01, Front Cover - Alamo Industrial · TO THE OWNER/OPERATOR/DEALER All implements with moving parts...

© 2005 Alamo Group Inc.

ALAMO INDUSTRIAL1502 E. WalnutSeguin, Texas 78155210-379-1480

Assembly Instruction Manual

Tractors equipped with additional options, special equipment, tractor manufacturer modi-fications, new tractor models, or Customer alterations may prevent this Mount Kit frombeing properly mounted to the tractor. Alamo Group is not responsible for modifications tothe MountKit to accommodate these differences.

INTERSTATER

John Deere JD-5425 & 5525(Cab 4WD) & (ROPS 2 WD)

Published 07-05 Part No. 02982933

INTERSTATER

TO THE OWNER/OPERATOR/DEALERAll implements with moving parts are potentially hazardous. There is no substitute for a cautious, safe-mindedoperator who recognizes the potential hazards and follows reasonable safety practices. The manufacturer hasdesigned this implement to be used with all its safety equipment properly attached to minimize the chance ofaccidents.

BEFORE YOU START!! Read the safety messages on the implement and shown in your manual.Observe the rules of safety and common sense!

WARRANTY INFORMATION:

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

© 2005 Alamo Group Inc. 0- 1

Interstater (JD-5425 & JD-5525 Asy. Man.) 07/05

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 forcomplete customer satisfaction

It is hoped that the information contained in this and other Manuals will provide enough detail toeliminate the need for contact of the Alamo Industrial Technical Service Dept. However, it should beunderstood 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 receiveentirely to many calls with only a minimum amount of information. In some cases, the correspondenthas never gone out to look at the equipment and merely calls inquiring of the problems described to himby the operator or customer.

Most calls received by Alamo Industrial Service can be classified into approx. 6 general categories.1. Hydraulic or Mechanical Trouble Shooting.2. Request for Technical Information or Specifications.3. Mounting or Fitting Problem.4. Special Service Problem.5. Equipment Application Problems.6. Tractor Problem Inquiries.

HOW YOU CAN HELP:Make sure the call is necessary! Most of the calls received may not be necessary if the Dealer

Service Technician would do the following.

1. Check the Service Information at your Dealership provided by Alamo Industrial, Thiswould include, Service Bulletins, Information Bulletins, Parts Manuals, Operators Manuals, AssemblyManual or Service Manual, many of these are available via the Alamo Industrial Internet site (www.Alamo-Industrial.Com). Attempt to diagnose or repair problem before calling.

2. If a call to Alamo Industrial is needed, Certain Information should be available and readyfor the Alamo Industrial Service Staff. Such information as, Machine Model, Serial Number, Your DealerName, Your Account Number and Any other information that will be useful. This information is vital forthe development of a prompt and correct solution to the problem. This will also help to develop adatabase of problems and related solutions, which will expedite a solution to future problems of a similarnature.

3. The technician may be asked to provide detailed information about the problemincluding the results of any required trouble shooting techniques. If the information is not available, Thetechnician may be asked to get the information and call back. Most recommendations for repairs willbe based on the procedures listed in the Service Manual / Trouble Shooting Guide and Informationprovided by customer.

CONTACT ALAMO INDUSTRIAL:Alamo Industrial, 1502 E. Walnut St. Seguin TX. 78155, Technical Service Dept. PH: 830-379-1480

© 2005 Alamo Group Inc. 0- 2Interstater (JD-5425 & JD-5525 Asy. Man.) 07/05

INDEX - INTERSTATERITEM PAGE NO.

INDEX INTERSTATERIntroduction (Index Section) .................................................................... 0-1General Information (Index Section)........................................................ 0-4 to 0-5Index........................................................................................................ 0-2 to 0-3

SECTION 1Pre-Delivery Inspection Checklist............................................................1-1 to 1-4

SECTION 2Driveshaft & Pump Installation................................................................ 2-1 to 2-11Driveshaft & Pump Schematic............................................................... 2-2Pulley Adapter......................................................................................... 2-3 to 2-4Install Pump Driveshaft............................................................................2-4 to 2-5Install Front Pump Mount Asy.................................................................. 2-5Tank Mounting Brackets.......................................................................... 2-6Tank Installation...................................................................................... 2-6 to 2-11Tank Bumper Installation......................................................................... 2-6Install Pump (Motor Supply Pump).......................................................... 2-7Install Pump (Cylinder Supply Pump)..................................................... 2-7 to 2-11Pump to Tank Hoses.............................................................................. 2-10Oil Return Pressure Gauge.....................................................................2-11Oil Temperature Gauge...........................................................................2-11Hood Modification.................................................................................... 2-11

SECTION 3Mainframe Installation.............................................................................. 3-1 to 3-7Identify Main Frame................................................................................. 3-2Remove Tractor Steps............................................................................ 3-2 to 3-3Install Main Frame................................................................................... 3-2 to 3-4Install Cylinder Support Weldment.......................................................... 3-4Wing Lift Frame....................................................................................... 3-4Wing Lift & Tilt Cylinders......................................................................... 3-5Hydraulic Shematic (Useing Tractor Hyd for Cylinders)......................... 3-5

SECTION 4Wing Mower Installation.......................................................................... 4-1 to 4-15Wing Magnetic Cut Off Switches and Mounts.........................................4-2 to 4-5Wing Mower Pivot Brackets.................................................................... 4-3 to 4-5Cut Off Magnetic Pick-up Switch Wiring................................................. 4-4 to 4-7Wing Lift Cylinders.................................................................................. 4-10Motor Cut Off Solenoid............................................................................ 4-5Wing Hose Connections......................................................................... 4-10Electrical Schematic............................................................................... 4-7 to 4-9Motor Hose Schematic............................................................................ 4-10

Continued Next Page



ITEM PAGE NO.

SECTION 5Joystick, Valve & Control Cables.............................................................5-1 to 5-17Prepare Control Valve (Cylinder Control)................................................ 5-2Install Control Valve (Cylinder Control).................................................... 5-2Connect Control Valve Hoses................................................................. 5-2 to 5-6Connect Control Cables to Valve............................................................ 5-2 to 5-6Hydraulic Schematic, RH Wing Only..................................................... 5-4Joystick Mounting Bracket Installation.................................................... 5-7 to 5-11Control Cables & Wire Harness Through Tractor Floor......................... 5-2 to 5-11Cable Control Handles............................................................................ 5-8 to 5-11Push Pull Cut Off Switches.................................................................... 5-8 to 5-11Control Valve Hose Schematic............................................................... 5-4 & 5-12Control valve for Rops Model.................................................................. 5-13Wire Harness Schematic....................................................................... 5-15 to 5-17

SECTION 6Rear Mower Installation........................................................................... 6-1 to 6-8Install Rear Lift Chains to Tractor............................................................ 6-2Upper And Lower Hitch Pins....................................................................6-2 to 6-3Driveline Connection................................................................................6-3Leveling Rear Mower............................................................................... 6-4Driveline Slip Clutch Preparation............................................................. 6-5Shields and Guards................................................................................. 6-5Lubrication Chart..................................................................................... 6-6Initial Start Up Procedure......................................................................... 6-7 to 6-8Oil Tank Filling......................................................................................... 6-7 to 6-8

SECTION 7Mounting Specifications & Component ID............................................... 7-1 to 7-4Cab Tractor, 2WD Bill of Materials Listing.............................................. 7-2 to 7-8ROPS Tractor, 2WD Bill of Materials Listing.......................................... 7-9 to 7-12Component Identification......................................................................... 7-13 to 7-18

INDEX - INTERSTATER


GENERAL INFORMATION:The tools you will need at the assembly site are as follows:

1. Impact wrench or socket and ratchet set.2. Rubber mallet.3. Box-end, Allen, and adjustable wrenches.4. Alignment pins.5. Forklift or hydraulic floor jacks with rolling back boards.6. Small chain hoist or block-and-tackle.7. Multidirectional Levels.8. Hydraulic Filter Buggy or Cart.9. Safety shoes, safety glasses, and gloves.

A hard hat should be worn by anyone working under any raised component.

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 unclutteredassembly area and a crew that is sensitive to the hazards involved in putting this implement togetherwill help prevent accidents. Keep all unauthorized personnel from the area. Do not allow children nearthe assembly site nor allow them on or near the tractor after assembly. There is no safe place foranyone except the operator on the tractor and those assisting with the assembly.

RECOMMENDED TORQUE VALUES CHART:

RECOMMENDED TORQUE IN FT.-LBS. (Nm)COARSE AND FINE THREADS

2 (B) 5 (D) 8 (F)

Bolt Plain Three SixDia. Head Dashes Dashes

1/4" Not used 10 (14) 14 (19)5/16" Not used 20 (27) 30 (41)3/8" Not used 35 (47) 50 (68)7/16" 35 (47) 55 (75) 80 (108)1/2" 55 (75) 85 (115) 120 (163)9/16" 75 (102) 130 (176) 175 (237)5/8" 105 (142) 170 (230) 240 (325)3/4" 185 (251) 300 (407) 425 (576)7/8" 160 (217) 445 (603) 685 (929)1" 250 (339) 670 (908) 1030 (1396)1-1/8" 330 (447) 910 (1234) 1460 (1979)1-1/4" 480 (651) 1250 (1695) 2060 (2793)



To help you assemble your new Brahma and mount it to your tractor, we provide you withdrawings, instructions, and general information. When needed, you can get information orclarification from Your Dealer or Alamo Group Customer Service.

This publication provides general information not specifically for your case or tractor, but, inconnection with the drawings and Parts Section, this publication offers you some valuableassistance - please read it thoroughly.

The mount kits are made for selected tractors with standard configurations. Only the notedoptions and tire sizes listed in the model specifications will work with these mount kits. Otheroptions, front axles, or different tire sizes may prevent the mount kit from fitting your nonstandardtractor. Alamo Group cannot take responsibility for these problems or any modifications made tothe unit.

Throughout these instructions, In the Parts Mnaual, Operators Manual and decals on unit you willsee the following symbles, pay close attenion to them. References are made to right or leftdirections. Right and left are determined by sitting on the tractor seat and facing the direction oftravel.

This is the Safety-Alert symbol. When you see this symbol on your machineor in these instructions, be alert to the potential for personal injury. Followrecommended precautions and safe operating practices.

DANGER! A signal word - DANGER, WARNING, or CAUTION - is used with the Safety Alertsymbol. DANGER identifies the most serious hazards.

WARNING! Safety signs with signal word WARNING are typically used to point outmore serious hazards.

CAUTION! General precautions are listed on CAUTION safety sign. CAUTION alsocalls attention to safety messages in these instructions.


NOTES

Section 1 - 1© 2005Alamo Group Inc.


Section 1INTERSTATER

John DeereJD-5425

&JD-5525

SAFETYSECTION

Section 1 - 2© 2005 Alamo Group Inc.


Read these assembly instructions through completely and understand thembefore proceeding with the assembly of the equipement.

A safe and careful operator is the best operator. Safety is of primary importance to themanufacturer and should be to the owner/operator. Most accidents can be avoided bybeing aware of your equipment, your surroundings, and observing certain precautions. Thefirst section of this manual includes a list of Safety Messages that, if followed, will helpprotect the operator and bystanders from injury or death. Read and understand theseSafety Messages before assembling, operating or servicing this Implement. This equip-ment should only be operated by those persons who have read the Manual, who are re-sponsible and trained, and who know how to do so safely and responsibly.

The Safety Alert Symbol combined with a Signal Word, as seen below, is used throughoutthis manual and on decals which are attached to the equipment. The Safety Alert Symbolmeans: “ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!” The Symboland Signal Word are intended to warn the owner/operator of impending hazards and thedegree of possible injury faced when operating this equipment..

CAUTION! The lowest level of Safety Message; warns of possible injury. Decals located on the Equipment with this Signal Word are Black and Yellow.

WARNING! Serious injury or possible death! Decals are Black and Orange.

DANGER! Imminent death/critical injury. Decals are Red and White. (SG-1)

Practice all usual and customary safe working precautions andabove all---remember safety is up to YOU. Only YOU can preventserious injury or death from unsafe practices.



Si no lee Ingles, pida ayuda a alguien que si lo lea para que letraduzca las medidas de seguridad. (SG-3)

PELIGRO!

!LEA EL INSTRUCTIVO!

READ, UNDERSTAND, and FOLLOW the following SafetyMessages. Serious injury or death may occur unless care istaken to follow the warnings and instructions stated in the SafetyMessages. Always use good common sense to avoid hazards.

(SG-2)

!Si no lee Ingles, pida ayuda a alguien quesi lo lea para que le traduzca las medidasde seguridad. (SG-3)

PELIGRO! LEA ELINSTRUCTIVO!

WARNING! Perform service, repairs and lubrication according to the maintenance section. Ensure the unitis properly lubricated as specified in the lubrication schedule and all bolts and nuts are properlytorqued. Failure to properly service, repair and maintain this Implement in good operatingcondition could cause component failure and possible serious injury or even death. (SG-35)

WARNING! Operate this Equipment only with a Tractor equipped with anapproved roll-over-protective system (ROPS). Always wear seatbelts. Serious injury or even death could result from falling off thetractor--particularly during a turnover when the operator could bepinned under the ROPS. (SG-7)

DANGER! Never work under the Implement, the framework, or any lifted compo-nent unless the Implement is securely supported or blocked up toprevent sudden or inadvertent falling which could cause serious injuryor even death. (SG-14)

WARNING! Use caution and wear protective gloves when handling sharp objects such as blades, knives,and other cutting edges. Be alert to worn component surfaces which have sharp edges. Sharpsurfaces can inflict severe laceration injuries if proper hand protection is not worn. (SG-37)



Many of the parts are heavy and require lifting assistance. Do not try tolift the heavy parts by yourself. Get help from another employee or froman overhead crane.

