New Holland TS-100A, TS-115A, TS-135A, TS-125A, ts110 Assembly Manual

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BOOM ARM MOWER

Assembly Instruction Manual

New Holland - Cab 2 WD / 4 WD

TS-100A, TS-115A, TS-125A, TS-135A

Published 01-05 Part No. 02982279

ASSEMBLY MANUAL

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

ALAMO INDUSTRIAL

1502 E. Walnut Seguin, Texas 78155 210-379-1480

TO THE OWNER/OPERATOR/DEALER

All implements with moving parts are potentially hazardous. There is no substitute for a cautious, safe-minded operator who recognizes the potential hazards and follows reasonable safety practices. The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents.

BEFORE YOU START!! Read the safety messages on the implement and shown in your manual.

Observe the rules of safety and common sense!

WARRANTY INFORMATION:

Read and understand the complete Warranty Statement found in this Manual. Fill out the Warranty Registration Form in full and return it within 30 Days. Make certain the Serial Number of the Machine is recorded on the Warranty Card and on the Warranty Form that you retain. The use of "will-fit" parts will void your warranty and can cause catastrophic failure with possible injury or death.

NOTES

INTRODUCTION

ABOUT THIS MANUAL:

The intent of this publication to provide the competent technician with the information necessary to perform the CORRECT Assembly to the Alamo Industrial Product. This will, in turn provide for complete customer satisfaction

It is hoped that the information contained in this and other Manuals will provide enough detail to eliminate the need for contact of the Alamo Industrial Technical Service Dept. However, it should be understood that many instances may arrive where correspondence with the Manufacturer is necessary.

CONTACTING MANUFACTURER: (Please help us Help You! Before You Call! )

Alamo Industrial Service Staff Members are dedicated to helping you solve your problem, or your customer’s service problem as quickly and efficiently as possible. Unfortunately, we receive entirely to many calls with only a minimum amount of information. In some cases, the correspondent has never gone out to look at the equipment and merely calls inquiring of the problems described to him by the operator or customer.

Most calls received by Alamo Industrial Service can be classified into approx. 6 general categories.

1. Hydraulic or Mechanical Trouble Shooting.

2. Request for Technical Information or Specifications.

3. Mounting or Fitting Problem.

4. Special Service Problem.

5. Equipment Application Problems.

6. Tractor Problem Inquiries.

HOW YOU CAN HELP:

Make sure the call is necessary! Most of the calls received may not be necessary if the Dealer Service Technician would do the following.

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

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

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

CONTACT ALAMO INDUSTRIAL:

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

Maverick (NH TS-100A,115A, 125A, 135A, Asy. Man) 01/05

Index -1

INDEX - ASSEMBLY INSTRUCTION

Introduction

Manual Introduction............................................................................Index-1

Section 1 - Model Specifications

DO NOT DO LIST (IMPORTANT).....................................................1-2

Maverick Boom Specifications...........................................................1-3 to 1-6

Hose Fitting Torque Chart..................................................................1-6

Bolt Torque Chart...............................................................................1-7

Section 2 - Tractor Preparation

General Information........................................................................... 2-2 to 2-8

Section 3 - Pump & Driveshaft Installation

Remove Engine Guards for Access to engine compartment........... 3-2

Pulley Adapter Installation..................................................................3-2

Install Shaft Half of Driveshaft............................................................3-3

Install Tank Mount Rails.................................................................... 3-4

Install Pump....................................................................................... 3-4 to 3-7

Reinstall Engine Guards & Covers................................................... 3-8

Page

Section 4 - Hydraulic Tank & Control Valve Installation

Install Hydraulic Tank to Tank Mount Rails........................................4-2

Tank Hose Routing............................................................................ 4-2 to 4-3

Control Valve Fitting Identification......................................................4-4 to 4-5

Head Tilt Lock Valve.......................................................................... 4-5

Valve Hose Marking Codes............................................................... 4-6

Diverter Valve.................................................................................... 4-6 to 4-8

Oil Cooler & Cooling Fan Assembly.................................................... 4-9

Section 5 - Battery, Exhaust, Fuel Tank Modification & Main Frame Installation

Battery Relocation / Modification....................................................... 5-2

Exhaust relocation / Modification....................................................... 5-3

Fuel Tank Installation / Modification................................................... 5-4 to 5-5

Under Mount Component Information................................................5-6 to 5-7

Frame Installation.............................................................................. 5-8 to 5-11

