 1 CONTROLLER 3 AXIS 5 BUTTON 02981375 1 HARNESS WIRE CONTROLS 02981376 1 HOUSING DISPLAY amp SWITCH 02981531 1 MODULE XP2 EXPANSION 02981532 1 MODULE XT2 EXPANSION 02981533 1 MODULE XS EXPANSION 02964028A 1 SWITCH PUSH PULL 02982252 1 DWG
55. Sectn 02981848 1 K FJX L FJX Hose 16 16FJX 16FJX 54 Lg Red Tie Motor P Dipper Sect n 02981849 1 H FJX N FJX Hose 16 16FJX 16FJX 58 Lg Org Tie Motor R Dipper Sectn 02981850 1 B FJX E FJX Hose 12 12FJX 12FJX90 102 Lg Blu Tie Case Drain Lift Sect 02981851 1 J FJX M FJX Hose 12 12FJX 12FJX 56 Lg Blu Tie Case Drain Dipper Sect n NOTE 1 Hose End 1 amp End 2 these are where the ends of that hose connect the letter shows location of that end and show type hose fitting at that end NOTE 2 The hoses have plastic ties on the to show which hose is which The colors are abreviated to YEL Yellow YEL W Yellow with Whiter stripe GRN Green GRN W Green with White Stripe RED Red RED W Red with White Stripe BLU Blue BLU W Blue with White Stripe ORG Orange ORG W Orange with White Stripe NOTE 3 Sect Location where hose is located on boom Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 15 Mounting Component ID Hyd Hose Connections 30 FT Boom Z Hole in Side Y Hole in top of Lift Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 16 Mounting Component ID Hyd Hose Connections 30 FT Boom Part No Qty End 1 End 2 Description 02981879 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg Yel Tie Door Lift Sect n 02981880 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg Yel Wht Tie Door Lift Sectn 02981855 1 Y MJ Z F
56. See Figure 4 for oil Grade with a cleanliness level of IS016 14 11 Always use a good Filter Maintenance program and Oil cleaning system before adding any oil to system Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 2 ATTENTION 10 F a F308 40F 60F 70 90 F 110 AMENER ICE aner AW VG 46 Ca mors VG d FW XXE VG 100 The correct hydraulic fluid is dependent upon ambient temperature Refer to chart when selecting proper grade 02982828 Prime Hydraulic Pump 1 The Hydraulic Pump MUST be Primed The hy draulic pump is primed by putting oil directly in to the pump Looking at the pump out near the end of the pump there is a Allen plug See Figure 5 Remove this plug and install only approved hydraulic oil oee Step 1 through 3 of hydraulic tank filling Fill the cavity completely full up to plug threads IMPOR TANT This must be done before the unit is ever started Make cer tain that the O Ring Seal is on plug and reinstall it after cavity is full of oil now the pump is primed The Unit still will not operate until the next step of setting the electronics to operate the system Figure 5 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 3 CONTROL VALVE BOOM amp MOTOR CONTROL Maverick Boom and Motor Control Circuits It is advised that this section be read before proceeding with any repairs or test with the dis
57. This is to allow hoses to be routed to where they clear other items when connecting hose put the end on that has the correct fitting as noted in drawing with 90 or the straight fitting if note marked hose routing that is to make hoses clear other items Do Not connect hose to different letter items all hose end must connect to the same letter on both ends TO ID HOSES Always check Size Length Fittings and Color Plastic Tie to identify the hoses Some hoses will have the same color tie but the size length or fittings will be different Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 11 MOTOR amp BOOM PUMP HOSE ROUTING Listed Below are the location part number hose size type and function of the hoses at the tank this list is to be used with figure 21 as a reference Item PartNo Qty Description A 02981427 1 Hose 8FJX 8FJX 90 24 Lg w Red Tie Charge Filter to Pump B 02981428 1 Hose 8FJX 8FJX 90 21 Lg w Blu Tie Case Drain to Tank C 02981429 1 Hose 12FJX 12FJX 23 Lg Pump to Suction Filter hose under pump and cannot be seen in drawing D 02981430 1 Hose 12FJX 12FJX 31 Lg w Red Tie Pressure Filter to Supply E 02981431 1 Hose 4FJX 4FJX 90 35 Lg w Red Tie Pump Load Sense to Valve PX Connects to top side of pump as shown F 02981432 1 Hose 4FJX 4FJX 90 20 Lg w Blu Tie Pump Regulator to Tank Connects to bottom side of pump not seen
58. VERTER HOSES IN SLEEVE Includes next 4 Items 02982155 1 HOSE 4 AFJX AFJX90 82 LG GREEN TIE 02982156 1 HOSE 4 AFJX AFJX90 82 LG GREEN WHITE TIE 000859 2 PLASTIC TIE 00900913 1 CORDURA SLEEVING BLACK 2 54 ID X 6 5 FT LG 02982136 1 ASY SWIVEL DOOR HOSES IN SLEEVE includes next 6 Items 02982128 1 HOSE 4 AFJX AFJX90 94 LG YELLOW TIE 02982129 1 HOSE 4 4FJX AFJX90 94 LG YELLOW WHITE TIE 02982294 1 HOSE 4 AFJX AFJX90 94 LG GREEN TIE 02982295 1 HOSE 4 AFJX AFJX90 94 LG GREEN WHITE TIE 000859 2 PLASTIC TIE 00900913 1 CORDURA SLEEVING BLACK 2 54 ID X 5 5 FT LG Hose Bundle P N 0298215 is in Component Box P N 02982396 which is in Mount Kit P N 02982395 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 7 Mounting Component ID 30 ft Cab 4 wd 02982397 Bolt Bag Consist of the following Item No T 3 Soon LEE que Part No 02982397 029 6344 00022200 02971158 00059500 02032200 02959587 00037200 5312316 02963646 00748547 02972088 02918600 00759457 00011700 00755954 02976113 02980722 03200269 02959390 00752824 00756077 02975669 02979791 00751688 00010300 Qty O RA a ire ae ND IN ee ie ee OR SD a Description BOLT BAG ASSEMBLY ITEMS 1 THROUGH 25 BOLT HEX HEAD 7 16 NC X 1 1 4 PL GR8 LOCKWASHER 7 16 PL LOCKWASHER 20MM NUT HEX 1 NC PL LOCKWASHER STD 1 BOLT HEX HEAD 3 4 10NC X 6 PL GR8
59. alve is filtered before returning to tank at this loca tion See Figure 36 The sensor monitors back pressure created by the filter assembly while cylin der circuit is in operation When the back pressure reaches 25 psi the switch will trigger and prompt the operator for a filter element change WARNING This filter does not have a by pass The element must be changed at the appropri ate time to avoid element damage and system contamination 44 WARNI N 4 a ible x y a LI Diverter Valve Plug m y F am ANE FIGURE 38 f FIGURE 38A Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 16 Decal Mounting 6 Oil Cooler amp Fan Assembly The oil cooler fan assembly bolts to the tank rail mount bracket between tractor front axle and hydraulic tank The mounting holes are inthe tank rail mounting brackets See Figure 37 amp 37A There will be two hose connected to the cooler one from the motod case drain to the cooler and one from the cooler to the tank return These hose will have blue plastic ties on them Installing Warning and Instruction Decals 1 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 th
60. ashers on all 3 4 and 20 mm bolts when using nut on bolts it will need two hardened washers one on each side See Figure 27 Double check the frame mounting bolt tightness RH Side Q Rear Top Mounting Holes use 3 4 X 2 1 Ss 4 bolts in these 4 places Front Mounting N Holes use 3 4 X 3 Rear of 2 1 4 bolts in SN Tractor these 8 places Install with these openings to front of tractor LH Side of Front of Tractor Tractor Rear Mounting Holes use 3 4 X P N 02981168 Center Section Under Mount Frame Wldmnt 3 1 2 bolts in these 8 places Figure 26 6 Install Boom Rest Weldment The boom rest weldment for the 24 foot boom and the 30 ft boom are not the same See Figure 29 The boom rest weldment bolts to the RH Side on the Rear Frame mount weldment behind the tractor axle weldment See Figure 30 It is recommended that this be installed using an overhead hoist and supported by the hoist until boom rest and support brace See Figure 28 amp 30 are completely installed The Boom Rest Support also serves as the top axle strap for the RH Axle mount See Figure 30 Hear View eu ME o VO L ED aA DENNE LS Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 6 Frame Installation T Install LH Axle Strap The Axle Strap bolts down over the top of the Axle LH Side and bolts EG S mis run through the Rear Frame rails The RH Side shown from RH the axle strap is part of th
61. bled with the hydraulic swing cylinders hoses pivot bearing assembly boom mount weldment and mounting pins installed See Figure 35 amp 36 2 Under Frame Weldment The Under frame weldment center section is designed for the turret assembly to mount on the RH side Remove the one long mounting pin and the front and back short mounting pins See Figure 36 amp 37 Checkto make certain the mounting bolts mounting the center ubder frame weldmentare installed with the bolt heads unter frame weldment and nuts are on top visible looking down if they are in wrong the swing cylinders will hit the bolts causing damge to cylinders and bolts See Figure 37 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 8 Frame Installation Turret Mount Center Section Attaching Pin Under Frame fr ng Pin Weldment Figure 34A sens Turret Mount Attaching Pin Long Pin Turret Attach ing Pin Short Pin one Front side and one rear side Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 9 Frame Installation 3 Turret Assembly Installation Theturret assembly mounts on the RH side onto the center section under frame See Figure 36 amp 37 Using a hoist or other lifting device lower the turret assembly until it is level with the underframe Slide the turret assembly inward toward the under frame until the retaining pin tube on under frame an turret assembly
62. chnical Service Dept However it should be understood that many instances may arrive where correspondence with the Manufacturer is neces sary CONTACTING MANUFACTURER Please help us Help You Before You Call Alamo Industrial Service Staff Members are dedicated to helping you solve your problem or your customer s service problem as quickly and efficiently as possible Unfortunately we receive entirely to many calls with only a minimum amount of information In some cases the correspondent has never gone outto 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 Hydraulic or Mechanical Trouble Shooting Request for Technical Information or Specifications Mounting or Fitting Problem Special Service Problem Equipment Application Problems Tractor Problem Inquiries ot DO Im 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 ofthese are available viathe Alamo Industrial Internet site www Alamo Industrial Com Attempt to diagnose or repair problem befo
63. correct order to make certain of correct operation See Figure 4 5 6 7 8 9 amp 10 9 Two Head Options There are two heads available 60 See Figure 4 5 amp 6 which has the G Figure 4 n head Swivel attachment on it The 50 Head which igure amp BENT will not have the swivel attachement See Figure9 amp 10 If using the 50 head leave the ports for swivel cylinder on boom capped See Figure 8 60 Inch we a 10 Connect Hose From Boom to Control ERAM siet Valve The cylinder hoses will connect to the control valve mounted on the front of the tractor with the exception of the Door and Swivel Cylinder hoses they will connect to the diverter valve and then there are two hoses that connect to thediverterr valve to the 6 spool control valve See Figure 11 The hoses for door and swivel will be routed under the tractor along the center under frame weldment to the diverted valve which will be mounted on the LH side of the tractor on the front frame mount bracket fe ee rr MT he Bud ta M a a i Figure 7 79 L Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 4 Boom Head Installation 12 Hose Blue Tie auem CMS Motor Case Drain Door Cyl 4 Hose a Yellow White Tie Be E Cyl 4 Hose oo Green White Tie Frama Cyl 4 Hose Green Hie 50 Inch Head w o SwivelHitch Mount Maverick John Deere 6615 6715 Asy Man 02 05