WARNING! The operator and all support personnel should wear hard hats,safety shoes, safety glasses, and proper hearing protection at alltimes for protection from injury including injury from items thrown bythe equipment. (SG-16)

Always wear safety shoes with steel toes when working on this equipment.It is recommended that the safety shoes have metatarsal guards.

When welding use Welding hood with the appropriate OSHA requiredprotective lens, welding apron, and welding gloves.

DANGER! Always disconnect the wire leads from the mower valve solenoid beforeperforming service on the Tractor or Mower. Use caution when workingon the Tractor or Mower. Tractor engine must be stopped beforeworking on Mower or Tractor. The Mower Blades could inadvertently beturned on without warning and cause immediate dismemberment, injuryor death. (SBM-12)

DANGER! Never run the tractor engine in a closed building or without adequateventilation. The exhaust fumes can be hazardous to your health.

(SG-23)

WARNING!

WARNING!

WARNING!



Before starting the mower make sure the area is clear and the floor hasbeen swept. The mower blade can throw objects several hundred feet.Thrown objects could damge property or cause severe bodily injuries evendeath.

WARNING! Make certain that the “Slow Moving Vehicle” (SMV) sign is installed insuch a way as to be clearly visible and legible. When transporting theEquipment use the Tractor flashing warning lights and follow all local trafficregulations. (SG-6)

DANGER! Start tractor only when properly seated in the Tractor seat. Starting atractor in gear can result in injury or death. Read the Tractor operatorsmanual for proper starting instructions. (SG-13)

DANGER! Do not operate this Equipment with hydraulic oil leaking. Oil isexpensive and its presence could present a hazard. Do not check forleaks with your hand! Use a piece of heavy paper or cardboard. High-pressure oil streams from breaks in the line could penetrate the skinand cause tissue damage including gangrene. If oil does penetrate theskin, have the injury treated immediately by a physician knowledge-able and skilled in this procedure. (SG-15)

WARNING! Always read carefully and comply fully with the manufacturers instruc-tions when handling oil, solvents, cleansers, and any other chemicalagent. (SG-22)

DANGER! All Safety Shields, Guards and Safety devices including(but not limited to) - the Deflectors, Chain Guards, SteelGuards, Gearbox Shields, PTO integral shields , andRetractable Door Shields should be used and main-tained in good working condition. All safety devicesshould be inspected carefully at least daily for missingor broken components. Missing, broken, or worn itemsmust be replaced at once to reduce the possibility ofinjury or death from thrown objects, entanglement, orblade contact. (SGM-3)

DANGER!



DANGER! NEVER use drugs or alcohol immediately before or while operating theTractor and Implement. Drugs and alcohol will affect an operator’salertness and coordination and therefore affect the operator’s ability tooperate the equipment safely. Before operating the Tractor or Imple-ment, an operator on prescription or over-the-counter medication mustconsult a medical professional regarding any side effects of the medi-cation that would hinder their ability to operate the Equipment safely.NEVER knowingly allow anyone to operate this equipment when theiralertness or coordination is impaired. Serious injury or death to theoperator or others could result if the operator is under the influence ofdrugs or alcohol. (SG-27)

DANGER! Operate the Tractor and/or Implement controls only while properly seatedin the Tractor seat with the seat belt securely fastened around you.Inadvertent movement of the Tractor or Implement may cause seriousinjury or death. (SG-29)

WARNING! Engine Exhaust, some of its constituents, and certain vehiclecomponents contain or emit chemicals known to the state ofCalifornia to cause cancer and birth defects or otherreproductive harm. (SG-30)

WARNING! Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the state of Califor-nia to cause cancer and birth defects or other reproductiveharm. Wash Hands after handling. (SG-31)

WARNING! Use extreme caution when getting onto the Implement to perform repairs, maintenance andwhen removing accumulated material. Only stand on solid flat surfaces to ensure goodfooting. Use a ladder or raised stand to access high spots which cannot be reached fromgound level. Slipping and falling can cause serious injury or death. (SG-33)

WARNING! Avoid contact with hot surfaces including hydraulic oil tanks, pumps, motors, valves andhose connections. Relieve hydraulic pressure before performing maintenance or repairs.Use gloves and eye protection when servicing hot components. Contact with a hot surfaceor fluid can cause serious injury from burns or scalding. (SG-34)

WARNING! Avoid contact with hot surfaces of the engine or muffler. Use gloves and eye protectionwhen servicing hot components. Contact with a hot surface or fluid can cause serious injuryfrom burns or scalding. (SG-38)

© 2005 Alamo Group Inc. Section 2 - 1


INTERSTATER

John DeereJD-5425

&JD-5525

Driveshaft & PumpInstallation

Section 2



Driveshaft & Pump Schematic

12341234

123456123456123456

Aux Hyd Pump(Cyl Circuit)

** PumpMountPlate

MountingBolt & Washer

DrivenPulley

DriveBelt Shield

Drive Pulley &Splined Sleeve

Weldment* Driveshaft

Bearing

* BearingCollar

Driveshaft

SplinedDriveshaft Hub

Adapter

LocknutPulley Adapter &Mounting Bolts

Tractor EnginePulley

Pump MountWeldment

Right Wing Only Single Pump &Dual Wing Tandem Pump

* Driveshaft Bearing installs intopump mount weldment here.

** Small (Cyl Hyd) Pump Mount Plate mounts here

NOTE: ** The Aux. Pump is used with independant hydraulic. Ifthe tractor hydraulics are used to supply the hydraulic cylindersthe Aux. Pump will not be used as the pulley & belt will not beused.

12345123451234512345



Pump & Drive Shaft Installation:The Tractor will need modification to some of its components before mounting the Switch

Blade Mower Assembly. Perform thess modification before attemting any of the unit assemblyinstruction.

1. Raise the Hood of tractor to remove Bat-tery. Lift the Tractor Hood, the battery is locatedunder the hood and in front of the radiator (SeeFigure 1 & 2). The battery will need to be discon-nected and removed from the tractor, also thebattery hold down strap (See Figure 2). The Bat-tery can be set on the floor (Concrete) only for ashort period of time, if it is going to be set up for awhile the battery should be set on a wood surfacefor storage and a trickle charge connected to it toprotect it from discharge. Always store the batteryaway from flames, sparks or any extreme heat.

2. Remove Engine Side Cover. There areside covers that bolt to the radiator that blockaccess to the front of the engine. The LH or the RHside cover will need to be removed (See Figure 4the LH side is shown). Save the mounting bolts asthey will be reused when cover is reinstalled.

3. Remove the lower Bolster Cover Plate.The lower bolster cover plate is accessible fromthe bottom side of the tractor behind the bolsterand engine (See Figure 5). This plate bolts to thetop plate that is under the radiator, the lower platemust be completely removed from the under sideand will not be reused. Note: the front axle pivot pinis shown as referenc only, DO NOT remove it.

Figure 1

Figure 2

Figure 3

Engine SideCover (RH

Side Shown)Figure 4

Driveshaft, Pump & Tank Installation



radiator, air conditioning condenser ,oil cooler orany electrical wiring, IT WILL NOT BE RE-QUIRED. The Battery should already be re-moved, if not see step one. The radiator has twobolts on each side that mounts down to the bolstercover plate (See Figure 7). There are two on eachside LH & RH. Also notice the side protectionshield is still installed on the RH side (See Figure7), it is easier to work with these shields removedbut can be done with them left on.

5. You will need some one to help you re-move the cover from under the radiator. Havesone one lift the radiator and other componentswhile the cover is removed out toward the front ofthe tractor. An over head hoist / crane can be usedto lift and support radiator, air conditioning con-denser and oil cooler, BUT EXTREME CAUTIONMUST be used not to damage the componentswhen lifted.

6. With the cover removed set the radiatorand components back down on the tractors bol-ster, do not bolt them down, they will sit there fineas the hoses will not let them fall (See Figure 8).Note the electrical wiring that is left laying acrossbolster, no electrical connections other that thebattery need to be disconnected to remove thecover..

Upper PlateUnder Radiator

Lower Plate Above Front Axle

Front AxlePivot Pin

TwoMounting

Bolts

Figure 5

Figure 6

Upper Plate FrontRetainining Bolts

Upper Plate

Figure 7

Upper Plate SideRetainining Bolts

Figure 8

4. Remove Tractor Upper Bolster Cover Plate. The tractor bolster upper cover will need to bemodified and will have to be removed from the tractor to perform this modification. The radiator will needto be unbolted from the bolster BUT NOT removed from tractor. DO NOT disconnect any hoses for




A. Find the front from the rear of cover.B. Mark a half circle as shown in figure 9.C. This half circle should be a minimum

of 3 inches deep and 5 inches wide

8. Cut Bolster Cover Plate. Make certain thatthe Engine end of cover is cut. How you cut this isthe technicians choice, we recommend a torch ora plasma cutter (See Figure 10). After the halfcircle is cut out of cover, use a grinder to clean theedges to eliminate any sharp edges (See Figure11). After Cover has been cut and cut edgescleaned up set cover aside for now.

9. Install Engine Pulley Adapter. The Enginepulley adapter will bolt to the crankshaft pulley ofthe tractor. Looking at the front of the engine at thecrankshaft pulley there are four bolts and washersretaining a plate to the front of the pulley, thisspacer comes already on the tractor but will not beused. Remove these four bolts removing thespacer. The spacer will not be used but the fourbolts and washers will. Install the furnished pulleyadapter (P/N 02973992) to the front of the crank-shaft pulley with the tractor four bolts and washers(See Figure 12). Tighten the four bolts down toJohn Deere specifications as specified in the Johndeere Manual pertaining to these four bolts.

TOP

FRONT END

Figure 9

Cut OutHere

ENGINEEND

Figure 10

7. Bolster Cover Modification. The cover will have to be cut, this is to allow the pulley adapter forthe drive shaft clearance. Lay the cover where you can mark it for cutting (See Figure 9). This showsthe cover turned around from the way it was removed and is laying on the front tire for marking cut.

Figure 11 Figure 12

CrankshaftPulley

PulleyAdapter P/N02973992

Existing 4Bolts &

Washers




10. Install Spline Hub to Pulley Adapter. The Splined Hub (P/N 02981489) bolts to the pulley adapter(See Figure 13). The Hub has 1" X 15 Spline center with four mounting bolts & lockwashers (P/N02976344 Bolt, Hex Head 7/16"-NC X 1-1/4" - PL - GR8 and P/N 00022200 Lockwasher 7/16" PL).Torque the mounting bolts to 65 ft. lbs. (See Figure 13).

11. Modify Tractor Bolster Front. The bolsterof the tractor will need a hole cut into it that alignswith the engine crank shaft, this hole should be cutwith a hole saw to prevent jagged edges. Thebolster has a DIMPLE in it in the front to showwhere the center of the crankshaft is (See Figure14), this dimple is cast into the bolster when it ismade. Using a Minimum of a 1-1/2" dia. hole sawcut a hole into the bolster using this dimple as acentering reference point (See Figure 15). It isbest to cut this hole before reinstalling bolstercover, but if you have already reinstalled it us a 2"X 4" wood block to hold cover up away frombolster (See Figure 15) noting cover is not bolteddown. After hole is cut in bolster note that the holeis not closed at the top, the amount open at the topwill vary with the size hole cut. A 7/8" drive shaftwill go through this hole, Alamo Industrial recom-mends a 1-1/2" dia hole minimum.

12. Reinstall Bolster Cover. The bolster coverwill install in the same manner as it was removedsee previous steps 4 and 5. Make certain that noelectrical wires are where the should not be. Usethe same bolts that were removed to reinstallcover. Before bolting the cover down you will needto check the fit where you cut the half circle out toclear crankshaft pulley adapter and splined hub,this should be checked from the top and the bot-tom (See Figure 17 & 18).

Figure 14

CrankshaftAlignment

Dimple

Figure 15 Figure 16

CutHole


Figure 13

Spline Hub P/N 02981489 Hub Mountiing Bolts

and Washers (4 ea)



Leave bolts loose until all the bolts have been in-stalled, this will allow the cover to be moved aroundfor alignment. Once all the bolts have been in-stalled tighten all the cover retaining bolts.

14. Re-install Battery. The battery can be rein-stalled now along with the battery hold down. DONOT reconnect the batter cables to the batter atthis time.

15. Re-install Engine Side Shields. Re-installLH and RH side engine shields that were removed.Use the same mounting hardware that was re-moved (See Figure 21).

13. Check Modified Bolster Cover for fit. Make certain the cover will not hit the crankshaft pulley,pulley adapter or the splined hub (See Figure 17 & 18). If cover will not hit install the retaining bolts intothe cover that were removed when cover was taken off.

Bolster Cover

Hood LatchBracketBattery Hold

Down

Figure 19

Figure 20 Figure 21

LHEngineSide

ShieldShown

Bolster Cut Out to allow

driveshaft clearence


Figure 17

Figure 18

Bolster Platemodification CutOut Seen FromTop as installed



17. Install Driveshaft Carrier Bearing & LockingCollar. The pump mount weldment has a carrierbearing in it (See Figure 1 & 10). There is a lockingcollar on the bearing, make certain the set screw inlocking collar is loosened before trying to slide it overthe driveshaft. It is recommended that the bearing IDbe coated with an anti-seize compound where shaftgoes through bearing (See Figure 12). Start thedriveshaft through the carrier bearing (See Figure 10)and the OD of the bearing be coated with LocktiteCoumpound. Driveshaft should be inserted com-pletely through the Carrier Bearing and into the crank-shaft pulley adapter (See Figure 1 & 11). Check theclearance between drive shaft and tractor front bol-ster, clearance should not be a problem but check tomake certain.. If the driveshaft doesn't have clear-ance the bolster will have to be ground down. DONOT Tighten locking collar on carrier bearingyet.