Boom Rest Installation.......................................................................5-11

Frame Counter Weight Installation....................................................5-12

Boom Turret Assembly Installation................................................... 5-13 to 5-14

Front Axle Stabilizer Kit..................................................................... 5-15

Maverick (NH TS-100A,115A, 125A, 135A, Asy. Man) 01/05

Index -2

INDEX - ASSEMBLY INSTRUCTION

Section 6 - Lexan Door Installation

Lexan Door Installation...................................................................... 6-2 to 6-4

Section 7 - LH Wheel Weights

Standard Wheel Weight.................................................................... 7-2 to 7-3

Auxiliary Wheel Weight......................................................................7-4

Section 8 - Joystick / Wire Harness / Valve Installation

Wire Harness tractor Preparation......................................................8-2

Replace Tractor Seat Arm Rest........................................................8-3

"E"-Stop Switch Installation............................................................... 8-4

Joystick Installation............................................................................ 8-4 to 8-6

XS Module Installation........................................................................8-6 to 8-8

Interior Wire Harness Installation.......................................................8-7 to 8-10

Exterior Wire Harness Installation..................................................... 8-11 to 8-13

Diverter Valve Harness Connections................................................... 8-14 to 8-16

Cab Decals........................................................................................8-17

Page

Section 9 - Boom / Head Installation

Boom Mounting.................................................................................. 9-2 to 9-5

Boom Lift Cylinder Pin Installation..................................................... 9-2 to 9-3

Boom Cylinder Schematic.................................................................9-6

Valve Hose Schematic.......................................................................9-6

Hose Routing and Connecting...........................................................9-2 to 9-12

Hydraulic Hose Color Identification Codes...................................... 9-8 to 9-12

Tank Hose to Boom Connections......................................................9-10 to 9-12

Tank Hose Schematic / Routing........................................................9-11 to 9-12

Section 10 - Fill Oil Tank / Setting Electronic Display Controls

Fill Unit with Oil...................................................................................10-2 to 10-3

Prime Pump.......................................................................................10-3

Setting Electric Display Control Box..................................................10-4 to 10-11

Joystick Operation............................................................................. 10-12

front Pump & Tank Cover Installation............................................... 10-13

Section 11 - Mounting Specification / Component Identification

Mount Kit Components...................................................................... 11-2 to 11-37

Component Parts Identification / Descriptions..................................11-2 to 11-37

Section 12 - Pre-Delivery Inspection Check List

Check List.......................................................................................... 12-2 to 12-3

Maverick (NH TS-100A,115A, 125A, 135A, Asy. Man) 01/05

Index -3

NOTES

Maverick (NH TS-100A,115A, 125A, 135A, Asy. Man) 01/05

Index -4

Section 1

Model

Specifications

Maverick Boom

24' & 30'

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 1 - 1

SPECIFICATIONS - MAVERICK

READ THIS BEFORE BEGINNING ASSEMBL Y, REPAIRS OR TESTING:

The Maverick has computerized electronics. The electronic

components can be damaged if care is not taken when performing repairs, testing and/or during assembly.

DO NOT

1. DO NOT short any wires across or allow them to be shorted out.

2. DO NOT attempt to jump across any wires or supply them with alternate power

source.

3. DO NOT install higher rated fuses than are recommended by manufacturer.

4. DO NOT do any welding on unit unless the computer modules are unplugged first, this

is to prevent a power surge going into modules (THIS IS VERY IMPORTANT). This could also apply to the tractor components. Check Tractors repair guide for specific instruction about tractor model and type.

5. DO NOT attempt to repair or adjust a component that is not intended to be repaired,

example sealed components as there are no serviceable components inside.

6. DO NOT let anyone attempt any testing or repairs unless they are an experienced

and qualified technician. Technicians must have proper tools, gauges, meters etc. to perform proper diagnosis and/or repairs.

7. DO NOT perform any repairs with dirty tools or in dirty area. When working on hydraulic

components keeping system clean and free of contamination is important.

8. DO NOT start or engage system if the oil level is not at the proper level or condition. Never

start or run unit low or out of oil.

9. DO NOT install / add any oil unless you know it is the correct type and the container is

clean. Make certain the oil is not contaminated with dirt or any liquid.