64. d is the main electrical power supply to the system this can be checked on the display unit when power is on The set up portion as shown in the next pages should be checked to make certain the joystick and motor functions are set correctly Check all the connections if not operating properly If the settings are not correct the system will not function properly Check the emergency stop E Stop switch if it is in the off position the system will not operate and the system cannot be set properly Never short across any of these components as the type electronics used can be seriously damaged Always use a volt ohm meter to test any circuits Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 4 CONTROL VALVE BOOM CONTROL Maverick Boom Control System 1 Operating the Boom Control functions is done so by means of a load sensing electronic over hydraulic system There are three main areas of that system the electronic network instrumentation and hydraulic components 2 System components are The hydraulic System The electronic network The instrumen tation and Operator Interface 3 The Hydraulic System The hydraulic components are responsible for transferring me chanical power into hydraulic power There are two separate hydraulic circuits the boom circuit and the mower head circuit 4 How the boom is controlled The system progression starts with operator input at the joystick Fig
65. draulic spool actuators for proportional characteristics Valve Construction Multi Section Individual Spool with electro hydraulic solenoids Tie rod bolt together type Valve Controller Mechanical over Electric 3 axis multi function lever type joystick Valve Porting and Hose Connections Hoses connect to valve as shown by color code See Decal P N 02981986 below Electrical connections connect as shown Reference label on connector and corresponding solenoid Hose Connector Attachment Stripe to Cylinder Base e e E ETET Solid te Cylinder Red 02981986 8 Valve Spool Functions amp Spec s Boom Feature Main Relief at Inlet 3335 psi Valve Spool Functions amp Specs Band Spool Cyl Travel Port Work Port Pressure Color No Function Direction Relief Rating G W 1 Swing Forward B 3045 psi 2 0 G 1 Swing Back A 3045 psi 2 0 OR 2 Lift Down B 1160 psi 7 92 OR W 2 Lift Up A Plug 7 92 B W 3 Dipper Out B Plug 3 17 B 3 Dipper In A 1160 psi 3 17 Y W 4 Telescope Out B 2030 psi 3 17 Y 4 Telescope In A Plug 3 17 R W 5 Tilt Up A Plug 3 17 R 5 Tilt Down B 2030 psi 3 17 G 6 Swivel CW top A 2755 psi 6 60 G W 6 Swivel CCW top B 2755 psi 6 60 Valve Spool Functions amp Specs The Cylinder Cycle has adjustable settings slow medium and fast Time Cylinder cycle of unit Time indicates the time for the Cylinder to travel the fu
66. e 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 00763977 Notice to Owner 02964677 Important Boom Rest 02963524 Attention Boom Swing 02965093 Proper Engine Operating 02965262 Warning Hose Burst 02967827 Multi Hazard 3 Multi Hazard Danger Decal This is in stalled on the Left Side Window of Cab on the inside to Drivers Left P N 02967827 See Figure 39 4 Warning Hose Burst Decal This installs on the Right Side Window of Cab on the Inside to Drivers Right P N 02965262 See Figure 40 5 Notice To Owner Decal This installs on the inside top rear of Right Door Glass P N 02964677 See Figure 41 6 Attention Boom Swing Decal This installs on the inside top rear of Right Door Glass P N 02963524 02964677 02965093 FIGURE 41 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 17 NOTES Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 18 Section 9 MAVERICK Boom amp Head Installation John Deere Tractor JD 6615 6715 Section 9 1 Boom Head Installation Boom Installation Boom Hoses 1 Turret Assembly The turret assembly has BRSWiterex s Hose Bling Gyl Hose the cylinders connected and the hoses are con with Green Tie withGreen nected to the cylinders The end of the hoses will White Tie
67. e boom support brace side of tractor weldment and also bolts down over the axle with the bolts through the rear frame rail See Figure 30 amp 31 Make certain that all the bolts mounting the frame components and the boom rest are prop erly torqued see the bolt torque chart 8 Reinstall LH Rear Tire and Wheel Rein stall the LH rear Tire and Wheel now if it has not already been done Use a hoist to lift and secure Figure 27 the rear tires is recommended as they are very heavy Boom Rest Support Weldment f 24 ft or 30 ft boom Boom Rest Weldment P N 02982392 Bolts to f 30 ft boom boom rest Bolts to top of Figure 28 tractor axle Figure 29 RH Side Boom Rest Support amp Axle Strap Weldment LH side of tractor Upper axle strap P N02974704 1 toad Figure 30 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 7 Frame Installation Counter Weight Installation 24 amp 30 Foot Boom 1 Counter Weight CWT Installation The Counter weight See Figure 1 mounts on the LH side Under Frame Weldment Its is retained with three pins the long pin on top the short pin at the rear and a short pin at the front Using a hoist or other sufficient lifting device align the weight with the frame The Frame for the weight will slide over the under frame until the upper long pin is aligned with the mounting tube of the weight and the mounting tubes of the under frame Install
68. ed and all hydraulic pressure has been relieved Check for Hydraulic oil leaks at the hose connections Operate the boom and mower head throughout its full range of motion and check for hose s rubbing pinching or kinking Make sure the Return Filter Gauge is reading in the Green after Oil is warm Check the function of the Mower Head On Off Valve and switch for proper function Make sure that the tractor will not start with the mower on off switch in the on position Check the Blade Rotation for the Rotary Mower Head to make sure it is turning Clockwise looking from the top of the mower deck Make sure the control valve boom movements agree with the valve operation decal Make Sure Boom Movement operates as expected and is smooth and under control no air in the control system Look for any unusual or excessive noise or vibrations Make sure the left rear wheel of the tractor stays on the ground when the boom is fully extended horizontally with 200 lbs placed on the outside of the mower head Post Operation Inspection Check that the oil in the hydraulic tank has not turned milky in color or has foam on top Check that there are no loose fasteners or hardware Maverick John Deere 6615 6715 Asy Manl 02 05 2005 Alamo Group Inc Section12 3 NOTES Maverick John Deere 6615 6715 Asy Manl 02 05 2005 Alamo Group Inc Section 12 4 INDUSTRIAL Maverick Assembly Manual John Deere JD 6615 6715 2005 Edition P N 02
69. eed This parameter is provided for customizable operation Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 9 CONTROL VALVE INSTRUMENTATION Maverick Operator Interface continued Choose Lutterhead tor Set Up FL ALL Others EE F2 Tinbercat Sick lebar P RES uc BET O Key the corresponding F key for the head attachment that will be used This is an important step because this parameter chooses which direction the fluid will enter the motor The Timbercat Sicklebar mower is the only head attachment that currently requires the operator to send reverse flow for all others chose F 1 key for standard directional flow sel lp Complete FL to Enable Joystick D ee Le Key F 1 to activate Joystick the Boom will not move until the joystick is activated The Boom function Set up is now complete the boom speed the head attachment has been chosen and the joystick has been activated Motor Power Condition FL to Enable Cutterhead 0l US CS DETTE _ O Key F 1 to power motor This is best done when the engine RPM is at idle speed Doing this at high RPM will cause the system pressure to surge sending fluid over the relief and causing excess heat to be introduced into the system At any time the Cutter Head Motor E Stop emergency stop can be pushed to disable the motor circuit If this is done the Switch must be raised in the run position before the mot
70. el Weight ss 7 4 Section 8 Joystick Wire Harness Valve Installation Wire Harness tractor Preparation 8 2 Replace Tractor Seat Arm Rest 8 3 E Stop MEN 8 5 Jo SS ANN 8 4 to 8 6 SOE 8 6 to 8 8 Interior Wire Harness Installation 8 7 to 8 10 Exterior Wire Harness Installation 8 11 to 8 16 Diverter Valve Harness Connections 8 14 to 8 16 Oil Cooler Faner 8 14 to 8 16 Hydraulic Tank Mounted Sensors 8 15 to 8 16 NO SS EE 8 17 Section 9 Boom Head Installation BOOM Mo UNUN eserse eon OEE 9 2 to 9 5 Boom Lift Cylinder Pin Installation sss 9 2 to 9 3 Boom Cylinder Scie malle esasescs metet pu dense anne us MR OTHER OUIUSUREE 9 6 Valve Hose SChemalic o phe R heo Roa po ER Lr xt Ha cS SER st Es ns iep ars 9 6 Hose Routing AAC oa IE 161010 NOE 9 2 to 9 12 Hydraulic Hose Color Identification Codes 9 8 to 9 12 Tank Hose to Boom GONNECUONS Lassa nu 9 10 to 9 12 Tank Hose Schematic ROUE 2 ne 9 11 to 9 12 Section 10 Fill Oil Tank Setting Electronic Display Controls SEE e E 10 2 to 10 3 Pine Fr UO EEE EE 10 3 Setting Electric Display Control BOX ocasion donis mans 10 4 to 10 11 DONS RO DO ANON RE 10 12 front Pump amp Tank Cover Installation 10 13 Section 11 Mounting Specification Component Identification John Deere 6615 amp 6715 Components On
71. ents in this mount kit WARNING DO NOT WELD On This Unit During or After Installation DO NOT WELD any components or items on this unit after the installation of the maverick Boom has begun The Maverick Boom uses electronic modules and compo nents that could be damaged by welding Before doing any welding ALL ELEG TRONIC MODULES AND DISPLAY COMPONENTS MUST BE UNPLUGGED Check the Tractors Opertion Repair Service or any other manual from the tractor manufac turer of the tractor to find any special electronic or special proedures about the tractor electronics Taking a few minutes to check could save you from a major damage to the electronics Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 2 7 NOTES Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 2 8 Section 3 MAVERICK John Deere Tractor JD 6615 6715 Optional RH Lexan Door Installation Section 3 1 Lexan RH Door Kit Installation John Deere 6615 amp 6715 Lexan Door Kit No Important Instructions RH Lexan Door Kit Remove amp Dis Assembly of Factory Stock Glass Door 1 The Removal of Factory Glass Door The removal of the factory glass door you will need to consult the Tractor manufacturers repair assembly manual Save the parts that are removed from the factory glass door as they will be needed on the Lexan Door The installation of the lexan door will be the same as the fact
72. escope Cyl IN AA6 Telescope Cylinder Out AA7 Dipper Cylinder Down AA8 Dipper Cylinder Up AA9 Lift Cylinder Down AA10 Lift Cylinder Up AA11 Swing Door AA12 Swing Door BB Solenoid Valve Connection for Diverter Valve Z1 _ E Connector XT2 Module F Connector XP2 Module AA12 G2 Exterior Harness to G1 Interior Harness H1 Lock Valve Connection AA11 H2 Lock Valve Connection Ri Cooler Fan Connection AA10 S1 Temperature Connection Sensor AA9 T1 Pump Solenoid 1 Connection AA8 V1 Pump Solenoid 2 Only on Timbercat Head AA7 v W1 Charge Filter connection X1 Return Filter Connection AA6 d Y1 Common Connect to White Wire at Filter AAS5 Y2 Signal Connect to Black Wire at Filter AA4 Z1 Negative Chasis Ground AA3 AA2 8 gt G2 AA1 Vi TT F Y W 1 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 12 H 1 LEE OE Delshelelelel E 1 aonococononas a acoooscsowocss L Exterior Wire Harness Schematic P N 02981375A Six Spool Control Valve External Wire Connec tions for valve are marked A and B on Valve amp AA1 thru AA12 on wire harness connections To Diverter Valve O O E I 2 z QU D CO O L Pressure Supply Port P XT2 Expansion 1 Transmission EA E m y Bolts on LH side i Bolt RH side in front of Valve FIGURE 30 yi
73. f the oil supplier Oil residue on the ground can result in unjury from slipping or falling Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 2 5 General Information Installation Requirements TRACTOR PREPARATION FIGURE 1 amp 2 1 Temporally remove ROPS and fenders from tractor axle Move left rear tire out so that it is 50 inches from the outside of left rear tire to the center of tractor Then move the right rear tire out so that it is 96 inches between the outside of the left and right rear tires Refer to your tractor s Operator s Manual for instructions on Rear Wheel Adjustment for your particular tire FIGURE 1 Hydraflate rear left tire as much as needed for stability but aed in factory Ge ene HUE FIGURE 1 96 WARNING Never operate the tractor with a loose wheel rim or disc Always tighten nuts to the specified torque and at the recommended intervals 2 Extend front wheels out so that it is 55 inches between the inside of the tires This will allow no interference between tire ane a mount bracket FIGURE 2 SE mS FIGURE 2 55 TT i Il iil i LILI IC IL AN SNE Li H Hii E S 5 ME LT LEE N Sa ooo SR per on aioe gt sells MA ied Tractor Area Cleanliness The Tractor all tools and work area must be clean of dirt and debris when assembling any hydraulic components DO NOT leave any hydraulic component open to the elements DO not use a