18. Install Pump Drive Shaft. The pump DriveShaft has a 7/8" X 13 spline on both ends (SeeFigure 23). Eather end goes toward the engine andfits into the spline hub that was bolted to the crank-shaft (See Figure 13). Coat the splined end of thesahft with a anti-sieze compound be fore inserting itinto the pulley adapter (See Figure 24). Figure 23

16. Install Machined Pump Mount Plate The machined pump mount plate (P/N 0) bolts to the frontof the bolster in the four existing threaded bolt holes (See Figure 22). These bolt holes will have plasticplugs in them that will need to be removed (See Figure 14). The pump mount Plate (P/N 02979436 )bolts to the tractor with 4 mounting bolts (Bolt P/N 02975692 - Hex Head M20-P2.5 X 50MM PLGR10.9 , Lockwasher P/N 02971158 - M20) tighten these four bolts down at this time (See Figure 25).

P/N1

Drive Shaft

7/8" x 13Spline End

7/8" x 13Spline End

Figure 24

Check Clearenceof Driveshaft andBolster here

Apply Anti-Siezeto ID of Bearing.

Figure 25

Figure 22




20. Install Hydraulic Tank. The hydraulic tank mountsbetween the two front tank mounting rails (See Figure27). DO NOT remove any caps and/or plugs from thehydraulic tank, leave the tank closed until ready to installlines and this will keep contamination out of hydraulicsystem. Use an overhead hoist isrecommended for installing the hydraulic tank (SeeFigure 27). After hydraulic tanks bottom mounting stripsare aligned with the holes in the Tank Mount Rails insertthe retaining bolts, two on each side. But only snug thebolts for now, do not tighten them as they will have to bealigned with the bumper weldment later. (See Figure28).

21. Install Bumper. The bumper installs in front ofthe hydraulic tank with two bolts on each side (SeeFigure 28). Sometimes this will take some movingaround to align the bolts and holes, usually this can bedone by inserting a punch into one of the holes or bysomeone assisting you.

22. Tighten Hydraulic Tank, Tank Mount Rails &Bumper Mounting Bolts. Tighten the bolts now that arein the Tank mount rails, Hydraulic tank & Bumper now.Make certain all are tightened securely (See Figure 29).


Figure 26

Figure 27

Figure 28 Figure 29

19. Install Tank Mount Rails. The tank mount rails are are different from LH & RH, These will mountonly on the side they were designed for, notice the bend outward on rails (See Figure 26). Leave these boltsa bit loose it will make it easier to install hydraulic tank assembly (See Figure 27, 28 & 29)




23. Install Driveshaft Spline Coupler PulleyWeldment. Make certain the carrier bearing andlocking collar are installed on driveshaft and bear-ing is installed into pump mount. Install splinedcoupler and pulley weldment (See Figure 30 & 31).Thispulley is used to drive the cylinders supplyauxillary pump. this will need to be mounted beforpump can be mounted.

24. Coat Splined Pump Shaft with Anti SeizeCompound. Coat the splined shaft with anti-seizecompound, do not use excessive amount (SeeFigure 32).

25. Install Pump Retaining bolts. The pumpretaining bolts are to be installed by hand. Thepump should be seated into the opening providedin the pump mount weldment for the pump flangering (See Figure 33). Install the two pump mount-ing bolts and tighten them. DO NOT use the boltsto force pump flange into the pump mountweldment, if you do you will break the flange earsoff of the pump. If the pump will not go by pushingit in take the pump out and check the opening forexcess paint or burrs. The pump must be installedwith suction to LH side of tractor.

Figure 31

Figure 33

Install & Tightenthe two pumpmounting bolts

P/N 702785Pulley Weldment(Use w/Aux. Hyd

System)Figure 30

Figure 32

Apply Anti-Siezeto spline pumpshaft.




26. Adjust Splined Coupler/ Pulley Weldment.The splined Coupler Pulley weldment must beadjusted to run in the correct location. Note thelong end of the splined coupler goes on first andhas a roll pin that is driven trough the splinedcoupler. Push the pulley outward until the splinedcoupler is slid as far as it will go onto the PumpShaft (See Figure 34). Pull the driveshaft out of thecrankshaft pulley adapter until it is in the splinedcoupler / pulley weldment as far as it will go.Tighten the setscrew in the carrier bearing lockingcollar, this will prevent the drive pulley weldmentalignment from moving. Double check to makecertain the locking collar is tight against driveshaft.NOTE: If driveshaft is tight and will not slide out tocoupler by hand, use a pair of locking grip pliers onthe shaft next to the tractor bolster, use a small prybar between pliers and bolster to slide shaft out ofcrankshaft pulley and make certain it is into thesplined coupler as far as it will go (See Figure 34).

27. Install Small Auxiliary. Pump. The smallauxiliary pump mount above the larger pump andis to supply the cylinders with hydraulics. TheDrive belt is already installed on the driveshaftpulley. The small pump is mounted on a plate withtwo mounting holes, one round and one slotted.Set the pump up against the larger pump mountweldment and slip the drive belt over the pulley(See Figure 35). You can insert the retaining boltinto the LH side of small pump mount plate to holdit up but do not install a nut on it. The Belt guard andpump mounting plate uses the same bolts (SeeFigure 36 & 37). Install the belt guard with the boltsthrough it into the Large Pump Mount Weldmentand through the small pump mount plate. Installthe two retaining locknuts on the these two bolt butdo not tighten them yet.

28. Adjust Drive Belt on Small Auxiliary Pump.The small pump mount plate has a 3/8" squarehole that is designed to be used with a 3/8" driveratchet or breaker bar to adjust the belt. Snug thepump mounting bolts and put a 3/8" drive ratchetinto the hole. Pull up until belt has about the sametension as an automotive belt. Tighten the mount-ing/adjusting bolts (See Figure 38 & 39).

Coupler /Pulley mustbe on pump shaft asfar as it will go

Figure 34

Figure 35

Figure 36

Note the longbolts, these are

to mount theAux Pump belt

cover on



BeltGuard

PumpMountPlate

SmallPump

In Suction

Side

OutPressure

Side

Figure 40


UseFlatwasher

here

Figure 39

SlottedAdjusting

Hole

3/8"square

hole

3/8"Ratchet

SmallHyd

Pumpfor Hyd

CylSupplyFigure 38

nuts with some mark such as a dab of paint from apaint marker or anyway that you want so you willknow that bolt has been tightened.

30. The small cylinder hydraulic Supply Pumpwill have a short hose that connects to the smallpump and to the tank suction port that is in the tankexclusively for the small pump. The suction hose willneed cut to length. make certain suction hose is notkinked. (See Figure 40 & 41) which shows theseports. Make certain the Elbow (pressure port of outertandem pump (See Figure 40) is installed and tight-ened pointing to the rear of the pump.

31. Prepare Pump Fittings The Pump will needto be prepared for connecting the hoses. There arefittings that must be changed or angles if fittingchanged.. The Fittings in the pump should already beinstalled when you receive it from the factory (SeeFigure 39 & 40). The outer large cap on the tanksuction ports will need to be replaced with elbowfittings and hose barbs (See Figure , 41). Coat thefittings that screw into pumps and tank with a pipesealer (NOT Teflon Tape), do not put excess sealeron O.D. of fittings and none on I.D. of fittings (SeeFigure 41).

29. Recheck All Bolts and Components that have been installed . The bolts and components thathave been installed should be check before moving on the next step. Make certain that all bolts have beentighten. It is a good practice to mark the bolts and

Figure 37

BeltGuard



CaseDrain To

Tank

SuctionPortFromTank

PressureOut Port To RH

Wing Motor

Tank SuctionPort, Small

Pump

CaseDrain From

Pump

Figure 41

Small PumpPressure Port

Leave Cappedon RH Only

Model


32. Connect MotorPressure Supply Hoses toPump.

SINGLE WING: The Pump for the RH WingOnly (Single Pump ) hasone pressure hose. TheRear (closest to TractorEngine) it the supply for theRH Wing Motor. The LHfitting is the Motor PressureSupply. The hose for the RHWing should be marked witha red plastic tie on it, Con-nect these two hoses at thepump now (See Figure 41).When single wing there willonly one suction port of tankused, leave a cap on theother port (See Figure 41 &43).

DUAL WING: The Pump for the dual wingis a tandem pump and willbe connected different thanthe single wing. The tandempump has two suctionhoses, two case drain hosesand two pressure hoses(See Figure 42).

33. Connect Pump Suc-tion Hose. The Case drainhose should already be con-nected, if not connect it now.

SuctionPortFromTank

CaseDrain To

TankPressureOut Port To RH

Wing Motor

Pressure OutPort To LH Wing

Motor

Tank SuctionPort, Small

Pump

Figure 42

Hose & Fittings with Pipe thread will need a thread sealer used (do not use excess sealer and no sealeron ID of fittings). The Pump Suction hoses will be sent longer than needed and will need to be cut to fit,DO NOT install any suction hose with kinks in them. Kinked hose could starve pump of oil (See Figure41 & 42). The Auxiliary. Pump Suction hose will need to be connected now (See Figure 41 & 42).

34. Cover Pressure Hose with Sleeving. The pressure hose will be run through the hose retainingring that will be bolted to the side of mainframe mounting bracket (See Figure 44 and 45), slide the hosesleeving up over the pressure hose . Slide sleeving up until it is about 2 inches past the edge of thehydraulic tank. Leave the hose fittings loose at the Pump for now as you may have to take them off laterto insert hoses through the hose ring and down the side of the frame if you have not done so already.

SingleWing

DualWing



Figure 46

Tank ReturnFilter

ElbowFitting

PipeTee

ReducerFittting


36. Install Return Filter Pressure Gauge. Thereturn filter pressure gauge screws into the side ofthe return filter housing. This gauge is a low pressuregauge that is marked in green and red areas. (SeeFigure 48). The Oil Pressure return gauge has arubbery tip on top of it, the tip till have to have the tipof it cutoff. Using a utility knife (or suitable knife) cutthe tip off now (See Figure 48). This will need to bedone before unit is run.

Return Hose from 4Spool Control valve

Port Marked "T"

Oil Level Sight Glasswith Temperature

Gauge

Return Hosefrom Wing

Motors

Figure 44

SleevingMaterial

Figure 45

Figure 43

Leave these connec-tions plugged as theyare not used on RH

Wing Only units

Figure 47

35. Install Hose Fittings into Return Filter in Tank. There is a return filter in the top of the RH side oftank. In the end of the filter housing install a Tee Fitting with an Elbow in it. In the end of the Tee there willbe reducer to allow the installing of a smaller hose. This reducer is where the return hose from the controlvalve will connect (See Figure 46 & 47).



37. Install the Oil Level Sight Glass. The Oil Level sight Glass screws into the Hydraulic tank. This isto covered with oil when tank is a at operating level (See Figure 47).

38. Install the small pump pressure hose to pump. The pressure hose connects to the RH side of thesmall pump and is run down the RH side of the frame with the return hoses (See Figure 49) and will connectto the control valve for hydraulic supply. The return hose from the valve will be connected to the tank returnfilter fitting (See Figure 47).

39. Fittings in Tank Left Plugged. When installing the RH Only Wing a Single pump will be used. Thiswill leave fittings on tank that will remain plugged (See Figure 50 & 51). When installing the dual wing allthe ports in tank will be used.

Figure 48


ReturnPressure

Gauge

Figure 50

Figure 49

To Control Valve, PressureLine ("P" Port on Valve)

TankSuction

Line

Cyl. Controlvalve Supply

Pump

Primary PumpSuction Hose

Primary PumpPressure Hose

Primary PumpCase Drain

Hose

Figure 51

Leave these connec-tions plugged as theyare not used on RH

Wing



NOTES



INTERSTATER

John DeereJD-5425

&JD-5525

Mainframe Installation

Section 3



1. Identify and locate the frame rail (See Figure 1), Sub-frame Weldment. The tractor drawbarretainer and drawbar will have to be removed. The rear of the frame will bolt into the same holes thedrawbar was removed from (See Figure 3). The frame will be slid under the tractor and lifted up underthe tractor. The Dual wing mainframe shown below, the single wing mainframe will look like the dualwing with the exception there are no wing mounting lugs on the H side of frame.

2. Remove RH Side Steps. The steps on the RH side of the tractor will be removed and not usedso as not to interfere with the clearance of the mower head. Any factory options that mount on RH side(if equipped) will need to be removed also for clearance. It will be dealer and/or customers choice onwhere and if the optional equipment is remounted somewhere else for use. (See Figure 2). On thedual wing units the LH step will also need to be removed.

3. Install Main Frame to Tractor. The frame rail (See Figure 1) will be slid under the tractor on theFrom the rear (See Figure 3). Do NOT tighten the frame mounting bolts until all the bolts have beeninstalled as frame will need to be moved slightly for alignment as the bolts are installed. The frame canbe installed by balancing the frame on a floor jack, if using this method it is recommended two peopleperform this to prevent the frame from falling. Raise the frame up to the tractor frame (See Figure 3),

4. Raise the frame rail up under the tractor. Until the rear mounting plate is under the rear axle andaligned with factory holes in the center of rear axle housing. Using the jack raise the frame up until it isagainst the rear axle housing. Install the new bolts and lockwashers. Do not tighten these bolts until allbolts are installed into the frame.