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 1 - 2

SPECIFICATIONS - MAVERICK

1. CUTTING CIRCUIT SPECIFICATIONS

Hyd. Pump Speed (Front Aux Pump)...................................1950 RPM

Hyd. Motor Speed..............................................................1220 RPM

Hyd. Motor Rated HP.........................................................199 HP

Hyd. Motor Rotation

Relief Valve Setting At Motor............................................. 4000 PSI

Relief Valve Setting At Pump............................................ 4500 PSI

Hyd. Pump Flow

Hyd. Oil Operating Temperature @ 100° F Ambient........ 155 - 165 ° F.

Hyd. Oil Filtration,

Hyd. Tank Capacity........................................................... 17-1/2 Gal.

Hyd. Motor Start Stop Time (Approximate)....................... 6 Seconds

Cutting Diameter, (Rotary Head).......................................58 Inch

Spindle...............................................................................4.5 “ by 9” Heat Treated Alloy

Blade Bar Type..................................................................Stacked 3 Leaf

Blade Bar Size...................................................................1-1/4” Thick X 5" Wide (Ea. Leaf)

Blade Bar Material............................................................. T1 Steel

Blade Swing.......................................................................360 Deg Swing

Blade Material....................................................................High Carbon Alloy Steel

Cutter Weight. (Approximate w/ Rotary Head)..................950 lbs.

Cutter Deck Opening & Closing........................................Hyd. Operated Door

Recommended Hydraulic Oil............................................ ISO AW Hyd. Oil (See decal below)

Fluid Cleanliness level.......................................................ISO 16/14/11

(as viewed f/ Top of the Deck)................CW (Clockwise)

(Front Pump @ 1950 RPM)........................25.3 GPM

(Discharge f/ Charge Pump)..................... 10 Micron

(bottom) & HRFB Steel (top & Middle)

ATTENTION

10°F

20°F

The correct hydraulic fluid is dependent upon ambient temperature. Refer to chart when selecting proper grade

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

30°F

AW ISO VG 32

40°F 60°F 70°F

AW ISO VG 46

AW ISO VG 68

Section 1 - 3

90°F

AW ISO VG 100

110°F

02982828

SPECIFICATIONS - MAVERICK

2. BOOM SPECIFICATIONS

Boom Reach 24 Foot Boom......................................................... Out 24'

Boom Reach 30 Foot Boom......................................................... Out 30'

Frame............................................................................................Manufactured Box Sections

Pins................................................................................................Chrome Plated Alloy

Bushings........................................................................................Greasable

Weight, 24' Boom..........................................................................1250 lbs.

Weight, 30' Boom..........................................................................1450 lbs

Boom Rest.................................................................................... Tractor Axle Mounted

Boom Mounting..............................................................................ROPS or CAB Tractor Optional

3. FILTRATION

Control Valve Functions: Control functions include All Hydraulic Cylinders used to manipulate the

Maverick Boom. The boom and frame cylinders are powered by a self contained hydraulic system. The pump is loctated on the front of the tractor. There is an in-line pressure filter (P/N 02981371) between the closed center load sense pump and cylinder control valve. There is a return filter (P/N 02981391) mounted to the tank that filters the fluid returning from the control valve to the tank. Filter change recommended for every 200 to 250 hours. An electronic monitoring system monitors element back pressure for indication of clogged filter prior to element change.

Mower Head Functions: Mower Head Functions are operated by Pump, which is mounted to the

front of the Tractor Engine. This will have an in-line Filter installed into hydraulic circuit, This filter should be changed on a regular maintenance schedule. Filter are rated by Micron size (10 Micron), Filters should be replaced with original Alamo Industrial Replacement Filters to make certain the correct rated filter element is installed at all times. (Pressure Filter is P/N 02968922 and Return Filter Replacement Element is P/N 02968923)

4. HYDROSTATIC PUMP SPEC'S

Cutter Head Pump Circuit Spec's:

Pump Type...............................................................Piston Type

Pump Speed (Front Engine Mounted)......................Run Engine to 540 PTO Speed

Relief Setting at the Pump........................................4500 PSI

Pump Flow (Front Engine Operating Speed)...........25.3 GPM

Boom Cylinder Pump Circuit Spe'c's:

Pump Type...............................................................Piston Type

Pump Speed............................................................ 1800 RPM

Pump Flow (Front Engine Operating Speed)...........15.6 GPM

Low Pressure Standby.............................................250 PSI

High Pressure Comp................................................3000 PSI

Horse Power at 1850 RPM (Engine Speed)............ 28.5 HP

5. HYDRAULIC HOSE CODES

Hydraulic Hose Band Mark Color Codes:

Hose's and/or fittings are marked with a Color Coded Plastic Band around it. Some Bands are a solid Color and some have a Colored with a Stripe. The purpose of the colored bands are to provide a quick reference for hose and port connection. A metal band is also attachted to the hose, on that band is an Alamo Industrial Part Number for reference if needing a replacement hose. Always Check Hose Size, Color Code & Part Number

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 1 - 4

SPECIFICATIONS - MAVERICK

Boom Cylinder Circuit Hoses:

Color Tie (Code) Hose Size Hyd. Function

Green G SAE # 6 Swing, Back (Rod End) Green / White G/W SAE # 6 Swing, Forward (Base End) Orange OR SAE # 6 Lift, Down (Rod End) Orange / White OR/W SAE # 6 Lift, Up (Base End) Blue B SAE # 6 Dipper, In (Rod End) Blue / White B/ W SAE # 6 Dipper, Out (Base End) Yellow Y SAE # 6 Telescope, In (Rod End) Yellow / White Y/W SAE # 6 Telescope, Out (Base End) Red R SAE # 6 Head Tilt, Up (Rod End) Red / White R/W SAE # 6 Head Tilt, Down (Base End) Green G SAE # 4 Swivel, CW (Rod End) Green / White G/W SAE # 4 Swivel, CCW (Base End) Yellow Y SAE # 4 Door, Open (Rod End) Yellow / White Y/W SAE # 4 Door, Closed (Base End)

Motor Circuit Hoses:

Color Tie (Code) Hose Size Hyd. Function

Red R SAE # 16 Pressure Flow to Motor Orange OR SAE # 16 Return Flow From Motor Blue B SAE # 8 Case Flow From Motor to Boom Blue B SAE # 12 Case Flow at Boom to Tank

6. HYDRAULIC CYLINDER PRESSURE RA TES:

Cylinder Type....................................................... Welded Cylinders

Cylinder Working Pressure................................... 3000 PSI

Hydraulic Cylnder Repair Specs:

Cylinder Cylinder Piston Nut Gland Seal Kit Part No. Function Torque ft. lbs. Torque ft. lbs. Part No.

02981275 Swing 400-500 80-120 (Head) 02982066 02981278 Lift (30 ft.) 400-500 80-120 (Head) 02982069 02981279 Lift (24 ft.) 400-500 80-120 (Head) 02982070 02981277 Dipper 400-500 80-120 (Head) 02982068 02981280 Tilt 400-500 80-120 (Head) 02982071 02961480A Door (Rotary) 150-250 80-120 (Head) 02975528 02970710A Door (Flail Axe) 40-60 80-120 (Head) 02975532 02971423 Slide (Timber Cat) 400-500 50-60 (Tie Rod) 02973505 02811000A Door (Ditcher) 150-250 80-120 (Head) 02975528 02981316 Stabilizer 40-60 80-120 (Head) 02982073 02981315 Swivel (Rotary) 300-400 80-120 (Head) 02982072 02981276 Extension 300-400 80-120 (Head) 02982067

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 1 - 5

SPECIFICATIONS - MAVERICK

7. VALVE SPECIFICATIONS

Valve Type: Multi-Section, Load Sense, Pressure Compensated, Directional control Valve.

Features electro-hydraulic spool actuators for proportional characteristics.

Valve Construction: Multi-Section, Individual Spool, with electro-hydraulic solenoids. Tie rod

bolt together type.

Valve Controller: Mechanical over Electric. 3-axis, multi-function, lever-type joystick. Valve Porting and Hose Connections: Hoses connect to valve as shown by color code. See

Decal P/N 02981986 below, Electrical connections connect as shown, Reference label on connector and corresponding solenoid.

8. Valve Spool Functions & Spec's (Boom Feature):

Main Relief at Inlet 3335 psi - Valve Spool Functions & Specs:

Band Spool Cyl. Travel Port Work Port Pressure Color No. Function Direction Relief Rating

G/W 1 Swing Forward B 3045 psi. 2.0 G 1 Swing Back A 3045 psi. 2.0 OR 2 Lift Down B 1160 psi. 7.92 OR/W 2 Lift Up A Plug 7.92 B/W 3 Dipper Out B Plug 3.17 B 3 Dipper In A 1160 psi. 3.17 Y/W 4 Telescope Out B 2030 psi 3.17 Y 4 Telescope In A Plug 3.17 R/W 5 Tilt Up A Plug 3.17 R 5 Tilt Down B 2030 psi 3.17 G 6 Swivel CW (top) A 2755 psi 6.60 G/W 6 Swivel CCW (top) B 2755 psi 6.60

Valve Spool Functions & Specs: The Cylinder Cycle has adjustable settings, slow, medium

and fast, Time Cylinder cycle of unit, Time indicates the time for the Cylinder to travel the full amount of its extension or retraction. The lift times up and down are taken with the dipper fully extended and begin with the Deck flat on the ground. All Cycle times are measured at the rated Tractor RPM. Test Times should vary as according to the setting being used.