74. foot Maverick Mounted on 4 WD Tractors Only 02982395 Maverick Mount Kit JD 6615 amp 6715 Cab 4 wd Consist of the Following Items ltem Oe NOP SNS Part No 02982395 02971789 02976671 02982396 02982392 02982380 02982383 02982388 02982390 02982412 Qty Se Ne Ll ll Description MAVERICK 30 FT BOOM MOUNT KIT ITEMS 1 THROUGH 9 WHEEL WEIGHT KIT 1400 LBS AUXILLARY WHEEL WEIGHT KIT 408LBS COMPONENT BOX JD 6615 6715 MAVERICK BOOM REST WELDMENT RIGHT FRONT RAIL WELDMENT LEFT FRONT RAIL WELDMENT RH REAR RAIL WELDMENT LH REAR RAIL WELDMENT KIT JD6015 6020 LEXAN DOOR 02982396 Component Box Consist of the following Item No T 3 0 99 cJ 9 QI Pe NS Part No 02982396 02982157 02982292 02982397 02979790 02976087 02978480 02974704 02982431 02975257A 02981382 02982434 02981465 Qty 1 1 1 1 1 2 1 1 1 2 1 1 Description COMPONENT BOX ASSEMBLY ITEMS 1 THROUGH 12 HOSE BUNDLE HOSE 12 12FJX 12FJX 24 LG BOLT BAG JD6615 6715 MAVERICK CRANKSHAFT PULLEY ADAPTER PUMP MOUNT PLATE MACHINED SPACER PUMP PLATE REAR AXLE STABILIZER STRAP WELDMENT FRONT AXLE STABILIZER KIT DRIVELINE ASSEMBLY 1 15 SPLINE TANK MOUNT PLATE JD6615 7020 LH OR RH SAME INST MANUAL DEERE MAVERICK PUMP COVER MOUNT ASSEMBLY Component Box P N 02982396 is in Mount Kit P N 02982395 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 6 Mounting Component ID 3
75. h mounting kit if longer bolts are used they could go through adapter and pulley causing damage Tighten the four bolts that retain the pulley adapter to the pulley now it will be easier than trying to tighten them later See Figure 3 amp 4 Pulley Adapter P N 02979790 Figure 5 Slide the two driveline half assemblies apart and lay the tube half aside for now Make certain that the four retaining bolts for the Pulley adapter to the crankshaft pulley have been tightened 3 Install Shaft Half of Driveline with Flange Yoke Note the driveline universal joints should be timed See Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 4 3 Pump Driveshaft Assembly Instructions 4 Check the length of the spline shaft of the driveline is a must To make certain you have the right driveshaft measure the shaft it should be 12 1 2 long Measure Shaft Only If you would need to cut the shaft the correct way to cut this shaft is with a saw after cutting use a file amp grinder to chamfer the cut end and clean the splines DO NOT cut shaft with a Torch as this will change the hardness of the shaft 5 From the side of the tractor LH side slide the Shaft Half of driveline shaft end first down into the opening below the radiator from engine side insertit through the existing hole and or cut hole until the shaft is pointed toward the front of the tractor and the flange yoke is over far enough to align w
76. h the Yoke to hold Driveshaft up and to help loosen the Bolts in the clamp Yoke See Figure 14 This can be loosened with a hand Wrench or a Socket whichever is easier for you See Figure 14 Some times it is easier to test fit the Tube End of Driveshaft to the Pump while the Pump is on the bench 4 Remove Pump Shipping Bracket The pump is shipped using a bracket that bolts to the pump and the tank assembly Before pump can be installed it will have to be unbolted from pump and tank The shipping bracket is for shipping only and will not be used When unbolting pump from tank assembly there are hoses that will have to be disconnected from pump as tank to pump hoses filters are connected when assembly is shipped Caution must be taken when disconnecting these fittings and or hoses to keep the capped to keep contamination out of them 5 Coat Pump Shaft w Anti Seize Compound Coating the pump shaft with a quality Anti Seize Compound will help protect the shaft and possibly make it easier if there is a need to disassemble See Figure 16 Hoses will have to be disconnected so pump can be removed from tank assembly during pump mounting All hose and fittings need to be covered and sealed to keep them free of contamination A recommended way to do this is sandwich bags and rubber bands that will work well a 1 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 4 6 Pump Driveshaft Assembly Instructions Ins
77. ie FIGURE 7 S BA em ES i l ie D CS 1 zu b F 1 FIGURE 9 Es i p p LL IT Luis t rg ci T dl te AA near AS Section 5 9 NOTES Maverick JD 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 5 10 Section 6 Maverick Boom Main Frame Installation John Deere Tractor JD 6615 6715 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 1 Frame Installation O Under Mount frame Asy 1 Before beginning any repairs on this section make certain the boom is extended outward to full extend and laying on the floor Before removing the Boom Pivot Pin support the boom with an overhead hoist so as when Pie is removed boom can be lifted out of the way NEVER REMOVE ANY PINS OR BOLTS unless boom is supported at pivot end and head end is resting on the floor 2 The under mount frame asy is made up of the Turret Center Section Frame Weldment Boom Mount Swing Cylinders Swing Cylinder Trunnion Mount Turret Cylinder Link and Counter Weight 3 The Turret Asy will be shipped assembled to the Boom mount with the hoses and cylinders plus attaching hardware assembled to it 4 The Swing Cylinders have replaceable mounting bushing which can be replaced by removing the bottom cover and trunnion mount weldment The Cylinders can be dropped down enough to replace the bushing The replace the Trunnion Mount weldment Also by removing the cylinders the Turret Cylinder link ca
78. ight it will increase the wheel weight by 408 Ibs This makes the total bolt on wheel weights equal 1800 Ibs 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 02976671 Qty Part No Description 2 00012200 Lockwasher 7 8 2 00012300 Nut 7 8 NC 2 00760266 Bolt 7 8 NC X 5 1 2 GR8 3 02976644 Auxiliary Wheel Weight Plate 136 lbs Each 2 Install Auxiliary Wheel Weights The Auxiliary Wheel Weight bolt to the larger 1400 Ib 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 02970758 Auxillary Weight Figure 5 Figure 4 Attaching Stots Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 7 4 Section 8 MACHETE Joystick Wi
79. ility on the network See Figure 11 The XS is responsible for receiving the signals from the joystick and other in cab inputs and making them available on the network REFERENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANUFAC TURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com Maverick John Deere 6615 6715 Asy Man 02 05 Section 10 7 2005 Alamo Group Inc XP2 Expansion Power Analog Inputs 4 Prop Output 4x Digital Inputs 4 Digital Outputs 4 Freq Inputs 2 E Gas Op 110 XT2 Expansion Transmission Analog Inputs 10 Prop Outputs 2x J1909 CAN hub 4 Digital Outputs 6 Freq Inputs 3 E Gas 1 Op 111 FIGURE 10 XS expansion signal CONTROL VALVE INSTRUMENTATION Maverick Instrumentation Instrumentation The Maverick Boom uti lizes instrumentation for certain decision making activities Listed below are the sensors included on this unit Tank Temperature Sensor Charge Pres sure Filter Switch Valve Pressure Filter Switch and Return Filter Switch Tank Temperature Sensor The tank tem perature sensor monitors the fluid temperature in the area of the pump suction screens the tempera ture is real time and is used on the network to accomplish certain objectives The first is to display on the interface while the cutter circuit is operating The sec
80. in Boom Mount Attaching Pin Long Pin Turret Cylinder Link Center Section Frame Weldment Boom Mount Attaching Pin Medium Pin Boom Mount Machined Boom Mount Attaching Pin Short Pin Swing Cylinders Swing Cylinder Pivot Bushings Swing Cylinder Trunnion Mount Weldment Swing Cylinder Cover Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 3 Frame Installation Frame Installation 1 Frame Components The frame will include the rear axle mounts a LH amp RH Frame rail Two front frame mounts a LH amp RH One center frame LH Rear Frame weldment See Figure 17 18 19 20 amp 21 Mount Weldment P N 02982390 2 Install Frame Components The Frame components will only fit one way The Frame com ponents are a Bolt together assembly no welding will be required The Frame components will bolt together and to the tractor using mostly 3 4 and or 20 mm bolts Each 3 4 amp 20 mm bolt will use hardened flat washers one on the head side when bolts go into the tractor castings Two washers used when bolts use a nut and go through the Ei 17 frame These hardened washers are important Igure RH Rear Frame Mount Weldment P N 02982388 RH Front Frame Mount Weldment P N 02982380 Figure 19 Center Frame Weldment P N 02981168 LH Front Frame Mount Weldment P N 02982383 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Sec
81. ith the four threaded pulley adapter holes 6 Align the four holes in the flange yoke of driveline with the four threaded holes in the pulley adapter Install the four retaining 7 16 X 1 1 4 long bolts P N 02976344 and 7 16 lockwasher P N 00022200 into flange yoke into adapter tighten them at this time These four bolts can be tightened by using a long socket extension run through along side the driveline shaft If the driveshaft needs to be turned to reach the pulley adapter mounting bolts Insert the tube end of the driveshaft over the shaft end of driveshaft slide a bar through the yoke of the driveshaft and this will allow you to turn the pulley adapter to reach hard to get to bolts See Figure 7 amp 17 T Set the tube end of driveshaft aside for now as it will be installed later But always remember the driveline universal joint must be aligned timed when assembling the driveline halves oplined Clamp Yoke Tube End Flange Yoke Shaft End Drive Shaft a Assembly WM m ut i n pa i Sus 11 Figure 6 o Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 4 4 Pump Driveshaft Assembly Instructions Install Tank Rail Weldments 1 Install Tank Rails The tank mount plates P N 02981382 LH and RH are the same part number and will fit either side can be installed before driveshaft to engine or after These will bolt on using the two holes to the bac
82. k of the tank mount plate This will need to be done before the hydraulic tank can be mounted do not tighten these two bolts two each side now as if they are left a bit loose it will be easier to align the hydraulic tank between them later See Figure 8 9 amp 10 RH Side Shown Figure 11 RH amp LH Side are Tractor End the same part Tractor Figure 10 LH Side Shown Tube End of Driveshaft Splined Clamp Yoke Installing Pump Mount Plate amp Tube End of Driveshaft Vg Install Pump Mount Plate Install Front Pump Plate See Figure 11 use the 2 Spacers on the JD 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 11 tighten them to required Torque See Bolt Torque Chart Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 4 5 Pump Driveshaft Assembly Instructions Installing Pump Mount Plate amp Tube End of Driveshaft 2 Install Tube End of Driveline Pump End Slide the Tube half of driveshaft through Pump Mount Plate and Tractor Crankshaft Access Hole See Figure 12 amp 13 You will have to align the Universal joints when doing this time the Driveshaft Slide the two together where the Universal are in time See Figure 5 this will help the driveshaft to operate smoothly 3 Loosen Splined Clamp Yoke Insert a bar throug