5. Install Front Frame Mounting Brackets. The front frame mounting brackets will consist of a RHand a LH Bracket (See Figure 4, 5 & 6). Bolt these mounting brackets to the tractor frame with twobolts on each side. These brackets will bolt to the sub frame with two bolts and nuts each. All themounting bolts should be installed before tightening the bolts. Tighten all the bolts in sub-frame frontand rear now (See Figure 4, 5 & 6).

Figure 1

P/N 02983067Main Frame Weldment

Dual Wing (Cab or ROPS Tractor)

Front

Rear

LH Side

RH Side

Install Main Frame / RH Only & Dual Wing



7. Install Wing Lift frame. The RH wing lift framepivots on two hinge pins, one to the front and one to therear. When installing these pins they must be aligned ina way that will allow the retaining bolt to be installed (SeeFigure 9, 10 & 11). On dual wing models the LH Liftframe will install the same as the RH.

8. Install Hydraulic Cylinders. Install the hydrauliccylinders as shown. The ends will have to be installed onthe rod ends, Note the collars on the cylinders. Thesecollars have locking bolts in them and must be installedwith the bolts to the top where they are accessible afterassembly is complete (See Figure 11).

Remove RH& LH Steps

Figure 2

Figure 3

Figure 5 Figure 6

RH Front FrameMounting Bracket

LH Front FrameMounting Bracket

6. Install Cylinder Support Weldment. The cylinder support weldment (P/N 106771) bolts to theframe rail (See Figure 6). Tighten the mounting bolts once installed. On dual wing units the LH willinstall the same as the RH. The LH support will not have the mount with the 4 holes welded to the topof it (See Figure 7 & 8).


Figure 4



9. Check the Lift and Tilt Cylinders. check tomake certain that when the Lift cylinder and the TiltCylinder were installed the grease fittings and thelocking collars are pointed in the right direction (SeeFigure 14 & 15). When installing these they must beinstalled with the rod end clevis grease fitting facingup and out (See Figure 11, 12 & 13). Do not removeany shipping plugs from cylinders or hoses until youare ready to install the hoses, this will keep thesystem and components clean while unit is beingassembled.

Figure 11

CylinderLockingCollars

Figure 10

Frame HingePins

Hinge PinRetaining Bolt

Figure 9

Frame HingePins

Frame HingePins

RH Lift Frame

Figure 7 RH Lift CylinderSupport Weldment


Figure 8

LH Lift CylinderSupport Weldment

RH Lift Frame



Wing Lift Cylinder

Figure 13

Wing FoldCyl.

Install withHyd. fittings

to rearGreaseFittings

must faceup.

Figure 12

GreaseFittings

must faceup & out

Cyl, Clevis &Hose ports mustpoint in thecorrect direction.

Figure 14

LH Lift Frame

Figure 15

RH Lift Frame


Figure 16

Remove Steps if notalready removed



NOTES



INTERSTATER

John DeereJD-5425

&JD-5525

Wing Mower Installation

Section 4

© 2005 Alamo Group Inc. Section 4 - 2Interstater (JD-5425 & JD-5525 Asy. Man.) 07/05


1. Assemble Brackets & Magnetic Switches.Locate the Magnetic switch mounting bracket, dualwings there will be two of these (See Figure 1). If Dualwings the two brackets will have the switches mountedon the opposite side (See Figure 2). Once these havethe switches bolted on lay the brackets aside for now.(See Figure 20)

2. Assemble Magnetic Switch Activators. Thismagnetic switch activator has a magnet inside and acover that must be installed (See Figure 4). There arebrackets that these bolt to. With dual wings there is aLH and RH bracket. Bolt the Magnetic activators to thebrackets (See Figure 5) LH Bracket Shown). Notethere are two sets of mounting holes. In figure 5 the setthat have the bolts through them is used to shut wingoff at 45 degree up. If the other set of holes are usedwing mower will shut off at 90 degrees up. The 45degree setting is recommended for standard applica-tions.

3. Install Switch Brackets & Head Mounting Brack-ets. Use a hoist to lift the Wing Mower and position it formounting. DO NOT get under Mower while lifted on ahoist (See Figure 6). Mower is only be positions so thatswitch brackets and hinge brackets can be installed tohead, this must be done before mower can be mountedto lift frame.

Small Screw Hole

Small Screw Hole

Slotted Hole forswitch wires

BracketMounting

Holes

MagneticSwitch

SwitchMountingScrew

Magnetic SwitchWire Plug

Figure 1

Figure 2

RH Wing Magnetic Switch & Bracket

LH Wing Magnetic Switch & Bracket

Figure 3 Figure 4

MagneticStich

ActivatorCase

MagnetInside

Cover

Wing Cut Off Switch:

NOTE: This section will show Dual Wing installation. The LH and RIGHT hand wing will assemble thesame except in a mirror image.




Mount Magnet Activator tothese hole for 45 degree

shut off.

Mount Magnet Activator tothese hole for 90 degree

shut off.

RHBracketShown.

Figure 5

Figure 6Always use overhead

hoist to position mowerdeck

Wing Cut Off Switch: (continued)

4. Install Mower Rear Mounting Brackets &Magnetic Switches. The Mower Hinge Link has aLH & RH (See Figure 7). These brackets will slideover the Hinge Pin which is bolted to the mowerdeck at the factory. There are two Threaded holesin the end of the hinge pin (See Figure 7) Thesetwo holes serve dual purpose. First they hole thehinge bracket on and the Magnetic Activator Bracketon. Some times you will need to loosen the Hingepin to align the two holes so the bracket will bolt on.(See Figure 8 & 9). Tighten the two mounting boltsin to the hinge pin. The Hinge bracket will still turnfree.

Figure 7 LH Wing Shown

LH WingRear Hinge

Bracket

TwoThreadedHoles in

Hinge Pin

Figure 8Hinge PinBracket

Magnetic ActivatorSwitch Bracket

LH Wing ShownFrom Rear

Figure 9

RH Wing ShownFrom Rear

Hinge PinBracket

Magnetic ActivatorSwitch Bracket




5. Install Mower Front Mounting Brackets.The Mower Hinge Front Bracket has a has a LH& RH (See Figure 10). These brackets will slideover the Hinge Pin which is bolted to the mowerdeck at the factory. This bracket will be bolted tothe Lift frame with four bolts. This hinge Pin WILLNOT have threaded holes as the rear hinge pindid.

6. Install Wing Mower to Lift Frame. Using theover head hoist position the Mower Deck (SeeFigure 10) to where the front hinge bracket willalign with the lift frame. Install at least two of themounting bolts and snug them down.

7. Install the wire harness to wings. The Wireharness will have a lead to each wing. These canbe determined by the length, the longer lead will goto the left wing. There is apiece of square tubewelded to the lift frame on the back for the wireharness to be run through (See Figure 11). Thewire harness will be run down and under the roundbar of lift frame. Leave harness here for now.

8. Install Magnetic Switch Pickup & Bracketas well as the rear hinge bracket. The Rear hingeBracket will install similar to the way the frontdoes, but not the same because the Magneticswitches and brackets bolt on with it. Beforeinstalling the rear Hinge bracket locate the mag-netic Switch Bracket (See Figure 12). There aretwo spacers about 3/4" long that must be installedbetween the magnetic switch bracket and thehinge Bracket (See Figure 12), Also the wireharness must be run between these two spacersand between these two brackets (See Figure 13 &14). Install the remaining two bolts and tighten allthe hinge bracket bolts, this will include the fronthinge bracket bolts. (See Figure 21)

9. Plug Magnetic Switch into Wire Harness.The wire harness should have a plug that alignswith the magnetic switch wire. Plug these to-gether now and continued to run wire harness upbehind the hinge and on up to the mower decksmotor. (See Figure 21)

Figure 10LH Wing Front Hinge

Pin Bracket

LH Wing ShownFrom Front

Figure 11

Figure 12






Figure 14

Figure 13LH Wing Shown

From Rear

LH Wing ShownFrom Rear

Wire Harness toMotor

Wire Harness toMagnetic Swithc

Figure 15

Figure 16


10. Connect Tilt Cylinder to Mower Deck. TheTilt Cylinder connects to the mower head (SeeFigure 15 & 16). Note you will need to remove thebelt guard to connect this cylinder so you will haveroom for the cylinder mounting pin to be installed(See Figure 16). When connecting the cylinderthe grease fitting on the rod end must face up, thelocking collar on the cylinder must face up and betightened on rod end. The RH Wing and the LHWing will mount the same. Install the RH wing thesame as the LH wing . Reinstall Belt Guard.

11. Install Wire Harness to Motor Solenoid.The thumb nut on top of the solenoid will allow thesolenoid to be turned to different direction if needed.(See Figure 17 & 21)

Cylinder Pin

Cylinder RodClevis with grease

fitting up

Clevis LockingCollar

LH Wing Shown From Front

RH Wing Shown From Rear

Figure 17

Soleniod

Wire Harness



Connecting Mower Motor Hoses:

1. Connect Motor Pressure & Return Hosesto Mower Deck. Connecting the Motor Hoses isvery critical that they a re connected to the correctfittings, If these hose are connected backwards itwill damage the cooling tubes on the deck, thecooling tubes cannot take the pressure it will makethem swell up and bulge.

IMPORTANT FACT. When connecting thehoses to the fittings on the mainframecrossmember remember the top hose is alwaysthew pressure hose and will only connect to themotor, never the cooling tubes on the deck. Thebottom hoses are the return hoses and will alwaysconnect to the cooling tubes on the mower deck.(See Figure 18 & 19). The RH wing will connectthe same as the LH mower (Shown). IMPOR-TANT. On the RH Wing the top hose is pressureand connect to the Motor and the bottom hoseconnects to the Tank return.

2. Double Check all Hose Connections. Be-fore operating the mower make certain all hydrau-lic hoses are connected correctly. IT IS MOSTcritical that you make certain NO HIGH PRES-SURE hoses are connected to the wet tubes ofthe mower deck, The wet tubes will expand (swellup) and be damage if the High Pressure hose isconnected to the deck wet (cooling) tubes. SeeFigure 21, 22, 23, 24, 25, 26 & 27. Looking at allthese figure before going on to next step is impor-tant.

3. Install Pump Cover. The front pump coverwill bolt to the tank, this cover will cover pumps andall hoses and/or fittings connected to the pump(See Figure 20). Set the cover down over thepumps. Align the hove in cover with the tabswelded to the tank (See Figure 20).

4. Install Rear Mower. Go on to the Install rearmower section which will also include the InitialStart up procedures. DO NOT START Tractoruntil you have completed the initial start up sec-tion.

Figure 18

Pressure Hosef/ Pump Pressure Hose

w/ 90 degreebend to Motor

Return Hose fromColling tube on deck

tophose

bottomhose

Figure 19

Return hose

PressureHose

Figure 20



Wing Cut Off Switch Wiring Schematic (Dual Wing)

#1#2

#1#2

Right WingMotor SolenoidValve

Left WingMotor SolenoidValve

Right Wing Safety Cut-off SwitchLeft Wing Safety Cut-off Switch

Black

Black/White

Black

YellowWhite

White

Yellow

Red

Brown

RedYellow

RightSwitch

LeftSwitchFuse

3 TerminalConnector

White

B/W

White Black

Brown (Start Terminal)Brown (Starter Solenoid)Red (to Accessory Terminal)Black (Ground @ Tractor Starter)

Right Wing MotorSolenoid Valve

Left Wing MotorSolenoid Valve

3 TerminalConnector

RightSwitch

LeftSwitch

BrownBrown

Black

Black/WhtYellowBlack/Wht White

CavityPlug

DOUBLE WING MOWERSHOWN(Single Wings have only the RightWing Motor Solenoid Valveharness)

Figure 21

Red


Motor Control Switch - Dual Wing

Starter Solenoid WireStarter Solenoid WireSwitched Power SupplyGround

LH Wing Push-Pull Switch

ConnectersShipped Loose inSeparate Plastic

Bag

# 12 Brn

# 16 Red# 16 YellowRH Wing &#16 WhiteLH Wing ON / Off

Switch Plug

SolenoidConnector

#16 Black/White

Figure 22

RH Wing Push-Pull Switch

Fuse Holderwith Fuse

(10 Amp Fuse)

#16 Black/White

Solenoid Connectorat Cutter Valve

# 16 Yellow

12345671234567123456712345671234567123456712345671234567123456712345671234567

# 12 BrownLine Connectorto StarterSolenoid

#16 Black (-)

#16 Red (+) toSwitched PowerSupply

#16 Black/White



3 TerminalConnector

CavityPlug

#16 White




Motor Control Switch - RH Wing Only


(10 Amp Fuse)

Push-Pull Switch

Connecters Shipped Loose inSeparate Plastic Bag

#16 Black(-)

Ring Connectorto Ground

# 12 Brown LineConnector toStarter Solenoid



# 12 Brn

# 16 Red# 16 Yellow

ON / OffSwitch Plug

SolenoidConnector

#16 Black

# 16 Yellow

#16 Black

Figure 23


Vent Plug

LiftCylTilt

Cyl

Cooling Tube

Cooling Tube

MotorReturnHose

MotorCaseDrain

MotorReturnHose

TankReturnFilter

HydraulicTank

Motor

Pump

Aux Pump

SuctionLine

Cyl ValveReturn Line

Cyl ValvePressureLine

CylControlValve

Pump & Motor Hyd Schematic (RH Wing Only)

Figure 24A



VentPlug

Motor Return Hose &Deck Cooling Tanks

Tank ReturnFilter & ReturnPressureGauge

Hydraulic Tank


Cyl ValvePressure Line

CylControlValve

RH WingTilt Cyl.

RHWingPump

Pump & Motor Hyd Schematic (Dual Wing)

RH MotorCase Drain

Motor

Aux Cyl.Pump

LHWingPump

Motor

LH MotorCase Drain


LH Motor Pres-sure LineLH Motor Pres-

sure Line

Aux Cyl. PumpSuction Line

Tandem PumpSuction Lines

Pump CaseDrain Lines

LH WingTilt Cyl.