Valve Leakage: Maximum internal Valve Leakage from the Cylinder. Ports to Tank at any Valve

Segment, Oil Pressure at 1450 PSI and Oil Viscosity at 102 SSU = 1.25 Cubic Inch / Minute

Standby (Pilot) Pressure: Standby (Pilot) Pressure = 200 to 250 PSI.

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 1 - 6

SPECIFICATIONS - MAVERICK

9. HOSE END FITTING TORQUE SPECS:

Hose End Type: 37 Degree Angle End Steel Hose End Fittings*

Dash Nominal Cyl. Torque Torque Size Size (in.) in. lbs. ft .lbs.

-4 1/4" 140 12

-6 3/8" 230 19

-8 1/2" 450 38

-10 5/8" 650 54

-12 3/4" 900 75

-16 1" 1200 100

-20 1-1/4" 1600 133

-24 1-1/2" 2000 167

-32 2" 2800 233 * Straight Threads do not always seal better when higher torques are used. Too much torque causes distortion and may lead to leakage. DO NOT over torque fittings and DO NOT allow any contaminants to enter system through fittings when installing them.

10. Special Torque Specifications (Rotary Heads)

Motor to Spindle Housing...........................................................100 ft. lbs.

Spindle to Deck..........................................................................425 ft. lbs.

Spindle to Adjusting Nut (Bearing Preload)............................... 25 in. lbs. Rolling Torque

Blade Bar Leaf Bolts ( 1-1/4" Bolts)....................................... 2000 ft. lbs.

Blade Bar to Spindle Bolts.........................................................400 ft. lbs.

Blade Bolts................................................................................ 400 ft. lbs.

Motor Plate............................................................................. See Set Up Instructions

11. TORQUE VALUES - BOLTS: Recommended Torque, Ft. lbs. & (Nm)

IMPORTANT! Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE, Component

Application Torque will vary depending on what is bolted down and the type material (Metal) that is being bolted together. Thread condition and lubrication will vary Torque settings.

ALWAYS CHECK MARKINGS ON TOP OF BOLT HEAD OR OTHER BOLT DESCRIPTIONS

Bolt Dia.

inch

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4

Inche Sizes

2 (B)

Plain Head

ft. lbs (*N-M) ft. lbs (*N-M) ft. lbs (*N-M)

Not Used Not Used Not Used

35 (*47) 55 (*75)

75 (*102) 105 (*142) 185 (*251) 160 (*217) 250 (*339) 330 (*447) 480 (*651)

5 (D)

3 Dashes

10 (*14) 20 (*27) 35 (*47) 55 (*75)

85 (*115) 130 (*176) 170 (*230) 300 (*407) 445 (*603) 670 (*908)

910 (*1234)

1250 (*1695)

8 (F)

6 Dashes

14 (*19) 30 (*41) 50 (*68)

80 (*108) 120 (*163) 175 (*230) 240 (*325) 425 (*576) 685 (*929)

1030 (*1396) 1460 (*1979) 2060 (*2793)

Bolt Dia. mm

6 8 10 12 14 16 18 20 22 24 27 30 33 36

Metric Sizes

4.8

ft. lbs (*N-M) ft. lbs (*N-M)ft. lbs (*N-M)

5 (*6) 11 (*15) 20 (*27) 37 (*50) 60 (*81)

92 (*124) 118 (*159) 160 (*217) 215 (*291) 285 (*386) 450 (*610) 600 (*813)

800 (*1084) 900 (*1220)

8.8

7 (*9) 20 (*27) 40 (*54) 70 (*95)

100 (*135) 155 (*210) 216 (*292) 270 (*366) 330 (*447) 500 (*678)

875 (*1186) 1200 (*1627) 1600 (*2169) 2100 (*2847)

10.9

12 (*16) 25 (*33)

58 (*78) 105 (*142) 140 (*189) 200 (*271) 280 (*379) 355 (*481) 430 (*583) 700 (*949)