83. k valve When the function to raise the Head is activated there is no electric signal from Joystick The pressure against the valve when head is being raised will force Valve open like a relief Valve allowing Oil to pass through it If this valve will not open it could stop head from lifting or dropping The valve is plumbed into the Hydraulic Circuitry of the Head Tilt Function and is located near the Control Valve 3 Hydraulic Lock Valve 2 Item Part No Qty Description y 2 p 02972208 Solenoid Valve Assembly 1 02971425 1 Seal Kit f solenoid Valve 2 02975198 1 Coil 12V DC w Dual a 8 32NF Studs 02975199 1 Cartridge Solenoid Valve 3 l 4 02975438 1 Adapter Hydraulic Straight 8MB 6FJX 5 02981890 1 Adapter Hydraulic Straight 5MB 6MJ Diverter Valve The Diverter Valve bolts onto the front frame mount bracket on the LH side of the tractor the holes are in the bracket See Figure 5 6 amp 7 The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two or more if valves are stacked functions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pressure The Port openings on this diverter valve are marked with letter number codes which show which port is connected to which hose and where that hose connect on other end See Figure 5 4 amp 7 Port Function amp Connection P
84. l Control Valve eS 40 External Wire Connec tions for valve are marked gt 2 A and B on Valve amp a AA1 thru AA12 on wire OD harness connections i O Te Pressure Supply Port P Diverter Valve C1 Port to Swivel Cyl Base End Port G W Tie Valve B Port to Diverter valve P1 Port G W Tie Diverter Valve C4 Port to Swivel Cyl Rod End Port G Tie 4 Through holes are mounting holes EN Diverter Valve C3 Port Valve A Port to to Door Cyl Rod End Diverter valve P2 Port Port Y Tie Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 9 Diverter Valve C2 Port to Door Cyl Base End Port Y W Tie Boom Head Installation 12 Routing Boom Hoses to Pump The Boom hose to the pump will be routed on the RH Side of tractor They will be run through sleeving material and hose support bracket See Figure 18 The Pump hoses must be connected correctly to the boom and pump There are 2 Pump to motor hoses and 1 motor case drain return hose for a total of 3 Note Motor Case Drain hose will be run through the Oil Cooler and then return to tank First is the 20 hose with the red plastic tie the lower connection at Boom See Figure 17 this is the pressure supply from the pump lower connection at pump See Figure 20 to the motor connection at the boom Second is the 20 hose with the orange plas tic tie the upper connection at boom See Figure 17
85. ll amount of its extension or retraction The lift times up and down are taken with the dipper fully extended and begin with the Deck flat on the ground All Cycle times are measured at the rated Tractor RPM Test Times should vary as according to the setting being used Valve Leakage Maximum internal Valve Leakage from the Cylinder Ports to Tank at any Valve Segment Oil Pressure at 1450 PSI and Oil Viscosity at 102 SSU 1 25 Cubic Inch Minute Standby Pilot Pressure Standby Pilot Pressure 200 to 250 PSI Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 1 6 SPECIFICATIONS MAVERICK 9 HOSE END FITTING TORQUE SPECS Hose End Type 37 Degree Angle End Steel Hose End Fittings Dash Nominal Cyl Torque Torque Size Size in in Ibs ft Ibs 4 1 4 140 12 6 3 8 230 19 8 1 2 450 38 10 5 8 650 54 12 3 4 900 75 16 1 1200 100 20 1 1 4 1600 133 24 1 1 2 2000 167 32 2 2800 233 Straight Threads do not always seal better when higher torques are used Too much torque causes distortion and may lead to leakage DO NOT over torque fittings and DO NOT allow any contaminants to enter system through fittings when installing them 10 Special Torque Specifications Rotary Heads MOIS tO Spindle NN E TT 100 ft Ibs ICIS DECK ER EE 425 ft Ibs Spindle to Adjusting Nut Bearing Preload 25 in lbs Rolling Torque Blade Bar Leaf Bolts 1 1 4
86. ll be the 6 hose with the Orange Tie and the 6 hose with the orange White Tie When pulling ex tending or collapsing cylinder always put the opened end of the hoses into a clean drain pan as oil will run out of the cylinder when extended or collapsed After installing the cylinder lower mounting pin re plug the hoses that were in the drain pan until ready to connect hoses T Connect Head to Boom The mounting pins to install the head onto the boom will be shipped installed in the mount weldment Re move the mounting pins Use the hoist to lower boom down over head to connect head Align the upper head mount pin The lower mount pin is the connect the lift link See Figure 4 amp 5 The Door Cylinder and the Swivel Cylinder are shipped installed on the head with the hoses connected to the cylinder u i i Figure 3C d Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 3 Boom Head Installation 8 Heads Are received from the Factory with the Cylinder and Head hoses Attached to Head The head will be received with the door cylinder swivel cylinder and Motor attached to the head gt SO len Head The Hoses for the cylinders and the motor will ag Swivel Hitch Mount connect to the boom There is a decal that is installed on the side of the boom that shows where the hoses connect to the fitting that have are located on the side of the main Boom The hoses must be connected in the
87. lugs are in the hole and not FIGURE 6 being pinched See Figure 9 amp 12 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 3 Joystick Electrical Mounting Resistor Harness P N 02981990 Is attached to the Joystick when it is recieved Wire Harness Side el SLE FSF wuy Pin Numbers 5 a S S E Locations 6 2 i PCB Assembly po i Pin Numbers amp Locations Joystick Side FIGURE 7 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 4 Joystick Electrical Mounting 4 Resister Harness to Joystick The Joystick will be shipped with the resister Harness connected to it as an assembly See Figure 7 amp 8 The Interior wire harness plug has 2 connectors on it A 9 Pin Connector labeled J1 and a 6 Pin Connector labeled P1 These two connections will plug into the interior wire harness with the same code when the interior harness is installed See Figure 7 amp 8 The Interior harness is run under the RH side Panel and along the rear panel You will need to cut a notch in the rear panel to allow the harness to pass between the two panels where they meet near the bottom 5 Interior Wire Harness The interior wire har ness has all the connections needed to connect interior components The RH side interior panel of cab will need to be loosened and or removed this allows mounting of the XS module See Figu
88. lve Connections fed 2 F O D 52 o 5 P c o D Se ER Q oo o o gt 45 HF n Lo OL eo o ON 100 ISAIMS PESH Q BT PS l CL J ET MN I FI on x mr PA i WIL peer ie Jeddig AY O ank Heturn Connection a ee m ci ar T2 Service Port Connection A Port A Port Load Sense Signal PL Pump Pressure Connection P1 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 20 Mounting Component ID Cyl Cntrl Valve Connections HYDRAULIC HOSE CODES Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some have a Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attachted to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose Always Check Hose Size Color Code amp Part Number Boom Cylinder Circuit Hoses connections from Control Valve Color Tie Green Green White Orange Orange White Blue Blue White Yellow Yellow White Hed Hed White Green Green White Yellow Yellow White Code G G W OR OR W B B W Y Y W R R W G G W Y Y W Hose Size SAE 6 SAE
89. ly listed read Component page for details Mount KIECORmIDOFODIS ae eme 11 2 to 11 26 Component Parts Identification Descriptions 11 2to 11 26 Section 12 Pre Delivery Inspection Check List Suede 12 2 to 12 3 Maverick John Deere 6615 6715 Asy Man 02 05 O 2005 Alamo Group Inc Index 3 NOTES Maverick John Deere 6615 6715 Asy Man 02 05 O 2005 Alamo Group Inc Index 4 Section 1 Model Specifications Maverick Boom 24 amp 30 SPECIFICATIONS MAVERICK READ THIS BEFORE BEGINNING ASSEMBLY REPAIRS OR TESTING The Maverick has computerized electronics The electronic components can be damaged if care is not taken when performing repairs testing and or during assembly DO NOT DO NOT short any wires across or allow them to be shorted out 2 DO NOT attempt to jump across any wires or supply them with alternate power source 3 DO NOT install higher rated fuses than are recommended by manufacturer 4 DO NOT do any welding on unit unless the computer modules are unplugged first this is to prevent a power surge going into modules THIS IS VERY IMPORTANT This could also apply to the tractor components Check Tractors repair guide for specific instruction about tractor model and type 5 DO NOT attempt to repair or adjust a component that is not intended to be repaired example sealed components as there are no serviceable components inside
90. n Rod End Telescope Out Base End Head Tilt Up Rod End Head Tilt Down Base End Swivel CW Rod Enq Swivel CCW Base End Door Open Rod End Door Closed Base End Hyd Function Pressure Flow to Motor Return Flow From Motor Case Flow From Motor to Boom Case Flow at Boom to Tank 6 HYDRAULIC CYLINDER PRESSURE RATES Oylinder TE Welded Cylinders Cylinder Working Pressure 3000 PSI Hydraulic Cylnder Repair Specs Cylinder Cylinder Piston Nut Gland Seal Kit Part No Function Torque ft Ibs Torque ft Ibs Part No 02981275 Swing 400 500 80 120 Head 02982066 02981278 Lift 30 ft 400 500 80 120 Head 02982069 02981279 Lift 24 ft 400 500 80 120 Head 02982070 02981277 Dipper 400 500 80 120 Head 02982068 02981280 Tilt 400 500 80 120 Head 02982071 02961480A Door Rotary 150 250 80 120 Head 02975528 02970710A Door Flail Axe 40 60 80 120 Head 02975532 02971423 Slide Timber Cat 400 500 50 60 Tie Rod 02973505 02811000A Door Ditcher 150 250 80 120 Head 02975528 02981316 Stabilizer 40 60 80 120 Head 02982073 02981315 Swivel Rotary 300 400 80 120 Head 02982072 02981276 Extension 300 400 80 120 Head 02982067 Maverick John Deere 6615 6715 Asy Man 02 05 Section 1 5 2005 Alamo Group Inc SPECIFICATIONS MAVERICK 7 VALVE SPECIFICATIONS Valve Type Multi Section Load Sense Pressure Compensated Directional control Valve Features electro hy
91. n be removed 5 The Turret assembly has a large bearing assembly bolted to it and then bolted to the Boom Mount This Bearing CANNOT be removed or replaced unless the Boom is disconnected from it first When disconnecting boom make certain the boom is supported as not to fall See Step 1 The Bolts retaining the turret to the bearing and the bolts connecting bearing to the Boom Mount MUST be torqued to the required specification This is very critical See the Bolt Torque Chart in the beginning of this manual 6 DO NOT remove any mount pins and or bolts unless the components are supported properly to prevent them from falling f The Turret Bearing Assembly has 3 grease fittings each 120 apart All three of these grease fittings must be greased because of the diameter of the bearing this to ensure an even distribution of grease though out the diameter of the bearing assembly 8 If the hoses for the swing cylinders are disconnected or replaced make certain that they are reconnected correctly as shown in this section Swing Cylinder Hose Routing If the hoses are not connected correctly the swing will not function correctly Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 2 Frame Installation Under Mount Frame Asy 24 amp 30 ft are the same except for the LH weight 30 ft model only LH Counter Weight Turret Asy Machined Turret Boom Mount Pin Weight Attaching Pin Long P
92. nd adjustable wrenches Alignment pins Forklift or hydraulic floor jacks with rolling back boards Small chain hoist or block and tackle Multidirectional Levels Hydraulic Filter Buggy or Cart Safety shoes safety glasses and gloves A hard hat should be worn by anyone working under any raised component LE al dl I er 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 An uncluttered assembly area and a crew that is sensitive to the hazards involved in putting this implement together will help prevent accidents Keep all unauthorized personnel from the area 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 assisting with the assembly To help you assemble your new Machete Boom and mount it to your tractor a detailed assembly instruction Manual is being provided with the mount kit to provide detailed instructions and part numbers Please consult this document for specific information When needed you can get additional information or clarification from Your Dealer or Alamo Group Customer Service 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