RHWingLiftCyl.

LHWingLiftCyl.

VentPlug

Cooling Tube Cooling Tube

Figure 24B


cccccccccccccccccccccc

123123123123

123123123123123

1234123412341234

12341234123412341234

Pressure Hose From Pump hasa 90° Fitting Connects here.

Pressure Hose Motor hasa 90° Fitting Connects here.

Return Hose to Tank Return Filterhas a 90° Fitting Connects here.

Return Hose from Cutter HeadCooling Tanks has a 45° FittingConnects here.

Main Frame w/ hose bulkhead fitting

RH side of tractor looking from front to rear of tractorSingle Wing Shown, Dual Wing has metal cross over pipe with a Tee in it for the return.

Pump & Motor Hydraulic Schematic (RH Wing Only)

Figure 25

NOTE: The Pressure hose willalways be connected to the topfitting and the return will alwaysconnect to the bottom.

Note 45° elbow onbulkhead fitting thahose connects to

Figure 26



Pump & Motor Hydraulic Schematic (Dual Wing)

RIGHT WING LEFT WING

Return to Tank from Wet Tubes of RH Wing

Pressure from Pumpto RH Wing Motor

Return to Tank from Wet Tubes of LH Wing

Pressure from Pumpto LH Wing Motor

MainframeTube Cross Over

Pressure from Pumpto RH Wing Motor

Pressure from Pumpto LH Wing Motor

Return to Tank from Wet Tubes of RH & LH

Wing

Hose Sleeving

Hose Sleeving

Hose Sleeving

ReturnLineTee

TRACTORRH SIDE

TRACTORLH SIDE

TRACTORFRONT

TRACTORREAR

IndicatesDirection of

Flow ININ

ININ

OUT

OU

T

OUT

Figure 27


Pump & Motor Hydraulic Schematic

RH WING ONLY HYDRAULIC MOTOR SHOWN

Return from FrontWet Tube to Tank

High Pressure fromPump to Motor

Return from Motorto Rear Wet Tube

and on to Tank

Case Drain fromMotor to Motor

Valve

NEVER CONNECTHIGH PRESSURE

HOSE TO WET TUBESON DECK !

Figure 28

TandemPump

RH WingPump Case

DrainLH WingPump Case

Drain

LH WingPump Suction

LineRH Wing

Pump SuctionLine

RH WingPump HighPressure

Line

LH Wing Pump HighPressure Line

HoseSleeving

Cyl System SupplyPump Suction Hose

Tandem Pump, Inner Pump for RH Wing& Outer Pump for LH Wing. RH WingOnly has a single pump.

Figure 29




Tank Return Hose fromWet Tubes on LH &

RH Wing Decks

Tank Return Hose fromCylinder Control Valve

to Tank

Tank Return Filter Assembly& Tank Return Pressure

Gauge

Oil LevelSightGlass

Oil TemperatureGauge

Figure 30

Lower Connection Alwaysfrom Deck Wet Tubes toFilter Tank Return Line(LOW PRESSURE)

Upper Connection Alwaysfrom Pump To Wing MotorsNEVER TO WET TUBES(HIGH PRESSURE)

Main Frame Cross OverBracket & Tubes (RHSide Shown, note TeeFitting in lower fittings

Nut on Bulkhead Fittings

Figure 31



over hose which allows the oil to cross from the reartube to the front tube,The Tubes and the cross overhose are in the oil return to tank circuit which has tobe low pressure..

Figure 32

Wings have a front and arear wet tube for coolingthe oil. At the outer end ofthe decks there is a cross



INTERSTATERJohn Deere

JD-5425&

JD-5525Joystick, Cable Connections

&Control Valve Connections

Section 5



Joystick , Valve & Control Cables (Cab)

2. Install The Cylinder Control Valve to Valve Bracket.The control valve is mount to the valve bracket using twobolts. These two bolts is all that will be needed to mountvalve to valve bracket. (See Figure 2).

3. Connect Remote Control Cables to Valve Bracket.Shown here are cables being connected t the valve mountbracket while it is lying on the bench (See Figure 3). It canbe done after bolting it to the tractor as well.

4. Bolt Valve Mounting Bracket to Mainframe . Thevalve mounting bracket is bolted to the Right Hand side ofthe tractor. It is bolted to the mainframe. There are twodifferent sets of hole in valve mounting bracket, this allowsthe location of the valve to be varied (See Figure 4)

Figure 1

Control Valve & Hose Installation: NOTE: This section only Applies if using the AuxillaryPump for cylindercontrol, if using tractor hydraulics for cylinder skip this section.

1. Remove standard control Handles. When using remote control cables and handles the standardhandles must be removed and discarded. This is done by removing the C-Clips and pins that hold thehandles to the valve body and the C-clips and pins that hold handles to the spools. (See Figure 1)

Figure 4

Figure 2 Figure 3

Figure 5



Joystick , Valve & Control Cables (Cab)5. Install sleeving over the return hoses fromheads and control valve and Control valve PressureHose. Slide the three hoses through the sleeving.Slide the hoses with the sleeving through the hosesupport ring bolted to the side of the tractor. Tie thesleeving using plastic ties around the hoses to keepit from moving (See Figure 9). Tie the sleeving withplastic ties around the pressure hose on the LH sideof tractor (See Figure 9)

6. Install return hose to cross member andHoses to Control Valve. Connect the return hose tothe cross member on right hand side of main framecrossmember (See Figure 6). The other end willconnect to the return filter Tee fitting (See Figure 7&10). Note: These hose are run through a sleevingmaterial and a hose support weldment (P/N02978281) which bolts to the tractor bolster (SeeFigure 9), this must be done before hoses areconnected or they will need to be removed to installthem.

7. Connect Pressure & Return Hose to Cylin-der Control valve. Connect the pressure hose run-ning from the RH side of small pump to RH Top sideof control valve, The port will be marked with a "P"cast into it, the other end is connected to the smallsupply pump (See Figure 7 & 8). Connect the returnhose that is connected to the Tee Fitting of the returnfilter to the Return side of the control valve with a "T"cast into it (See Figure 2 & 5)

Figure 6

Return Hosefrom Wing

Motors to Tank

Pressure Hoseto RH Wing

Motor

Return Line FromRH Wing DeckCooling Tanks

Figure 7

Return Hose fromHyd Valve "T" Port

Return Hose from MainFrame Crossmember

(Motor Return)

Figure 8

To Control Valve, PressureLine ("P" Port on Valve)

TankSuction

Line

Cyl. Controlvalve Supply

Pump

Figure 9Hose SupportWeldment P/N

02978281

Hose SleevingMaterial



Vent Plug

LiftCylTilt

Cyl

Cooling Tube

Cooling Tube

MotorReturnHose

MotorCaseDrain

MotorReturnHose

TankReturnFilter

HydraulicTank

Motor

Pump

Aux Pump

SuctionLine



CylControlValve

Pump & Motor Hyd Schematic (RH Wing Only)

Figure 10A



VentPlug

Motor Return Hose &Deck Cooling Tanks

Tank ReturnFilter & ReturnPressureGauge

Hydraulic Tank


Cyl ValvePressure Line

CylControlValve

RH WingTilt Cyl.

RHWingPump

Pump & Motor Hyd Schematic (Dual Wing)

RH MotorCase Drain

Motor

Aux Cyl.Pump

LHWingPump

Motor

LH MotorCase Drain


LH Motor Pres-sure LineLH Motor Pres-

sure Line

Aux Cyl. PumpSuction Line

Tandem PumpSuction Lines

Pump CaseDrain Lines

LH WingTilt Cyl.

RHWingLiftCyl.

LHWingLiftCyl.

VentPlug

Cooling Tube Cooling Tube

Figure 10B




1. Control Valve Cable Clips. Locate the fourcable mounting clips and four roll pins (shown layingon muffler bracket for illustration only in Figure 11).Start the roll pins into the clips as shown through oneside only (See Figure 11). Insert the Remote Cablethrough the Control Valve Mount Bracket (See Fig-ure 3). Install the large cable retaining / Adjusting nutonto threaded portion of cable housing (See Figure12). DO NOT tighten this large nut until later. On thetip of the threaded end of the cable there is a 1/4" nut.Screw this nut down onto cable. Insert the cable clipdown over threaded cable end (See Figure 13). Findthe four for dual wing and two for single wing 1/4" nutsupplied, install one onto end of cable down into clip.This nut should be screwed onto cable at least thethickness of the nut, do not screw it on so far that itwill interfere with the operation of the cable. Using thenut that was already on the cable screw the nut outuntil it is against the clip from the bottom side,tightening this nut against clip will lock the other nutinside of clip. (See Figure 13).

2. Connect Clip to Valve Spool. Turn the clipand the valve spool to where the hole in the clip andthe hole in the clip are aligned. Using a hammer drivethe roll pin through the hole in the spool and throughthe other side of clip (See Figure 14) . Make certainto keep the clip aligned when driving pin in. Turn theclip and spool as shown (See Figure 15), Continuethis with the other 4 cables and clips (See Figure 16).

3. Connect Cylinder Hoses to Valve. There aresix cylinder hoses for dual wing and three for singlewing that connect to Control Valve. One Pressure"P" hose and one Tank "T" hose. These hoses areconnected as follows (See Figure 16 , 18)

1. Tilt Cyl. Rod End RH Wing.2. Tilt Cyl, Butt End RH Wing.3. Lift Cyl. Rod End, RH Wing.4. Tilt Cyl. Rod End LH Wing.5. Tilt Cyl. Butt End LH Wing.6. Lift Cyl. Rod End LH Wing.7. "P" Pressure Hose from Pump8. "T" Return Hose To Tank

Connect hoses with elbow pointing down (See Fig-ure 17)

Cable Mounting Clips &Roll Pins (Qty 4 ea.)

Figure 11

Figure 12

Screw thissmall nut down

onto cable

Remote Control Cable Connections Cab Tractor:

Figure 13




Figure 14 Figure 15

Figure 16 Control Valve Hoses

1

2

3

4

5

6

7 8

Figure 19

1

2 3

Vent Plug

Remote Control Cable Connections Cab Tractor: (continued)

4. Control Valve Information. Shown Below is the valve used on the dual wing models, this is forillustration only and will not be the same as the single valve used on the RH only model, the cableconnectins will connect the same. The two right sections of the valve (as shown in Figure 14 & 15) arethe same as the single valve and will connect the same way (See Figure 17 and step 3).

Figure 17

Figure 18

Dual Wing Valve

Single Wing Valve

1

2

3

78




1. Drill Hole IN Floor Mat and Cab of Tractor toInstall Remote Cable Control cables and wire harnessinto Cab of Tractor. IMPORTANT! Read thiscomplete section before drilling any holes, this will helpmake certain that components will be installed cor-rectly.

There is one 1-1/2" minimum size holes thatwill need to be drilled into the floor mat completelythrough the floor of tractor (See Figure 20 ). This holeis best cut with round hole saw. Looking at the picturesnote the location of hole as compared the ribs that runacross the floor mat, this will give you indication of thelocation of this holes in floor mat.

IMPORTANT! The hole in figure 20 will gothrough floor mat and cab floor. Before drilling any holeslift floor and check to make certain there are no wires orlines that will be hit, look under cab to make certain it isclear of any that might interfere with hole.

2. Install Remote Control Assembly MountingBracket. The mounting bracket for the remote controllevers will bolt to the front cab post in two existingthreaded holes (See Figure 21). This bracket should betighten before mounting anything to it.

3. Install Wire Harness through floor Mat. TheWire harness will come to you with the on / off switchesattached, these switches will need to be removes toPush the Wire Harness up through the floor and bootcover (See Figure 20 & 22).

4. Insert Cables up through Boot Cover. Mark thecables as to which is which on the control valve as theyneed to be connected in the same order on the insideof the cab as they are connected to the control valve(See Figure 22).

5. Reinstall switches and Switch mounting bracket. Reconnect the switches and the mounting bracketsback to the wire harness (See Figure 26, 29 & 30).

6. Mark Which Cable is Which. It is important thateach cable be marked as to which one it is in relationship to the valve. Start with the cable closest to theengine and mark it 1, next mark 2 (See Figure 23).These marked cables will make a difference whenmounting the control cable handle assemblies to themounting bracket.

Figure 20

Figure 21

Figure 22



Tractor Front

Figure 24

Figure 25 Figure 26

7. Each controller assembly comes fully assembled. All required hardware etc. is included. Thecontrol cables are not included with the control handles and should be ordered separately. The Controllermust face forward as shown or controls will be backward (See Figure 24)

8. To attach the cable, manipulate the controller handle so that the attachment nut is exposed asshown. Remove the lower most nut and screw from the controller housing.Thread the cable nut into the controller attachment nut and tighten. (See Figure 25)


Mark on Cableto referencewhich it is onthe control

valve

Figure 23

9. Allow the controller handle to return to neutral.Slide the cable guide tube into the control housing andreinstall and tighten the housing screw.

10. Check the operation of the spool, cable andcontroller. Some adjustment at the valve end may berequired too ensure that the spool returns to neutralwhen the controller is in the neutral position. (SeeFigure 15)

11. The control lever assemblies utilizes a smallspring to make up for free play in the cable to valveconnection. The control valve spool spring providesthe centering capabilities of the controller and the valvespool. Lack of centering at the controller is nor-mally attributed to poor adjustment at the valve tocable connection or binding of the cables due topoor routing.