93. ness Code Connection Can 1 XS Module Can1 Connection 2 of 3 Connections Can2 XS Module Can 2 Connection 3 of 3 Connections CC1 Positive Key Switch Connection MUST Connect to key switch wire CC2 Negative Chasis Ground D XS Moudule C1 Connection 1 of 3 Connections G1 Exterior Harness G2 Plug coonnects Interior amp exterior Harness J1 Joystick Resister Harness 9 Pin Plug K3 Control Box Display Connection 1 of 2 Connections M1 E Stop Switch use or B of Switch M2 E Stop Switch use A or B of Switch X1 Control Box Display Connection 2 of 2 Connections FIGURE 14 Maverick John Deere 6615 6715 Asy Man 02 05 O 2005 Alamo Group Inc Section 8 7 Joystick Electrical Mounting 8 Wire Exterior amp Interior Harness Schematic The wire harness schematics and instructions will need to be used together to install the wire harness The interior Harness and the exterior harness will connect together with one plug connection Figure 14 16 17 18 amp 19 pertain to the interior harness Plugs have codes on them to identify where they connect the connections will have codes on them to identify where the connection goes The code on the plug and the code on the connection may not be the same see the code connection listings in the illustrations to identify the connection location 9 Plugs for Display Control Box The wire plugs for the display control box will come up through the small cover on
94. ng Specifications John Deere 6615 6715 Cab 4wd Effective Date 01 25 05 10 00 16 F 2 Min 11 00 16SL F 2M Max 2wd Front Tire 13 6 24 R 1 Min Max 4wd Front Tire 18 4 34 or 460 85R34 R 1W Min Max Rear Tire Mount Kits 30 Maverick 4wd Mount Kit eere eee nnn nnne 02982395 Options Extra Maverick Installation Manual 02982434 Standard Features 1 Replacement arm rest with joystick console 2 Neapco style driveline with double U joints 3 All mount kits include a 1400s wheel weight 4 30 mount kits include an additional 4084 auxiliary weight kit 5 3 8 Lexan replacement door and side window right side only 6 9 1 4 of ground clearance with the min tire size shown f Front axle stabilizer kit 4wd models only Restrictions 1 2wd tractors must be equipped with heavy duty eight bolt front wheel hubs amp spindles 2 30 Maverick booms must be mounted on 4wd tractors only due to front axle spindle loading 3 The right hand rail must be removed for boom transport clearance Manual Can Be Used For Other Models This Manual can also be used to mount these models 6415 6420 7220 7320 7420 amp 7520 The instructions will be the same but some of the components will be numbered different even though they may look the same Use the packing slips that are shipped with the kit to determine part number Do not use part numbers in this section they may or ma
95. ng boom on turret assembly Main Boom Mount Pin 4 Booms amp Lift Cylinder Mounting Pins din The Boom and lift cylinder mounting pins are shipped installed in the turrert assembly Re move both pins in preparation to mounting the boom See Figure 3 Lift Cyl Base Figure 3 ent Pin Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 2 Boom Head Installation 9 Lower Boom onto Turret Assembly Us ing an over head hoist lift the boom by placing a lift strap at the boom hinge point See Figure 2 the boom assembly will be shipped with the two boom end tie wired together See Figure 3A The wire tie will need to be removed as it is tied through the boom hinge pin hole Lift the boom above the turret assembly and lower it back down onto the turret assembly aligning the boom with the mounting pin hole Install the RAA Mount Pin through the turret and into the boom Make certain the pin Is installed cor igure 2A rectly as one side of the pin is self locking In design Tighten the pin retaining nut and install cotter pin See Figure 3C Lift Cylinder 6 Connect lower end of Lift Cylinder The Base end lower end of lift cylinder will mount 4 into the turret under the boom mount The Cyl inder will have to be extended to connect If cylinder has to be extended the best way is to unplug the ends of the lift cylinder hoses where they come out of the boom these wi
96. ny containers for fluids that are not clean and free of any other liquids DO NOT use rags cloth that has lint or fuzz on them when working on hydraulic components Keep all hoses capped until you are ready to connect them Maverick Cleaning The Maverick Components are designed to be water resistant But the sealing can be damaged by Pressure Washers Steam Cleaners Solvents or any other harsh chemical that would be used to clean the units components It is important to keep all electrical connections and components sealed and dry When washing and cleaning this unit it should be done with a non corrosive soap and low pressure spray of water It is recommended that all exposed electronic components be covered and protected from excess moisture Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 2 6 General Information Installation Requirements Lay Out Components in Display It is helpful to lay out the component in as neat a display as possible Lay out the Bolts according to size and length Lay out the Nuts and washer by size This will allow you to see how many of each part as you use them and help to identify any missing parts See figure 6 See Mount Kit Specification and Component Identification Section to help ID Components All the component that are received should be check and sorted as to what they are Shown below is a general example of the components laid out this is not a lay out of the compon
97. on Installation Requirements MARRNINEE Disconnect the negative lead ground from the battery terminal to prevent any nuus ELT low fe Y KA ga j j S p X N fad tr b SPE r LEVELING TRACTOR TRACTOR MUST be on level ground before assembly is begun The tractor must be level All tires must have the proper amount of air in them as per tire and or Tractors manufactures recommendations DO NOT level tractor by over inflating tires The tractor can be leveled by jacking it up and putting it on jack stands if needed Replacement Oil Filter 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 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 Unpacked the Mower unit carefully so that the seals on the hydraulic components are not broken or pulled off WARNING Before attempting to assemble the mower to the tractor move the tractor to a clean solid surface preferabl
98. ond is to be used to control the electric fan on the hydraulic cooler At any time the fluid level reaches 150 F the fan is activated and remains activated until fluid temperature drops to or below the desired temperature See Figure 12 The Charge Pressure Filter Switch The charge pressure filter switch is located at the filter in the charge loop on the hydrostatic pump See Figure 13 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operator for a filter element change of filter element The Valve Pressure Filter Switch The Valve pressure filter switch is located at the pres sure filter in the valve pressure circuit between the closed center load sense pump and the control valve See Figure 14 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operator fora filter element change WARNING This filter does not have a by pass The element must be changed at the appropriate time to avoid element danmage and system contamination B Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 8 CONTROL VALVE INSTRUMENTATION Maverick Instrumentation continued The Return Filter Switch The return filter switch is located at the return filter
99. oor 6 Access Panels of Tractor interior Panels in the cab will need to be loosened and or removed to gain access to connections and or mounting of components Do not remove any panels until instructed to do so Installing Seat Replacement Arm Rest te Replace RH Factory Arm Rest The fac tory seat RH arm rest will be replaced with a weldment designed to serve as the armrest and mount for the emergency stop switch and the joystick assembly See Figure 5 6 amp 7 Unbolt the Arm Rest Weldment factory arm rest and bolt on the replacement arm P N 02981415 rest The Arem rest is retained using the same type method as thr factory arm rest this is what allows the arm rest to be raised up and down See Figure 6 See the bottom of the welded replacement arm FIGURE 5 rest It may be required to use adie grinder in slotted hole th help with alignment of retaining bolt See Figure 6 Under Side of 2 Install Emergency Stop Switch The emer Welded Arm gency Stop E Stop Switch mounts into the arm Rest with rest in the smaller of the two holes The Knob and Slotted Hole mounting nut will need to be removed and the switch installed from the bottom of the arm rest Replace mounting nut and knob See Figure 5 7 amp 8 3 Locate Joystick Assembly The joystick assembly has a flange around the bottom it uses 4 screws to mount joystick to the arm rest Lower the wiring of joystick down through hole in arm rest Make certain the three p
100. or circuit can be reactivated Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 10 CONTROL VALVE INSTRUMENTATION Maverick Operator Interface continued Cutterhead is On Oil Temp nl I F RS DE Atthis time the motor circuit is powered and the mower head motor is active This screen also shows the tank temperature in degrees Fahrenheit To turn off the motor at this time Key F 1 Turn Ut doat ick key FL to Disable Jowstach EE i i The Joystick Master control switch must be off to prevent accidental movement of boom and cutting head when ever mower is not being operated such as when in transport Cylinder Supply Pump Pressure Adjust If Needed Ld as a Special Note If after setting the display d controls check to make certain that functions operate correctly If the Boom will not lift The Pump for the Cylinder supply may have to be adjusted Pressure Adjust This is a simple process that will require a 7 16 s Control 7 16 Hex wrench for this adjustment and a 1 2 wrench for the _ locking nut Looking on the LH side of the pump there are two adjustments one has a 7 16 hex head and the other a ridged round head Only adjust the one with the hex head DO NOT adjust or change the round ridged adjustment as it is set from the factory Adjust the 7 16 hex one by turning it in till it seats completely Do not force adjustment after is sea
101. ory glass door using most of the same hardware again consult the tractor manufacturer assembly repair instruction in the tractor manufacturer repair service manual Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 3 2 Section 4 MAVERICK Pump amp Driveshaft Installation John Deere Tractor JD 6615 6715 Pump Driveshaft Schematic Tractor Engine Pulley Time Universal Joints Pump End Pulley Adpater w Mounting Bolts amp Washers 4 bolts Clamp Yoke Driveline Asy SES ae i9 4 Driveline Mounting Bolts Mounting Bolts Pump Mounting Af Pump Mount Bolts Plate Bolts To Mounting Bolts Tractor Bolster p d a Pump Reference Pump Drive Schematic This Section covers the installation of Pump Drive Components Pump Assembly Some precautions that must be followed during the Assembly Process before unit is ever started for the first time Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 4 2 Pump Driveshaft 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 damage to components 2 All Fittings
102. ounting rails See Figure 1A amp 9 The tank hoses will have two connections one that is the motor case drain from the boom which is a 16 hose with a blue plastic tie The other hose is ashort 16 hose that connects to the cooler and them to the tank These will be connected later when the boom is mounted See Figure 9 2 Oil Cooler Operation Design Information The Oil cooler fan assembly is for cooling the oil being returned from the Motor Case Drain The fan is connected to the control box and is turned on amp off automatically It set to run on a program that will run the fan in the cooling rotation for a designated time then stop reverse the rotation cycle to clean debris off of cooler then stop and reverse the fan again and begin the cycle all over again The connection to the cooler on the exte rior wire harness is marked with code R1 The connection from the fan will have two wires a Blue connection and a black connection See Figure 8 9 Exterior wire harness con Tr i E nection marked R1 connects here FIGURE 8 Maverick John Deere 6615 6715 Asy Manl 02 05 2005 Alamo Group Inc Swivel Cyl Base End C1 Port G W Tie NE Swivel Cyl Rod N C4 Port G Tie From Valve A nnde me 1 094 Port to P1 Diverter e E FU Base End Port G WTie i HT d E hi alve A B Pc d piv tet Porya gt Por G Tie ior Cyl Ro t 3 Port vi