12. The control lever assemblies will bolt together toform a group of handles, there will be 4 handles boltedtogether along with the switch mounting brackets.(See Figure 23 & 24) The switches will mount to thesebrackets. Dual Wings models will have two switches.The switch for the left wing mount on the left and switchfor the right wing mounts on the right (See Figure 23 &24). The same two long bolts that go through cablecontrol handles will go through switch brackets.



16. Tie Cables and Wire Harness together. Tie thecables and Wire Harness together with plastic tiesinside the cab and outside the cab. This will keep themfrom moving around (See Figure 22).

17. Check Hydraulic Hose Routing. Shown belowis the routing of the hydraulic Cylinder & Control Valve.Double check these before running Unit. (See Figure28 & 29). The Hydraulic hoses must be connectedcorrectly to the cylinders and the Valve or the controlfunctions will not be correct according to the operationinstruction decal (See Figure 30 & 31).

13. Install Cable control Handle Assembly. The control cable assemblies slide over the threemounting bolts that are installed through the mounting brackets . The first cable to be installed will be theRight Wing Lift Cylinder, the next controller is the Right wing tilt cylinder. The controls need to be installedthis way to match the operation instruction decal (See Figure 27).

14. Install Electrical Control Switch. The push pull switch mounts onto the switch mount bracket andthe bracket is mounted between the control cable levers (See Figure 27). Note this switch can be mounton either side of handles, it is customers choice.

15. Adjust Cable Control Handles. The handles will have some adjustment Left and Right, up anddown by loosening the mounting bolts of the pivot mount. These adjustments will usually be changed afterassembly to suit the individual operator. It is helpful when possible to get the operator to test fit theseadjustments with you. (See Figure 27). The handles of controllers are adjusted at the valve mount plate(See Figure 15).


Figure 27

Figure 28 Figure 29



Valve to Cylinder Hose Connections (Cab & ROPS)

RH WingLift Cyl

RH WingTilt Cyl

LH WingTilt Cyl

LH WingLift Cyl

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○ VentPlug

VentPlug

Figure 31

1212

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○ ○ ○ ○ ○ ○ ○ ○ "T" Tank Return Port

RH WingLift Cyl

RH WingTilt Cyl

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Figure 30

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○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ "T" Tank Return Port

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RH Wing Only (Use with Aux. Pump)

Dual Wing (Use with

Aux. Pump)



Valve Connections ROPS Tractor:1. Install Valve Stand to Tractor on ROPS Tractor only. Attach Valve Stand to the top of the RightLift Cylinder Support with (3) 1/2" x 1-1/2" bolts, and (3) 1/2" locknuts (See Figure 32 & 35).

2. Attach Valve Stand to Valve Mount Bracket. Attach Valve Stand to the Valve Mount Bracket with (2) 3/8" x 1-1/4" bolts and (2) 3/8" locknuts (See Figure 33, 38 & 39).

3. Attach Control Valve to the Valve Stand. AttachControl Valve to the Valve Stand with (2) 3/8" x 1" bolts,(2) 3/8" locknuts. Attach the Top Cover and the BottomCover to the Valve Mount Bracket with (8) 3/8" x 1" bolts,(8) 3/8 washers and (8) 3/8" locknuts (See Figure 34 &39).

4. Install Mower Wing ON / Off Switches. Makecertain to install connector so that larger brown wiresare located on bottom poles of switch. This applies toDual Wing and Single Wing applications (See Figure 35,36, 41 & 44) Figure 32

Figure 33 Figure 34

MOWER ON/OFFSWITCH

Figure 35

Left or RightOn / OffSwitch

Brown

Red

Figure 36

Red

Brn*Brn

*White (for LH Wing Switch) ORYellow (for RH Wing Switch)

Plug as seenfrom back

where wiresplug in

Valve Connections (ROPS Tractor)




Valve Stand

Figure 37

Figure 38

Figure 39 Figure 40

5. Install Valve Supply and return hoses. Attach Valve pressure and return hoses to the valve (SeeFigure 10 & 42) These hoses must be connected according to the schematic shown in figure 10. Do notremove the caps from the ends of the hoses or the valve connections until hoses are being connected.

6. Install cylinder hoses to Valve. Attach thecylinder hose to the cylinders. If a single wing see figure30 and if a dual wing see figure 31. these hose must beconnected as shown in order for the control handles ofthe valve to match the valve operation instruction decal.

7. Connect cylinder hoses to valve. The hose willconnect to the control valve from the bottom. Thesehose must be connected correctly in order for the valvehandle to function as designed (See Figure 30, 31 &43).

8. Install lower Valve cover. The lower valve coverwill cover the hose connections to the valve. This is asafety item and unit must not be operated without thiscover installed at all times (See Figure 44).

9. Install upper valve cover. Install the upper valve/ switch cover on the top of the valve (See Figure 42)

10. Install operation decal for Valve. The decal withhandle function will be installed on the lower valve coverand the decal for the motor switch will install on the topvalve cover under the switches (See Figure 44)



Figure 41 Figure 42

Figure 43 Figure 44


Figure 45 Figure 46



(See Figure 47 thru 59 ). Also see the wire / harnessschematic on the following pages. Consult TractorRepair Manual for wiring schematic of Tractor to determinewhat wire is what on the tractor ignition switch.

2. Connect Power Supply for Motor Control Switches.Make certain the battery is disconnected before con-necting wires. The power supply wire must be connected toa wire that only has current when the tractors ignition switchis in the "ON" position. If the supply wire is connected toa constant active wire and the notor control switchs areleft on when tractor is parked they will run the batterydown. Figure 47

Figure 48 Figure 49

Wire Harness Connections (CAB & ROPS)Wire Harness Connections:

1. Connect Wire Harness to Tractor Starter Activation Wires. The wires to the starter from themotor control switches will need to be connected to the tractor near the ignition switch connections. Orthey can be connected near the starter solenoid, this is something the technician will need todecide asthey assemble the unit. Alamo Industrial recommends connecting the wires at thetractor ignition switch

Figure 50 Figure 51



Wire Harness Connections (CAB & ROPS)

Figure 52

installed is tied up and out of the way offolding components or any thing that maydamage them (See Figure 47 thru 59).

4. Wires from the safety switch mustbe routed close to cutter housing sidesheet and lift frame pivot points. This willprevent wires from being stretched andbroken when cutter housing is raised orlowered to maximum positions (See Fig-ure 53)

5. Route Wires for Cut Off Switches.The wire harnes for the magnetic cut offswitches mounted on the wing hinges willbe ran through a piece of square tubingwelded to the lift frame, this is to protectthe wires from be hung up on object whilemowing.

6. Wire Harness Components. The wireharness will be received in sections. Themain wire harness (Single or dual wings)and the wing harness, a RH harness anda LH harness. The RH and LH harnesswill both be used for a dual wing unit. andonly the RH harness for a single wing unit.

Figure 53


Battery

Brow

n W

ire o

f Har

ness

Cut TractorStarter Wire toStarter Solenoidand reroutethrough JoystickHarness Brown

ACC

Brow

n W

ire o

f Har

ness

Red

Wire

of H

arne

ssStarter

Blac

k Wire

Gro

und

Tractor Ignition Wire

Shown here is typical Igni-tion connection, Your Igni-tion may vary but the func-

Motor ControlWiring Har-

Tractor Ignition

Ignition

FIGURE 54

NOTE: Route wires in such a manner to prevent interference with the operation of tractor orINTERSTATER. Ensure that wires DO NOT lay against anything which could wear through insulationand cause a short circuit.

After connecting all wires, wrap wires with flex guard tubing. Neatly gather hydraulic hoses andflex guard tubing and strap together using plastic ties.

3. Checkall Wire Har-ness Rout-ing. Inspectall of the wireharness be-fore con-n e c t i n gthem. Makecertain thatall portionsof wire har-ness thathave been





3 TerminalConnector

RightSwitch

LeftSwitch

BrownBrown

RedBlack

Black/WhtYellowBlack/Wht White

CavityPlug

DOUBLE WING MOWERSHOWN(Single Wings have only the RightWing Motor Solenoid Valveharness)

#1#2

#1#2

Right WingMotor SolenoidValve

Left WingMotor SolenoidValve

Right Wing Safety Cut-off SwitchLeft Wing Safety Cut-off Switch

Black

Black/White

Black

YellowWhite

White

Yellow

Red

Brown

RedYellow

RightSwitch

LeftSwitchFuse

3 TerminalConnector

White

B/W

White Black

Brown (Start Terminal)Brown (Starter Solenoid)Red (to Accessory Terminal)Black (Ground @ Tractor Starter)

Figure 55

Wiring Harness Schematic (CAB & ROPS)



Motor Control Switch - Dual Wing




Bag

# 12 Brn


Switch Plug

SolenoidConnector

#16 Black/White

Figure 56



(10 Amp Fuse)

#16 Black/White


# 16 Yellow

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#16 Black (-)


#16 Black/White



3 TerminalConnector

CavityPlug

#16 White



Motor Control Switch - RH Wing Only



(10 Amp Fuse)

Push-Pull Switch


#16 Black(-)





# 12 Brn

# 16 Red# 16 Yellow

ON / OffSwitch Plug

SolenoidConnector

#16 Black

# 16 Yellow

#16 Black

Figure 57



Wing Wire Harness - RH Wing (Single Wing)

1212121212121212121212

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Black / White (-)(Inner Connector -

Connects to Black Wire)

Yellow (+)(Outer Connector - Con-

nects to White Wire)

Cap Connectorused on RHOnly Wing

Connectorto Main Harness

Wires connectto wing magnetswitch

Connector toWing MotorSolenoid

ConnectorGasket

ConnectorFasteningScrew

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Black / White (-)

BlackYellow (+)

White


Connectorto MainHarness

Schematic P/N 002496

Wire Harness P/N 002496

To LH Wingor Plugged

Note: RH Wing Only (SingleWing) will use P/N 002496 WireHarness only

Figure 58



Wing Wire Harness - LH Wing (Dual Wing)

White (+)(Outer Connector - Con-


Black / White (-)(Inner Connector - Con-

nects to Black Wire)





123123123123123123123123123123

Black / White (-)

Black

White (+)

White





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ConnectorGasket1234567890123456

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Note: Dual Wing will useboth P/N 002496 & P/N002497 Wire Harness


Figure 59



NOTES



INTERSTATER

John DeereJD-5425

&JD-5525

Rear Mower Installation

Section 6



Rear Three Point MowerConnection:

1. Install Rear Lift Chains Option. The rear liftchains will replace the three point lift links using thesame pins you removed from the lift links. Thesechains allow the mower to float with the contour of theground. These are optional equipment and may ormay niot have been ordered. (See Figure 1, 2 & 3).Note: Shown below is a New Halland Tractor in figure1, 2 & 3. The John Deere check chains will mounr thesame.

Rear Three Point Mower

Figure 1

Figure 2 Figure 3

Figure 4 Figure 5



2. The Rear Mower is a standard Three PointHitch mounted mower that is PTO driven through adriveline. It will be sent already assembled with thedriveline tied to it. (See Figure 1)

3. Connect Lower Hitch Pins. The lower hitchpins connect to the lift arms of the tractor with clickpins, these pins are furnished with the mower. (SeeFigure 5 & 7). It is best to connect the lower arms ofthe three point first. You can use the lower arms to

4. Connect Upper Hitch Pin. The upper hitch pinwill connect to the top three point adjustable Link witha pin and click pin. The Top Link is furnished with thetractor not with the mower. The Top Link is adjustablein length and is used to level the mower. (See Figure8)

5. Connect Driveline . The Driveline arrive tied tothe mower (See Figure 6 & 9). Cut the ties loose frommower. Connect the clutch end of the driveline to themower, the clutch is retained to the gearbox inputshaft by a clamp yoke on clutch hub. Slip the clutchonto the input shaft until holes in clamp yoke arealigned with the grooves in the input shaft. Install andtighten the two bolts and nuts. The QD Yoke endconnect to the Tractor PTO.


Figure 6

Figure 8

Figure 7

Figure 9



6. Leveling the Rear Mower & Adjust guttingCutting Height. The Rear Mower is leveled with thetop Three Point Link. The Cutting Height is adjustedby moving the Roller up or down by change thebearing bracket mounting hole. The is a decal on thedeck next the Operators/ parts manual cannister(See Figure 10 & 11)

7. Rear Mower Completely Connected. With therear mower completely connected. Check all Oillevels and grease mower components (See Figure14) before running mower. Also DO NOT start trac-tor if the rest of the assembly to the interstater is notdone. Make certain that all hoses, components, wir-ing is completed and Oil Tank for interstater hasbeen filled with oil.

8. Slip clutch is incorporated in the PTO driv-eline. It is designed to slip, absorb the shock load,and protect the driveline. It is important that theclutch lining plates slip when an obstacle or loadheavier than clutch setting is encountered. There-fore, if the machine sits outside longer than 30 daysand is exposed to rain and/or humid air it is impor-tant to make sure that the clutch lining plates are notrusted/corroded together. Before using the moweruse the following procedure to make sure the clutchwill slip and give the overload protection required.(See Figure 13) This is a required step because thedriveline has been sitting and may be stuck.

A. Loosen nuts on springs until the springs canfreely rotate, yet remain secure on bolts.

B. Attach mower to tractor and start the tractor.Set the engine speed at 1200 RPM.

C. Mark outer plates with marker, paint or anyform that will work for you to tell if the components of the clutch slipped.

D. Engage the PTO (approximately one sec-ond) and then quickly disengage it. Thefriction lining plates should break loose(check the mark).

E. Turn tractor off and tighten the nuts on thesprings to their original position of 1-5/16"compressed spring length.


Figure 11

Figure 12

Figure 10



FRICTIONLININGPLATE

SPRING BOLTWITH NUT

1-5/16" Standard1-3/16" Min.