103. play and electronics used in this application the system will test many components for you This is done by following the prompts on the display screen DO NOT pressure wash this system while the components are sealed the soaps acid and high water pressure used in the pressure washer can damage these seals and cause moisture to enter system causing damage DO NOT do any welding around these electronic components If welding is required in a repair the electronic components MUST be disconnected unplugged Un plug all components Joystick Modules Displays and any other electronic component If not unplugged the current from the welded can cause serious damage to electronic components Additional repair and diagnostic procedures for the electrical system is available on the internet web site of the manufacture of this system at REFERENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANUFACTURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com Make certain that the instructions you refer to is for the MDM system the manufacturer has more than one System The boom and motor control is electronic over hydraulics If these functions are not properly set or working properly the mower can not be operated Also make certain that all fluid levels are OK and with in operating limits The first thing that should be checke
104. r Circuit Hoses to Boom Connections Listed as reference Color Tie Code Hose Size Hyd Function Red R SAE 16 Pressure Flow to Motor Orange OR SAE 16 Return Flow From Motor Blue B SAE 8 Case Flow From Motor to Boom Blue B SAE 12 Case Flow at Boom to Tank Diverter Valve The Diverter Valve bolts onto the front frame mount bracket on the LH side of the tractor the holes are in the bracket See Figure 5 amp 6 The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two or more if valves are stacked functions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pressure The Port openings on this diverter valve are marked with letter number codes which show which port is connected to which hose and where that hose connect on other end See Figure 4 5 amp 6 Port Function amp Connection P1 Hose Hydraulic Pressure from Door Swivel B Port on Control Valve G W Tie P2 Hose Hydraulic Return to Door Swivel A Port on Control Valve G Tie C1 Hose to Head Swivel Cylinder Base End G W Tie C2 Hose to Door Cylinder Base End Y W Tie C3 Hose to Door Cylinder Rod End Y Tie C4 Hose to Head Swivel Cylinder Rod End G Tie Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 9 8 Hydraulic Hose Connections Oo OD Six Spoo
105. r Support Brckt See Mount Kit amp Component ID section for Axle sl Stabilizer component list Figure 42 2 Install Front Axle Stabilizer Cylinder Hoses The front axle stabilizer kit will consist of two hoses One hose will connect to the rod end of the stabilizer cylinder and connect to a Tee fitting on the B of the control valve where the boom lift cylinder hose connects See the valve cylinder hose routing in the boom head installation section The Second hose connect to the base end of the stabilizer cylinder and connect to the return port on the tank with a Tee fitting at the F Tank return connection See the tank hose routing in the boom head installation section for schematic of hose connections Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 11 NOTES Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 6 12 Section 7 MAVERICK Standard Wheel Weight amp Auxiliary Wheel Weight Installation John Deere Tractor JD 6615 6715 Rear Wheel Counter Weight Fill Left Rear Wheel with Liquid The Left Rear Wheel must be filled with liquid Alamo Industrial recommends a Calcium Chloride Water Mixture The recommended Ratio of a 30 70 mix 30 Calcium Chloride and 70 Water this mixture will add weight at about 10 5 Ibs per gallon Follow the Mixture procedures furnished by the Manufactured of the Brand of Calcium Chloride that
106. r cab behind the right hand side panel See Figure 13 amp 14 The Connections Three Separate Pugs Can 1 Can 2 amp D will be inside the side panel after it is reinstalled and will not be visible unless you remove the side panel See Figure 14 16 17 amp 18 The XS Module does not have a mount bracket it will need to be mounted by the assembly technician inside panel where it will be out of the way notinterfere with any tractor components and be secured It can be tied in or bolted The Only Plugs protruding from behind RH Interior panel shoud be the plugs for the display control box See Figure 14 16 17 amp 18 mm p oe O o u ee eee o o0 CON RR OO O o O 7 EE gum E XS Module P N 02981533 i int WII l FIGURE 13 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 6 Interior Wire Harness Schematic P N 02981375B Remove console cover tie strap J1 Joystick Connection 9 Pin XS Module P N 02981538 inside p console D XS Module P1 Joystick Connection 6 Pin Connector D Can 1 XS M Module Connector CC1 Pos Key Switch Connection CC2 Neg wae ae Chasis Module Ground Connector X1 Control K3 Control Box Display Box Display Connection Connection G1 Connects to G2 Plug 7 of Exterior Wire Har
107. raight 8MB 6MJ Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 5 4 Directional Control Valve Fittings A Bp Ports Ports L Port Load Sense Signal dpa iara P1 Port il ON BOO nu wi 19 9 ir ROS EC swine Es OO KK Dipper ETE a OO CIC Telescope Se nio Pr jack Head DP 186000 l Head Swivel Door 1j F er I a NO Tank Return Port LT il FT 7 IL LE ETT i wo Maverick John Deere 6615 6715 Asy Manl 02 05 2005 Alamo Group Inc Section 5 5 Directional Control Valve Fittings HYDRAULIG HOSE CODES AT VALVE Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some are Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attached to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose Always Check Hose Size Color Code amp Part Number See Figure 5 Boom Cylinder Circuit Hoses Color Tie Code Hose Size Port Diverter Hyd Function Green G SAE 6 A Swing Back Rod End Green White G W SAE 6 B Swing Forward Base End Orange OR SAE 6 A Lift Down Rod End Orange White OR W SAE 6 B Lift Up Base End Blue B SAE 6 A Dipper In Rod End Blue White B W SAE 6 B Dipper
108. re 6 amp Next pages for wiring schematics continued in step 6 Switch owitch Mounting Nut ARNA Wire Fasteners 4 Depth Control Clip Knob 29 S Knob Retaining Knob Plug ke FIGURE 8 mr la 4 FIGURE 9 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 5 Joystick Electrical Mounting 6 Interior Wire Harness continued The interior wire harness schematic See Figure 11 amp 12 shows the wire harness as it is run through the cab The XS Module will need to be mounted inside the cab the best place is behind the RH side panel See Figure 6 9 amp 12 The wire harness will need it be put under this panel also with the connectors in the appropriate place to connect with the interiorcomponents The harness to the joys stick will need to be run along the panel at the back of the cab CAUTION The Harness has two wires that run under the floor mat the positive wire MUST connect to the ignition key switch of the tractor for a power source DO NOT Connect the positive wire anywhere else See Step 9 amp Fiqure 14 wire CC1 The plug G1 will need to run through the floor to the exterior of the cab it will connect to the plug G2 of the exterior harness See figure 11 12 13 amp 14 Secure wires under arm rest Joystick P N 02981347 with Resister Harness FIGURE 12 P3 f XS Module P N 02981533 The XS module See Figure 13 mounts in side the tracto
109. re Harness amp Valve Installation John Deere Tractor JD 6615 6715 Joystick Electrical Mounting Installing Wiring Harness and Joystick 1 Preparing Tractor Floor Mat First thing to do is remove the Battery Cables from Battery Do Not perform any work on Tractor or Boom Electronics 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 1 amp 2 DO NOT Tear or Cut any Holes in Rubber Floor Mat as it will NOT be required You may find a rubber plug or you may have to cut a hole with a hole saw this will have to be decided during installation If you need to cut a hole check the under side of cab for any obstruction or any component that might be damaged before you cut the hole The hole is going to have to be oblong in order for the plug to go through it Measure Wire Harness plug Coded G1 to determine the size hole In Figure 2 below the tractor had two holes from the tractor manufacturer Check to make certain the installation will not interfere with the operators normal functions See Figure 1 amp 2 Floor mat can be reinstalled over wire harness with out cutting any holes in floor mat AV 12 AAA FT Bi Ri ni pa ja m FIGURE 2 a Hd s in 2 Remove Tractor RH Side Panel Remove the side panel on the RH side of the cab so the wire harness can be run down through and under top panel and will be cove
110. re calling 2 Ifacallto Alamo Industrial is needed Certain Information should be available and ready forthe 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 78155 Technical Service Dept PH 830 379 1480 Maverick John Deere 6615 6715 Asy Man 02 05 O 2005 Alamo Group Inc Index 1 INDEX ASSEMBLY INSTRUCTION Page Introduction MAT Index 1 Section 1 Model Specifications DO NOT DO LIST IMPORTANT 1 2 Maverick Boom EDEN tes teram dE 1 3 to 1 6 Hose Fitting Torque CAGE 1 6 Ble 1 7 Section 2 Tractor Preparation Generallihiormaton Sd ae 2 2 to 2 8 Section 3 Lexan Door Replacement Consul
111. re powered by a self contained hydraulic system The pump is loctated on the front of the tractor There is an in line pressure filter P N 02981371 between the closed center load sense pump and cylinder control valve There is a return filter P N 02981391 mounted to the tank that filters the fluid returning from the control valve to the tank Filter change recommended for every 200 to 250 hours An electronic monitoring system monitors element back pressure for indication of clogged filter prior to element change Mower Head Functions Mower Head Functions are operated by Pump which is mounted to the front of the Tractor Engine This will have an in line Filter installed into hydraulic circuit This filter should be changed on a regular maintenance schedule Filter are rated by Micron size 10 Micron Filters should be replaced with original Alamo Industrial Replacement Filters to make certain the correct rated filter element is installed at all times Pressure Filter is P N 02968922 and Return Filter Replacement Element is P N 02968923 4 HYDROSTATIC PUMP SPEC S Cutter Head Pump Circuit Spec s xi ojo c Piston Type Pump Speed Front Engine Mounted Run Engine to 540 PTO Speed Relief Setting at the Pump sss 4500 PSI Pump Flow Front Engine Operating Speeo 25 3 GPM Boom Cylinder Pump Circuit Spe c s FP m E E Piston Type Fe UN SD A E 1800 RPM Pump Flow Front Engine Operating Speed
112. red to operate two or more if valves are stacked funtions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pressure The Port openings on this diverter valve are marked with letter number codes which show wich port is connected to which hose and where that hose connect on other end See Figure 18 Port Function amp Connection P1 Hose Hydraulic Pressure from Door Swivel B Port on Control Valve P2 Hose Hydraulic Return to Door Swivel A Port on Control Valve C1 Hose to Head Swivel Cylinder Base End C2 Hose to Door Cylinder Base End C3 Hose to Door Cylinder Rod End C4 Hose to Head Swivel Cylinder Rod End Electric solenoid retaing n m Electric Solenoid 0 These 2 threaded holes on back side for mounting diverter valve to frame Not Seen C1 Port this side Not Seen to head swivel cyl base end VA Port this P1 Port Pressure from Control Valve door swivel port of control G valve o side Not c Seen to N head swivel These 4 holes are through holes R aloe N cyl rod end that would be used if this were a stacking valve to stack two or more valvestogether These holes are not used in this application d SN td ed C2 Port to door cyl base end P2 Port Return to control valve door swivel port of control valve C3 Port to door cyl Rod end Maverick John