Figure 13

9. Slip clutch is incorporated inthe PTO driveline. It is designed toslip, absorb the shock load, and pro-tect the driveline. After the first hourof operation, the slip clutch should bechecked for overheating. After thisfirst check, the slip clutch should bechecked weekly or anytime there isoverheating. To adjust the slipclutch, tighten the spring bolts 1/8(maximum) turn at a time. Boltsshould NEVER be adjusted to thepoint where the springs are com-pressed solid. The slip clutch shouldbe checked periodically and adjustedto compensate for wear. The liningplates are 1/8" thick when new. Re-place after 1/32" wear. If the mowerhas been idle for an extended periodof time, or in wet weather, beforeoperating check to be sure the fric-tion lining plates are not frozen orrusted together. Should this freezingoccur refer to the procedure de-scribed in the "Seasonal ClutchMaintenance" section on the nextpage. There are four friction liningplates in the slip clutch. Theseshould be checked weekly for oil orgrease, wear, and moisture whichcould cause corrosion on the driveplates. (See Step 8) NOTE: Aboveinformation is listed as a refer-ence and is listed in the opera-tors manual as well.

10. Check All Shields. Makecertain any shields that were re-moved during assembly the theyare reinstalled. DO NOT operatemower or tractor with anyshields or guards missing.

Figure 14



Lubrication Points

LUBRICATE ALL POINTS BEFORE OPERATING MOWER FIRST TIME

A Lift Frame Pivot PinB Wing Mower Belt Idler ArmC Cuttershaft BearingsD TIlt Cylinder Rod EndsE Lift Cylinder Rod EndsF Roller Bearings

G Rear Mower Idler ArmH Banjo BearingsJ Banjo CouplingK Driveline YokeL Driveline slip

Figure 15



Initial Start-Up Procedure

INITIAL START-UP PROCEDURE:1. Check all nuts and hex head bolts to ensure all are tight and all lock washers are fullycompressed (flattened).2. Check all hoses and hydraulic connections. Make certain they are secure.3. Inspect all moving parts and make certain that no wires or hoses will be caught or pinched when

the tractor or the INTERSTATER is in operation. Tie down loose wires and hoses.4. Thoroughly grease the INTERSTATER and install a lubricap on each grease fitting. Refer to

the Operation and Maintenance Section.5. Jack front of tractor up enough to allow axle to pivot through its full range. While turning

wheels through their limits, right and left, swing them up and down. Look for interferencebetween tires and any part of the INTERSTATER. If interference occurs, shims (notfurnished) must be welded to axle pivot stop or steering arm to limit the movement enough toavoid interference. Tractors with an adjustable front axle may require an outward adjustmentof the wheels.

6. To fill the INTERSTATER reservoir with new, clean hydraulic oil, follow the steps below.Refer to the Operation and Maintenance Section for specifications. (See Figure 16)A. With a hydraulic jack raise the right side of the tractor. This will tilt the tank and allow

only a minimum amount of air when filling.B. Avoid hydraulic contamination by filtering the hydraulic oil while filling the hydraulic

tank.C. Filter buggies or carts are commercially available for hydraulic system cleanup.

These consist of a high-efficiency, high-capacity filter, a circulating pump, a drivemotor, and hoses for connecting the overhauled machine’s hydraulic system.

D. After the first 10 hours of operation, replace the hydraulic filter with a new one. Anextra Filter Element is provided for you. Refer to the Operation and MaintenanceSection for instruction.

7. After the Interstater mower iscompletely assembled to thetractor and with the wings onthe ground, fill the mower hydraulic tank above the oil levelsight gauge approximately 5" or1" below the top of the tank.

8. With mower ON/OFF switchesin “ON” position and tractor fuelcut off, crank engine for about30 to 45 seconds to allow oil tofill pumps and motors. Checkthe oil level in the sight gauge.If no oil is seen add oil to bringthe level up to the sight gauge.NOTE: Do not fill the tank withoil above the level of the sightgauge. Over filling the tank withoil after the initial filling may result in oil being discharged

Figure 16

through the air filter on top of the hydraulic tank. Start the tractor and run it for 2 minutes andthen turn it off. Again check the oil level in the sight gauge. If the oil level is in the sight gauge,the unit is ready to run. If no oil is seen, add oil to bring the level up to the sight gauge.



CAUTION ROTATING KNIVES! Remove all foreign objects and stand clear ofcutter units. DO NOT GET NEAR!

NOTE: On tractor hydraulic powered circuit only, make certain that there is full flow from tractorhydraulic system to control valve. Refer to tractor manual.

9. After hydraulic system is fully charged and functioning properly, switch cutter units on, thenspeed engine up to 540 RPM PTO speed. Maintain this speed for about 5 minutes. Checkcomplete INTERSTATER, look for any leaks, loose connections, or anything that could causepremature wear or failure.FINAL CHECKRun INTERSTATER for about 1/2 hour at full speed. Check for leaks and vibrations. Frequentlycheck oil temperature. Make certain it does not exceed 180 deg.NOTE: When raising wings, make certain there is no interference with mower, frame, cylinders ortractor. Lift wings slowly.CAUTION: DO NOT leave unit unattended, and COMPLY WITH ALL WARNING DECALS.

If unit starts to make unusual noise, stop unit and check oil level. Also check for frothy oil whichwould indicate a leak on suction side of system.

Initial Start-Up Procedure



INTERSTATER

John DeereJD-5425

&JD-5525

Mounting Specifications&

Component Identification

Section 7



Mount Kit - Bill of Material - (ROPS)

John Deere 5425/5525ROPS / 2wd w/Straddle Mount Platform

Front Tire Size: 7.50-16 (F-2) Max Front Tire As of: 07-26-05Rear Tire Size: 16.9-30 (R-1) Max Rear Tire

Mount Kit:

Mainframe: Dual Wing (5" Offset Left & Right) ……......……...02983067

Component Crate:

Comp Crate: Dual Wing w/Aux Pump …………………..……. 02982994

Options:

Lift Chain Kit (See Spec Below) ………………………...………701150Extra Interstater Installation Manual ……………………..……..02982933Aluminum Canopy (Straddle Platform Only) ………………….. 02983053

Important notes Specifications:

1. This mount kit has been designed to fit tractors equipped with a “straddle mount operator station”.The dealer/customer is responsible for any required modifications for mounting tractors equippedwith an “isolated open operator station (IOOS)” (ie: flat platform) instead.

2. This kit is designed for tractors equipped with a vertical exhaust. Other exhaust styles may requiremodification at the dealer/customer’s expense.

3. Full Interstaters must be ordered with a 96" centered rear head. Right hand only models can beordered with a 96" centered or 88" offset right 8.5" rear head. Two lift chains arerecommendedfor centered heads, while offset heads should only be ordered with one.

4. The mainframe should allow approximately 13 3/4" of ground clearance with the maximum tire sizelisted above.

5. As with most Interstaters, the left wing must be lowered for ingress/egress to the tractor platform.6. For dual wing models, the left hand tractor steps must be modified for proper lift frame clearance.

For dual and single wing models, the right hand steps must be removed for clearance as well.Ingress/egress on the right is otherwise blocked by the control stand.

7. The pump mount in this kit is assembled with a carrier bearing to extend the life of the driveline andpulley weldment.

8. Additional counterweight may be desired for those tractors assembled with a single wingInterstater. Furthermore, tractors equipped with 24" rear wheels may require a wheel weightadapter to accommodate our standard 500# weight.

9. If the tractor is equipped with a mid-mount valve, it may also need to be removed for head/lift frameclearance. (This Valve would be mounted behind RH Step under Rips Platform).



IMPORTANT NOTICE: The following Part / Assembly Numbers are for reference and shouldnot be ordered as replacement parts, unless all the components in that assembly are wanted. Thesewill break down to bills of material of the components. Some of numbers listed are NOT individualParts but complete assemblies and/or box of assemblies. Check before ordering.

TRACTOR: ROPS, 2 WD, Use Aux Pump for Cylinders

Frame Asy P/N 02983067 (Dual Wing ): Includes Items Below( For John Deere 5425/5525 ROPS/2wd w/Straddle Mount Platform)Item Part No. Qty Description1 02983067 1 FRAME ASY.Above items are included in Frame Assembly P/N 02983067

Component Crate P/N 02982994 (Dual Wing ): Includes Items Below( For John Deere 5425/5525 ROPS/2wd w/Straddle Mount Platform)Item Part No. Qty Description1 108436 1 LIFT FRAME WELDMENT, RH2 108435 1 LIFT FRAME WELDMENT, LH3 02980152 1 CYLINDER SUPPORT WELDMENT, RH4 02980151 1 CYLINDER SUPPORT WELDMENT, LH5 106596 1 WLDMT,VALVE MTG BRKT6 106597 1 COVER,TOP7 106598 1 COVER BOTTOM8 002364 2 HOSE, # 16 - 16FJX - 16FJX45 - 65.5" LG9 002365 2 HOSE, # 16 - 16FJX - 16FJX90 - 62.5" LG10 002498 1 WIRE HARNESS, INT DUAL POWER11 703690 1 TANDEM PUMP ASY.12 702744 1 VALVE ASY, 4-SPOOL COMPLETE13 001772 1 HOSE, # 4 - 4FJX - 4FJX - 79" LG14 001773 1 HOSE, # 4 - 4FJX - 4FJX - 89" LG15 001774 1 HOSE, # 4 - 4FJX - 4FJX - 86" LG16 02963574 2 HOSE, # 4 - 4FJX - 4FJX - 64" LG17 02963052 1 HOSE, # 4 - 4FJX - 4FJX - 53" LG18 02980282 1 HOSE, # 6 - 6MP - 4MP - 94" LG19 02980283 1 HOSE, # 6 - 4MP - 8MP - 73" LG20 02980820 1 V ALVE MOUNT WELDMENT21 02982928 1 TANK RAIL, L.H. INTERSTATER22 02982929 1 TANK RAIL, R.H. INTERSTATER23 02974132 1 HOSE, # 20 - 20FJX - 20FJX90 - 50" LG24 02982995 1 CARTON SMALL PARTS, DUAL WING25 02982997 1 PUMP MOUNT ASY. W/ 1" CARRIER BEARING26 02983042 1 FRONT MOUNT LH INTERSTATER27 02983043 1 FRONT MOUNT RH INTERSTATER28 02983071 1 DRIVELINE, 1" X 1" X 27.875"29 02983072 1 HOSE, # 16 -16FJX -16FJX90 - 67" LG30 02983073 1 HOSE, # 16 -16FJX -16FJX - 51" LGAbove items are included in Component Crate P/N 02982994




Carton Small Parts P/N 02982995 (Dual Wing ): Includes Items Below( For John Deere 5425/5525 ROPS/2wd w/Straddle Mount Platform)

Item Part No. Qty Description1 001184 1 ADAPTER, PIPE COUPLER 12FP - 12FP2 001767 1 DRIVE BELT6 001796 2 HOSE BIB, # 12 HOSE - # 12 MP7 00751505 2 HOSE CLAMP8 00763977 1 DECAL, NOTICE TO OWNER10 02958920 1 ADAPTER, HYD ELBOW 20MP - 20MJIC9011 02961115 2 ADAPTER, PIPE 20FP - 20FP9012 02964028 2 SWITCH, PUSH - PULL SPDT 10A@12V17 107261 3 CORDURA SLEEVING - 40" LG18 702785 1 PULLEY ASY19 703902 1 LIFT PUMP ASY20 803213A 1 OPS MANUAL ASY, INTERSTATER24 02979022 1 BELT COVER WELDMENT25 02956851 1 ADAPTER, HYD ELBOW 16MJ -16FJX9027 02978281 1 HOSE RING WELDMENT28 001412 1 DECAL, CONTROL VALVE29 02962748 2 DECAL, ON-OFF SWITCH CUTTER VALVE30 03200285 3 DECAL, WATCH YOUR STEP31 03200328 1 DECAL, VALVE IN DETENT POSITION32 00758194 1 DECAL, WARNING BELT SHIELD33 001976 1 HOSE, SUCTION #12 - 9" LG34 02973992 1 PULLEY ADAPTER, MACHINED35 02981489 1 PULLEY ADAPTER MACHINED36 02982996 1 BOLT BAG, DUAL INTERSTATER37 02982933 1 ASSEMBLY MANUAL, JD-5524 & 5525 INTERSTATER38 00900913 5.5ft CORDURA SLEEVING 2.54 ID BLACK

Above items are included in Carton, Small Parts P/N 02982995 which is included inComponent Crate P/N 02982994

Bolt Bag P/N 02982996 (Dual Wing ): Includes Items Below( For John Deere 5425/5525 ROPS/2wd w/Straddle Mount Platform)Item Part No. Qty Description1 00001800 5 LOCKNUT, TOPLOCK 1/2"-NC PLB2 00010300 12 LOCKWASHER, 5/8"3 00011100 8 FLATWASHER STD. 3/8"4 00011400 12 BOLT, HEX HEAD 3/8"NC X 1"5 00015800 12 LOCKNUT, TOLOCK 3/8"6 00022200 4 LOCKWASHER, 7/16" PL7 00037200 4 LOCKNUT, TOPLOCK 3/4"-NC8 02892000 3 BOLT, HEX HEAD1/2"-13NC X 1-1/2" PL GR89 02918600 4 BOLT, HEX HEAD 3/4"-10NC X 2" PL GR8


Continued Next Page



Bolt Bag P/N 02982996 (Dual Wing ): Includes Items Below( For John Deere 5425/5525 ROPS/2wd w/Straddle Mount Platform)Item Part No. Qty Description10 02957276 7 BOLT, HEX HEAD M16-P2.0 X 45MM PL GR10.911 00752716 2 BOLT, HEX HEAD 1/2"-NC X 3-1/2" PL GR812 02976344 4 BOLT, HEX HEAD 7/16"-NC X 1-1/4" PL GR813 02976831 5 BOLT, HEX HEAD M16-P2.0 X 50MM PL GR10.914 00756077 1 WASHER, HARDENED 5/8"15 02975692 8 BOLT, HEX HEAD M20-P2.5 X 50MM PL GR10.916 02971158 8 LOCKWASHER, 20MM17 00759635 1 FLATWASHER, HARDENED1/2" NON-PLTDAbove items are included in Bolt Bag P/N 02982996 which is included in Carton, SmallParts P/N 02982995 which is included in Component Crate P/N 02982994




IMPORTANT NOTICE: The Common Crate is the same for all tractor unless there is a specialorder, Single wings and dual wings will use a different common crate of components. The followingPart / Assembly Numbers are for reference and should not be ordered as replacement parts, unless allthe components in that assembly are wanted. These will break down to bills of material of thecomponents. Some of numbers listed are NOT individual Parts but complete assemblies and/or box ofassemblies. Check before ordering.

Common Crate P/N 703515M (Dual Wing ): Includes Items Below( For John Deere 5425/5525 ROPS/2wd w/Straddle Mount Platform)Item Part No. Qty Description1 00017000 4 LOCKWASHER,1/4" PL STD2 00024100 4 FLATWASHER, STD 1/4" PL3 001783 2 HOSE #20 - 20FJX90 - BLANK -13" LG4 002496 1 WIRE HARNESS, RH WING5 002497 1 WIRE HARNESS,INT,L.H. WING6 00756059 1 DECAL, WARNING OIL LEAK7 02963561 1 ASSY,HYD PLBG,R&L,I/S8 02965093 1 DECAL, PROPER ENGINE OPERATING9 02971123 1 DECAL, WARNING PRESSURIZED TANK10 02971943 1 DECAL, ALAMO IND YELLOW11 02977417 1 DECAL OPERATORS MANUAL INSIDE12 10058000 4 BOLT, HEX HEAD 1/4"-NC X 1" PL GR513 103051 4 SHOE / WEAR PLATE14 106572 1 BUMPER WELDMENT15 107222 2 SWITCH MOUNTING WELDMENT16 00776031 1 CANISTER, PARTS MANUAL17 107224 1 CUT-OFF SWITCH MOUNT RH18 107225 1 MOUNT- CUT-OFF SWITCH LH19 701104A 2 LIFT CYL, W/0 FITTINGS20 701105A 2 TILT CYL, W/0 FITTINGS21 702706 4 OUTER PIVOT ASY, W/ZERK & CAP22 703516M 1 CARTON,SMALL PARTS, RH &LH (COMMON CRATE)23 02966305 1 DECAL, UNIVERSAL TRACTOR24 803213CA 1 CANISTER MANUAL, INTERSTATER25 02981133 1 TANK SUB-ASY, COMMON26 02981124 1 TANK COVER WELDMENT, INTERSTATERAbove items are included in Common Crate P/N 703515M

Carton Small Parts P/N 703516M (Dual Wing ): Includes Items Below( For John Deere 5425/5525 ROPS/2wd w/Straddle Mount Platform)Item Part No. Qty Description1 000859 30 TIE, PLASTIC2 001788 2 HOSE, #6 - 6FJX - 4MP - 13" LG3 002019 2 MAGNET, SWITCH ACTUATOR4 002020 4 SPACER, PLASTIC5 002369 1 DECAL, DANGER-MULTI HAZARD6 00751596 1 ADAPTER, PIPE, ELBOW

Common Crate - Bill of Material - Dual Wings

Continued Nex Page



Continued From Previous PageItem Part No. Qty Description7 00753840 2 DECAL, SAFETY WING LOWERING8 02956851 2 ADAPTER, HYD ELBOW 16MJ -16FJX909 02961001 1 FILTER ELEMENT10 02962963 1 DIAL INDICATOR, IN TANK FILTER11 03200300 2 HOSE BIB, 20MP - #20 HOSE12 700883 4 INNER PIVOT PIN W/ZERK13 702800 1 MANIFOLD ASY, RETURN RH1st / RHO14 703517M 1 BOLT BAG ASY,COMMON DUAL WNGS15 703520 2 SAFETY SWITCH ASY.Carton Small Parts P/N 703516M is included in Common Crate P/N 703515M

Bolt Bag Asy P/N 703517M (Dual Wing ): Includes Items Below( For John Deere 5425/5525 ROPS/2wd w/Straddle Mount Platform)Item Part No. Qty Description1 00001300 2 LOCKWASHER, 1/2"2 00001800 24 LOCKNUT, TOPLOCK 1/2"-NC PLB3 00002700 10 FLATWASHER,1/2" PL STD4 00011700 9 LOCKWASHER, 5/16" PL STD5 00013300 8 BOLT, HEX HEAD1/2"-NC X 2" PL GR56 00023500 5 FLATWASHER, 5/16" PL7 00037200 12 LOCKNUT, 3/4"-NC8 00695100 16 LOCKNUT, TOPLOCK 5/8"-NC9 00748823 2 BOLT, HEX HEAD 5/8"-13NC X 1-1/2" PL GR59 00750311 4 BOLT, HEX HEAD, 5/8"-NC X 3-1/2" ZP GR510 00750952 12 BOLT, HEX HEAD, 5/8"-NC X 2-1/2" ZP GR512 00755153 4 COTTER PIN, 3/16" X 1-1/2" PLATED13 02026200 2 HOSE CLAMP, 1-5/16" TO 2-1/ 4"14 02035400 4 BOLT, HEX HEAD 3/8"-NF X 3/4" PL GR515 02886900 4 CARRIAGE BOLT, 1/2"-13UNC X 1-1/2" PL GR516 02892000 2 BOLT, HEX HEAD1/2"-13NC X 1-1/2" PL GR817 02959390 12 BOLT, HEX HEAD 3/4"-NC X 2-1/4" PL GR817 02960018 6 ADAPTER, HYD ELBOW 4MB - 4MJ9018 02960054 2 PLUG, #4 MB W/T-VENT & O-RING19 02963584 8 LOCKNUT, 8-32 PL20 02963585 8 SCREW, SLOTTED #8-32 X 1-1/4" RD HD21 03101646 4 LOCKWASHER, 3/8"22 103266 2 CYLINDER PIN23 107242 4 SPACER24 2A381312 8 BOLT, PLOW 1/2"-NC X 1-1/2" GR525 37107B13 4 HAIR PIN26 8354 4 PIN, HYD. CYLINDER28 000032 9 BOLT, HEX HEAD 5/16"-NF X 7/8" PL GR5Bolt Bag Asy P/N 703517M is in Carton Small Parts P/N 703516M & is in Common Crate P/N703515M

Common Crate - Bill of Material - Dual Wings



P/N 108436Lift Frame WeldmentRH & RH Wing Only

(Cab or ROPS Tractor)

P/N 108435Lift Frame Weldment

LH Wing (Cab or ROPS Tractor)

P/N 02980151Cyl. Support Weldment LH


P/N 02980152Cyl. Support Weldment RH


P/N 02983067Main Frame Weldment

Dual Wing (Cab or ROPS Tractor)

Front

Rear

LH Side

RH Side


P/N 02983042Front Main Frame Mount LH


P/N 02983043Front Main Frame Mount RH




P/N 02982928Tank Rail LH

CAB or ROPS Tractor

P/N 02982929Tank Rail RH

CAB or ROPS Tractor

P/N 02982997Pump Mount Weldment

w/ Bearing(Cab or ROPS Tractor)


P/N 106596Valve Mounting bracket

ROPS Tractor(Use w/Aux. Hyd System)

P/N 106597Valve Top Cover


P/N 106598Valve Bottom Cover


P/N 02980820Valve Mount Weldment




P/N 02983071Drive Shaft

(Cab or Rops Tractor)

1" x 15Spline End

1" X 15 SplineEnd

P/N 02979022Belt Guard Weldment

(ROPS Tractor)(Use w/Aux. Hyd System)

P/N 108749Spacer, Cyl Collar

(1-3/16" ID X 1-7/8" OD X 1-1/2" LG)(Cab or ROPS Tractor)


P/N 702785Pulley Weldment

w/ Roll Pin(Cab or ROPS Tractor)

1" X 15 Spline ID

P/N 02973992Crankshaft Adapter

P/N 02981489Splined Pulley Adapter

1" X 15 Spline ID



P/N 02981133Tank Sub-Assembly


P/N 02981124Tank Cover Weldment(Cab or ROPS Tractor)


Side View Top View

P/N 107224Cut-Off Switch Mount, RH


Green Area "Good"(0 psi to 15 psi)

Red Area "Replace Filter"(16 psi to 60 psi)

Vent (Cut Off Top)

1/4" NPT

P/N 02962963Return Pressure Gauge

(Glycerin Filled)(Cab or ROPS Tractor)




P/N 002019Magnetic Switch Activator


P/N 002020Spacer, Plastic


P/N 703520Switch, Safety Cut-Off(Cab or ROPS Tractor)

Black Wire(Inner Connector -Connects to Black/

White Wire)

White Wire(Outer Connector -

Connects to Yellow Wire)

P/N 107222Cut-Off Switch

Mounting Weldment(Cab or ROPS Tractor)

P/N 106572Bumper Weldment


P/N 02978281Hose RingWeldment



Component ID - Wire Harness - RH Wing Only



(10 Amp Fuse)


#16 Black(-)




Wing HarnessConnector

# 12 Brn

# 16 Red# 16 Yellow

ON / OffSwitch Plug

Wing HarnessConnector

#16 Black

# 16 Yellow

#16 Black

Motor Control Switch




Component ID - Main Wire Harness - Dual Wing




Bag

# 12 Brn


Switch Plug

SolenoidConnector

#16 Black/White



(10 Amp Fuse)

#16 Black/White


# 16 Yellow

12345671234567123456712345671234567123456712345671234567123456712345671234567


#16 Black (-)


#16 Black/White



3 TerminalConnector

CavityPlug

#16 White

Motor Control Switch



Component ID - RH Wing Wire Harness

1212121212121212121212

123456789012345678901234567890

123456789012345612345678901234561234567890123456

Black / White (-)(Inner Connector -

Connects to Black Wire)

Yellow (+)(Outer Connector - Con-


Cap Connectorused on RHOnly Wing




ConnectorGasket


1234567890123123456789012312345678901231234567890123123456789012312345678901231234567890123123456789012312345678901231234567890123

123123123123123123123123123123123

Black / White (-)

BlackYellow (+)

White





To LH Wingor Plugged



Component ID - LH Wing Wire Harness

White (+)(Outer Connector - Con-


Black / White (-)(Inner Connector - Con-

nects to Black Wire)





12121212121212121212

Black / White (-)

Black

White (+)

White





123456789011234567890112345678901

ConnectorGasket1234567890123456

12345678901234561234567890123456

12345678901234123456789012341234567890123412345678901234123456789012341234567890123412345678901234123456789012341234567890123412345678901234



NOTES



INTERSTATER

John DeereJD-5425

&JD-5525

PRE-DELIVERY INSPECTIONCHECKLIST

Section 8



INTERSTATER PRE-DELIVERY INSPECTION CHECKLIST

Pre-Operation Inspection: Check the following items before operating the unit toassure that they are properly assembled. (See following page 1-4 for component location)

Saftey Equipment:

___ Operators Manual is with Unit.___ The Safety Decals are installed as listed in the Assembly Manual.___ 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.___ All Foot Guards and safety switch are installed and functional.

Frame:

___ Axle Plate Bolts are torqued.___ Head Mounting Bolts tightened.___ Frame attaching Bolts tightened.___ Front Support Bolts are torqued.___ Hydraulic Tank mounting Pins / Bolts in place correctly.___ All Welds inspected toinsure proper welds and locations.

Hydraulic System:

___ Oil Level in Hydraulic Tank is within the sight gauge. (Item 5 page 1-4)___ 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.

Flail Mower Head:

___ Skid Shoe Bolts are torqued to 120 ft-lbs___ Motor Bolts are torqued to 120 ft-lbs___ Belt Alignment& tension adjustment is correct.___ Cutter shaft bearings are properly lubricated___ Roller bearings are properly lubricated___ Blades swing freely.___ All Pins and Clips for Rear Mower are installed___ Clutch on Rear Mower has been checked for proper adjustment and conditions per

parts book reguirments.___ All Belt guards are installed correctly.



INTERSTATER PRE-DELIVERY INSPECTION CHECKLIST

Pre-Operation Inspection: Check the following items before operating the unit to assurethat they are properly assembled. (See following page 1-4 for component location)

Tractor Mower Operation Inspection:Using all Safety precautions, operate the Tractor and Mower unit for 30 minutes andwhile the unit is running check the following items: Note! Only make adjustments after the mower has been turned off and all motion has stopped and all hydraulic pressurehas 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.



Tractor - Mower Component LocationFor Check List

Right WingFlail

Left WingFlail

Rear CenterFlail

Pumps, Hyd.Tank & Cover

RH SIDE OFTRACTOR

LH SIDE OFTRACTOR

© 2005 Alamo Group Inc.

Insterstater Assembly ManualJohn Deere JD-5425 & JD-5525

2005 EditionP/N 02982933

Interstater (John Deere JD-5425 & JD-5525 Asy. Man.) 07/05

01, Front Cover - Alamo Industrial · TO THE OWNER/OPERATOR/DEALER All implements with moving parts...

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Transcript of 01, Front Cover - Alamo Industrial · TO THE OWNER/OPERATOR/DEALER All implements with moving parts...