113. red when the panel is put back on See Figure 3 Isert the end of the interior wire harness with the pug coded G1 down into the panel from top and out bottom of panel See Figure 3 amp 4 Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 2 Joystick Electrical Mounting Locating Joystick and electrical components 1 Joystick Assembly with Resister Harness The joystick has the resister wire harness attached to it when you received the joystick 2 Emergency Stop Switch The emergency Stop E Stop Switch will be sent with the knob and mounting nuts installed onto it These will need to be removed when mounting switch 3 Replacement Seat Arm Rest The Tractor seats Rh arm rest will be replaced with a fabricated one to mount E Stop Switch and Joystick 4 Wire Harness The Wire harness is in two piece The interior harness inside the cab and the exterior harness connecting to the interior harness and running outside the cab to the pump and tank area at the front of the tractor 9 Wire Harness through Floor of Tractor Cab Some tractors may have a hole all ready through the floor of the cab on the RH side Lift Floor mat and check if no hole possible with rubber plug in it a hole will need to be cut with a hole saw If cutting holes in floor of cab always check under side of floor to make certain there are no components that will be hit and damaged by saw DO NOT use a torch to cut holes in cab fl
114. rty visible Follow local Eratfic codes Newer parte with Cufing Head rived Fpasserty bystanders or irait are in the area fo reduer possibilty of injury or deat from Objects nomen by Bladesunder Guardar cutter sinuctun B Before demounling secure mplementin bansper postion ar leer ba ground i Pulido in park of eel fhe brake disengage PTO stop engine and rem ove key ad wail unii pase of rotation Has Gee is prevanl eniangiernen in mist ng parts whichean cause injury ar dest e Never mount or dismounta moving vehicle Cushingin runcver many cause injury or death 5 TRANSPORT SAFELY amp USE SMV LIGHTS amp T DO NOT OPERATE DO NOT MOUNT OR LOCK UF REFLECTORS WITH GUTTER OR DISMOUNT WHILE WING RAISED G E 00749117 WARRANTY INFORMATION Read and understand the complete Warranty Statement found in this Manual Fill outthe 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 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 Itis hoped that the information contained in this and other Manuals will provide enough detail to eliminate the need for contact of the Alamo Industrial Te
115. st connect to the same letter on both ends TO ID HOSES Always check Size Length Fittings and Color Plastic Tie to identify the hoses Some hoses will have the same color tie but the size length or fittings will be different Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 18 Mounting Component ID Swing Cyl Hose 24 30 C2 A iS JE 34 ma Bo H r Bl NOTE Male JIC Hose End To Extend Up Thru Holes Item Part No Qty Description A1 02981825 Hose 46 6FJX 6FJX 28 Lg B1 02981825 Hose 46 6FJX 6FJX 28 Lg C1 02981826 Hose 46 6FJX 6MJ 16 Lg Geen Tie C2 02981827 Hose 46 6FJX 6MJ 16 Lg Green White Tie 34 02968832 Plastic Tie Green 35 02968833 Plastic Tie Green White 0 dr L NOTE Hose are not shown in drawing this is for clarity The hose routing is for hoses which connect from one point to the other Use the instructions and hose descriptions listed to follow hose routing Example Hose A1 connects to one end marked A1 and the other end connects to the other connection marked A1 This is done with the other letters as well the hose must connect to the same letter mark on each end Some hose have a plastic colored tie on it to ID hose and location To ID hoses always check hose size length and colored plastic tie Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 19 Mounting Component ID Cyl Cntrl Va
116. t Tractor Manufacturer Door Replacement Instructions 3 1 to 3 2 Section 4 Pump amp Driveshaft Installation Pump Driveshaft Schematic seen 3 2 Pulley Adapter Installation 4 3 Install Shaft Half of Driveshaft rrannrnnrnnnrnrrnnnrnrrnnnrvrrnnnrnnrnnrennnnnee 4 4 Install Tank Mount Halls rene etna eonun Re npn pn rea canRunes 4 5 Install Pump Mount Plate cessere 4 5 to 4 6 HAr e Ve 4 6 to 4 8 Section 5 Hydraulic Tank amp Control Valve Installation Hydraulic Tank amp Valve Assembly Installation 5 2 PROM M scenes ed ue amount 5 3 to 5 4 Control Valve Fitting Identification 5 4 to 5 5 Hydraulic Valve Hose Referenc Sheet 5 6 Mer 5 7 Valve Hose Marking Codes 5 7 to 5 8 DNTV NM b to 5 9 Oil Cooler amp Cooling Fan Assembly 5 9 Section 6 Main Frame Installation Under Mount Component Information 6 2 to 6 4 me es TIO RE ES 6 5 to 6 8 Boom RES INSTAA NON usse ossa kok pehotV RE euh sans ERUE ODE GRE mai MEER ERE bESE 6 7 Frame Counter Weight Installation 6 8 to 6 9 Boom Turret Assembly Installation 6 9 to 6 10 Front Axle NNN 6 11 Maverick John Deere 6615 6715 Asy Man 02 05 O 2005 Alamo Group Inc Index 2 INDEX ASSEMBLY INSTRUCTION Page Section 7 LH Wheel Weights Standard Wheel Weight 7 2 to 7 3 Auxiliary Whe
117. talling Driveline Half to Pump 1 Install Pump to Driveline Half The pump is heavy and will be best to lift it with overhead hoist See Figure 18 With the tube half of driveline installed into tractor align u joints and a bar through the yoke See Figure 14 install the pump shaft into the clamp yoke See Figure 17 Install the clamp yoke of the tube half of driveline onto the pump slide the clamp yoke on pump shaft until you have about 1 8 to 1 4 gap between yoke and pump Do not install yoke so far on pump shaft that yoke will rub against pump in anyway Tighten the two bolts and nuts on clamp yoke at this time See Figure 17 18 19 amp 20 Driveline Tube Half with Figure 17 Clamp Yoke Installing Pump to Pump Mount Weldment 1 Install Pump to Pump Mount Weldment The Pump has the tube half of driveline attached and clamp yoke tightened To install the pump and driveline half it is best to use an assistant or overhead hoistto help you align the drivelines halves as they are slid together the Driveline must be timed universal joints aligned the same as shown inthe pump amp driveline schematic on See Figure 5 through 20 Slide Driveline half and pump together until the shoulder on the pump slide in the hole on the pump mount weldment See Figure 20 amp 21 When installing the pump always keep ports sealed to keep them clean and free of contamination The pump MUST be turned correctly This can be done by making certain
118. thatthe pump is mounted the same as it was on the hydraulic tank assembly when it was received Install the two 1 2 X 1 1 2 long pump mount bolts P N 02892000 and two 1 2 lockwashers P N 00001300 Tighten the two pump mounting bolts See Figure 21 Align Splines on Pump Shaft 1 MI vam Driveshaft clamp poke p inet A ud Te AC m O Tighten Clamp e i i E Yoke leave 1 8 to 1 4 gap btween yoke amp pump housing is amustto prevent i F rubbingofyokrto Mi WM housing Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 4 7 Pump Driveshaft Assembly Instructions Must have Gap Bolts To Figure 20 er Tractor Bolster Check All Components and Bolts 1 Check Driveshaft amp Pump Installation The pump and driveshaft installation needs to be recheck Make certain that all bolts and lockwasher are installed Make certain that the pump pulley adapter and flange yoke of driveshaft are in stalled square where they bolttogether The pump has aflange onthe housing that must be inserted into the hole of the pump mount plate Make certain that all bolts have been torqued to the proper specifications See Bolt Torque Chart It is recommended that you mark each bolt as it is Push Pump into Pump torqued this can be done with a paint marker or Mount until flush a marker of you choice so long as the mark can seen ata glance this will help notto miss torquing
119. the end on that has the correct fitting as noted in drawing with 90 or the straight fitting if note marked hose routing that is to make hoses clear other items Do Not connect hose to different letter items all hose end must connect to the same letter on both ends TO ID HOSES Always check Size Length Fittings and Color Plastic Tie to identify the hoses Some hoses will have the same color tie but the size length or fittings will be different Maverick John Deere 6615 6715 Asy Manl 02 05 2005 Alamo Group Inc Section 5 3 Hydraulic Tank Hose Routing Hose Connections To Pump And Hydraulic Tank See Figure 2 Item Part No Qty Description A 02981427 1 Hose 8FJX 8FJX 90 24 Lg w Red Tie Charge Filter to Pump B 02981428 1 Hose 8FJX 8FJX 90 21 Lg w Blu Tie Case Drain to Tank C 02981429 1 Hose 12FJX 12FJX 23 Lg Pump to Suction Filter hose under pump and cannot be seen in drawing D 02981430 1 Hose 12FJX 12FJX 31 Lg w Red Tie Pressure Filter to Supply E 02981431 1 Hose 4FJX 4FJX 90 35 Lg w Red Tie Pump Load Sense to Valve PX Connects to top side of pump as shown F 02981432 1 Hose 4FJX 4FJX 90 20 Lg w Blu Tie Pump Regulator to Tank Connects to bottom side of pump not seen Fo 1 Hose 4 Connects here w Tee Fitting Connect to Base End Stabilizer Cyl G 02981433 1 Hose 20FJX 12FJX 24 Lg Pump to Suction Filter H 02981462 1 Hose 12FJX
120. the oil is ISO AW 100 Hydraulic Fluid with cleanliness level of ISO 16 14 11 is a must however do not over fill or spill oil 3 Check that all the hydraulic connections are complete and tightened on the Motor Hydraulic Sys tem and the Cylinder Hydraulic System 4 Avoid hydraulic contamination by filtering the hy draulic oil while filling the hydraulic tank Filter buggies or carts are commercially available for Pre cleaning oil before it is installed or hydraulic system cleanup These consist of a high efficiency high capacity filter a circu lating pump a drive motor and hoses for connecting to oil supply See Figure 2 amp 3 When adding hydraulic oil use only new oil from a sealed barrel Used oil or oil from an open barrel may contain high levels of contamination Transfer the new oil into the hydraulic tank by using a hydraulic filter pump unit equipped with a properly operating micron filter to achive rquired cleanleness level is a must This will insure that the oil being added is safe to use Do not just pour the oil directly into the hydraulic tank since most oils even from a sealed barrel have contaminants that should be removed before operating the hydraulic sys tem See Figure 2 amp 3 4 Important Change the return filter in tank and Figure 3 suction filters at recommended hours of operation See Operators Manual for maintenace schedule The only hydraulic oil to be used is the AW ISOAW Tractor Hydraulic Oil
121. ting holes for Weight 4 Using a forklift lift Wheel Weight into Wheel When Wheel Weight is centered in Wheel Se cure 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 Wheel Weight Mntg Locknuts 5 Looking at the outside make sure the three special Wash Wheel Weight ers Figure 1 Item 2 are aligned C00 1400 Ibs with the Slots inthe Wheel Weight Tighten the three Bolts now You will need an assistant to hold the Fa other Side while you are tightening NON the Bolts While tightening Bolts check to make sure the three spe cial washers are seated correctly If these Bolts are tightened and washer are not seated into the recess on Wheel Weight dam age will occur See Figure 3 6 Remove forklift away from Wheel and Weight Recheck tight ness of Wheel Weight retaining l Bolts Bolts should torque to 500 Figure 3 ft Ibs Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 7 3 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 Ib we
122. tion 6 4 Frame Installation 3 Install Rear Frame Mount Rails Rear frame rails consist of a LH amp RH We have started with the Left Hand Rail Using a floor jack to lift the rail up under the rear axle Install the bolts up and into the tractors rear axle housing and snug the bolts down LH Rear Support the frame rail with a jack stand or leave the Frame floor jack under it See Figure 17 amp 22 Mount The RH Rear Frame Rail will basically install AA feiet the same bolts up under the tractor axle housing with the three point stabilizer bolt back up under frame rail See Figure 18 amp 23 The RH Rail looks different at the rear because the boom rest will bolt here later 4 Install Front Frame Mount Rails The Front Frame mount rails will consist of a RH amp LH See Figure 19 20 24 amp 25 These will only fit one way as they have a gusset reinforcement on one side that will be showing to the outside when installed These can be lifted by the technician installing them The LH and RH will install the same way Using 4 bolts each that screw into nuts on the inside of tractor frmae on the side of the tractor See Figure 24 amp 25 Make certain that all of these mounting bolts have hardened flatwashers on on both side of frame Bolt heads or nuts should not be againsr frame P N 102982 Figure 23 p RH Front Frame E Cr Weldment P N02982380 m Figure 24 Figure 25 7
123. ts Then back it back out 1 2 turn this will give you the 2800 psi required to operate the boom See Figure 16 amp 17 Hold the adjusting nut while turning the locking nut so the adjustment nut does not turn with it changing the setting Pressure Adjust Nut 7 16 Hex amp Locking Nut 1 2 Hex Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 11 CONTROL VALVE JOYSTICK JOYSTICK FUNCTIONS Figure 18 To operate a function the following series of events must work 1 The Joystick Controller is moved in the correct direction the required distance During its movement an electrical signal is sent to the electric Controller in the proper Valve Section of the Control Valve 2 The Electric Controller sends an electrical signal which causes the Proportional Control Valves to actuate the proper amount based on the signal from the Controller EXAMPLE Valves 1 amp 3 allow Pilot Pressure Oil to flow to the corresponding end of the Spool Thus causing it to move Valves 2 amp 4 allow the Oil from the opposite end of the Spool to return to the Tank NOTE Lift Swing and Dipper functions are Proportional Door and Tilt functions are ON or Off Only See later section for explanation of Proportional 3 The Spool position Transducer sends an electrical signal to the Electronic Controller which indicates the position of the Spool 4 The Electronic Controller will continue to adjust the Valves
124. ure See Figure 33 3 The Charge Pressure Filter Switch The charge filter pressure switch has three wire coming out of it a white black and Blue wire The Blue wire will not be used and will be cut off The charge pressure filter switch is located at the filter in the charge loop on the hydrostatic pump See Figure 34 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operator for a filter element change of filter element 4 The Valve Pressure Filter Switch The Valve pressure filter switch is located at the pressure filter in the valve pressure circuit between the closed center load sense pump and the control valve See Figure 35 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operator for a filter element change E WARNING This filter does not have a by pass The element must be changed at the appropri IGU RE 3 ate time to avoid element damage and system contamination Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 15 Exterior Wire Harness Schematic P N 02981375A 5 The Return Filter Switch The return filter switch is located at the return filter mounted on to the tank top The fluid returning from the cylinder control v
125. ure 6 Item A or other instrumentation Input is received at the CAN module Figure 5 Item B and joins the network That information is transferred via the network to the valve solenoid Figure 5 Item C which activates and moves the spool sending hydraulic fluid pressure to the cylinder Figure 5 Item D and moves the load X5 expansion signal Item A Item B FIGURE 6 Maverick Mower Head Circuit 1 The Motor Circuit The motor circuit for the cutting head operation is operated through display Figure 6 Item A By selecting the activation parameter the coil will shift the servo piston at the hydrostatic pump Figure 7 item B stroking the pump into the On position Flow will then be supplied to the hydraulic motor at the cutter head Figure 6 Item C Activate the motor circuit while the engine RPM is at idle Once activated the engine RPM can be raised to the 540 PTO required speed if the 540 PTO engine speed is not noted onthe tractors RPM gauge consulttractor owners manual to find what the required speed is At any time the Emergency stop switch Figure 7 Item D located on the joystick will deactivate the cutter motor circuit The blade will stop within 6 second when the emergency switch is shut Off Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 10 5 CONTROL VALVE ELECTRONIC NETWORK Maverick Mower Head Circuit continued from Previous page MDM Master Display Mini Analog
126. urely block up and support the tractor before attempting to loosen and move the tires Failure to properly block up the tractor can result in the tractor to suddenly move or fall crushing you or another worker Never work under any raised component or any component that is not securely blocked up or supported WARNING Many components of this mower are very heavy and must be handled by proper material handling equipment Do not lift components that weight over 50lbs by yourself C Use an overhead crane forklift or other coworkers to lift heavy items Ensure lifted components are securely supported Never walk or work under a lifted component Use extreme care when moving handling or adjusting the tractor tires The tires are extremely heavy and could fall and crush you gt D z 0 e Use an overhead crane or forklift to move the tires OC Properly fasten the tires to the material handling equipment to prevent the tire from falling WARNING The hydraulic oil is under high pressure and a hydrauli leak can cause oil to be injected under the skin e Before starting the tractor ensure all hydraulic connections have bee tightened Never check for leaks with your hands Use a piece of wood or cardboard to check for the leak making sure your hands and face are kept away from the leak area O Repair any leaks before operating the equipments Clean up all oil that has leaked according to the requirements o
127. ving material to the RH side of the tractor See Figure 12 On the Right hand side of the tractor the four hoses will connect to the diverter valve in the coded locations See Figure 11 Tie the hoses to the frame under the tractor See Figure 13 The two hoses from the diverter valve will continue along the LH side of tractor with sleeving material over them See Figure 13 to the front of the tractor They will have hose support brackets on them that bolt to the side of the tractor See Figure 13 where they will be connected to the valve at the Door Swivel Ports in the correct order See Figure 16 amp 17 The other cylinder hoses from the boom will be inserted into sleeving material and also be routed under the tractor to the LH side See Figure 14 They will continue up the LH side to the front of the tractor where they will connect to the valves ports The hoses will be held to the frame with metal hose hold ers bolted to the tractor frame See Figure 15 NOTE the hoses must be run through the sleeving material On the LH side there is a hole in the center frame weldment the hoses can be run through it if wanted Connect the hoses to the valve as shown See Figure 11 amp 17 Hose Support r VG JF Bracket 4 i x Vi h aA Sleeving Material for Hoses Figure 16 2005 Alamo Group Inc Section 9 7 Maverick John Deere 6615 6715 Asy Man 02 05 Hydraulic Hose Connections HYDRAULIG HOSE CODES AT VALVE
128. will be installed into plug next to Pump solenoid 1 which is used with all heads Note Unless the timbercat head is used only Solenid 1 will be installed which is Plug V1 leave plug T1 tie to othrer plug out of the way H1 amp H2 Lock Valve Connection BB Diverter Valve Y1 Connect to White Wire amp Y2 Connect Pump Solenoid SS AA See to Black Wire Valve Filter T1 Sol 2 amp V1 Sol1 AAN Below W1 Charge Filter L G2 Plug to Interior Wire Harness R1 Cooler Fan S1 Temp Sensor E XT2 Module 3b F XP2 Module FIGURE 25 Return Filter Plug Valve Valve Decal Below shows the Hose location and Plastic tie color on hose Label Function Label Also the markings for the wire harness plugs on valve A or B AA1 Swivel AA2 Swivel AAS Tilt AA4 Tilt AAS Telescope AA6 Telescope AA7 Dipper AA8 Dipper AAG Lift AA10 Lift AA11 Swing Door AA12 Swing Door FIGURE 26 NOTE Decal Stripes to Base and Solid to Rod end refers to the plastic ties on hoses only amp not electricl connections oee Figure 18 amp 18A Hose amp Connector Attachment W gt W gt W gt W gt W gt gt U Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 8 11 Exterior Wire Harness Schematic P N 02981375A AA1 Swivel Cylinder CCW Connection Markings on Exterior Wire Harness AA2 Swivel Cylinder CW AA3 Tilt Cylinder Down AA4 Tilt Cylinder Up BB AA5 Tel
129. y a concrete shop surface with an over head crane The crane should have arated capacity to lift the heaviest component or assembly A 5 ton crane is recommended for the assembly work If a smaller crane is used be sure not to exceed the rated capacity of the crane e Always follow all OSHA crane operating and inspection rules regulations inspection requirements and recommended practices when using the crane Q Never work under any component that is lifted by the crane Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc Section 2 4 General Information Installation Requirements WARNING Wear personal protective equipment when assembling the mower As a minimum that should include Safety Glasses Safety Shoes Gloves Hard Hat Hearing Protection Welding Helmet WARNING Before attempting to assemble ensure that the tractor engine is off and the tractor transmission is in the park position with the parking brake engaged O Remove the engine key and keep it in your pocket to prevent inadvertent starting or movement of the tractor C Place wheelblocks in front and behind the tractor wheels to preventthe tractor from moving Never attempt to start the tractor unless properly seated in the tractor seat with the seat belt fastened around you C Never attempt to operate the tractor and mower controls unless seated in the tractor seat with the seat belt fastened around you WARNING Sec
130. y not be the same for other model part numbers in this section are for 6615 amp 6715 tractor models Universal Joint Style Driveshaft Replacement Seat Arm Rest for Joystick Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 2 Mounting Specifications Wheel Weight 1400 Ibs eer ee PR sie P Pe misi Auxiliary Wheel Weights qty 3 of 136 RH Door Lexan Replacement Door lbs ea for total 408 Ibs Bolt on Ground Clearanc Front Axle Stabilizer 4 WD Only Maverick John Deere 6615 6715 Asy Man 02 05 2005 Alamo Group Inc 11 3 Common Box Component List IMPORTANT NOTICE These are parts that are shipped with every unit these parts will remain the same no matter which size boom is used or which model tractor is used DO NOT order any of these parts unless you are certain that that is what you want most theses a are complete assemblies and may contain more prts than are wanted to perform repairs If ordering parts that are listed here it is recommended that you look the parts in a regular parts manual under the specific assembly number 02981781 Common box Consist of the Following Items ITEM oe APR hr PART NO 00037200 02981381 02959924 10058000 02981441 00024100 00992000 00001000 02981377 00015800 00011100 02981383 02981384 02090800 02962181 02977622 02981803 02981373 02981704 03200762 02962181 00015800 00011100 00753642 02964135 02090800 02981371 00

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