1000 (*1355) 1700 (*2304) 2300 (*3118) 3000 (*4067)

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 1 - 7

NOTES

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 1 - 8

Section 2

Maverick Boom

New Holland Tractor

TS-100A, 115A, 125A, 135A

Tractor Preperations

Maverick (NH TS-115A, 125A, 135A, Asy. Man) 01/05

Section 2 - 1

General Information / Installation Requirements

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

To help you assemble your new Machete Boom and mount it to your tractor, a detailed assembly instruction Manual is being provided with the mount kit to provide detailed instructions and part numbers. Please consult this document for specific information. When needed, you can get additional information or clarification from Your Dealer or Alamo Group Customer Service.

This publication provides general information not specifically for your case or tractor, but, in connection with the drawings, this publication offers you some valuable assistance - please read it thoroughly.

These mount kits are made for selected tractors with standard configurations. Only the noted options and tire sizes listed in the Mounting Specifications will work with these mount kits. Other options, front axles, or different tire sizes may prevent the mount kit from fitting your nonstandard tractor. Alamo Group cannot take responsibility for these problems or any modifications made to the unit.

Throughout these instructions, references are made to right or left directions. Right and left are determined by sitting on the tractor seat and facing the direction of travel forward always.

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

DANGER! A signal word - DANGER, WARNING, or CAUTION - is used with the Safety Alert

symbol. DANGER identifies the most serious hazards.

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Section 2 - 2

General Information / Installation Requirements

WARNING! Safety signs with signal word WARNING are typically used to point out more

serious hazards.

CAUTION! General precautions are listed on CAUTION safety sign. CAUTION also calls

attention to safety messages in these instructions.

GENERAL INFORMATION

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

1. Welding equipment (including correct head gear, eye shields, and protective clothing.)

2. Impact wrench or socket and ratchet set.

3. Rubber mallet.

4. Box-end, Allen, and crescent wrenches.

5. Alignment pins.

6. Phillips and plain-head screwdrivers.

7. Forklift or hydraulic floor jacks with rolling back boards.

8. Over head hoist and floor jacks

9. Jack Stands and/or other support devices that are strong enough to support tractor and components

10. Multidirectional Levels.

11. Paint Scraper.

12. Hydraulic Filter Buggy or Cart.

13. Safety shoes, safety glasses, and gloves. A hard hat should be worn by anyone working under any raised component.

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 2 - 3

General Information / Installation Requirements

WARNING!

Disconnect the negative lead (ground) from the battery terminal to prevent any damage to the electrical system.

LEVELING TRACTOR:

TRACTOR MUST be on level ground before assembly is begun. The tractor must be level, All tires

must have the proper amount of air in them as per tire and/or Tractors manufactures recommendations.

DO NOT level tractor by over inflating tires. The tractor can be leveled by jacking it up and putting it on

jack stands if needed.

Replacement Oil Filter

Included in the packing box of this unit is a replacement filter element for filter assembly in the tank. This Mower unit's hydraulic components have been carefully cleaned and packaged at the factory to prevent contamination from entering the system. However, dust and dirt particles may enter into the sealed components through transportation, handling, rain, or just sitting in a dirty or harsh environment. Therefore to assure that the hydraulic system is properly clean, please prepare the area where the unit is to be assembled. The area should be on a hard concrete floor that has been swept clean of all dust and contaminants. Unpacked the Mower unit carefully so that the seals on the hydraulic components are not broken or pulled off.

WARNING!

Before attempting to assemble the mower to the tractor, move the tractor to a clean solid surface, preferably a concrete shop surface with an over head crane. The crane should have a rated capacity to lift the heaviest component or assembly. A 5-ton crane is recommended for the assembly work. If a smaller crane is used, be sure not to exceed the rated capacity of the crane. Q Always follow all OSHA crane operating and inspection rules, regulations,

inspection requirements, and recommended practices when using the crane.

Q Never work under any component that is lifted by the crane.

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Section 2 - 4

General Information / Installation Requirements

WARNING!

Wear personal protective equipment when assembling the mower. As a minimum that should include:

Q Safety Glasses Q Safety Shoes Q Gloves Q Hard Hat Q Hearing Protection Q Welding Helmet

Before attempting to assemble ensure that the tractor engine is off and the tractor transmission is in the park position with the parking brake engaged.

Q Remove the engine key and keep it in your pocket to prevent inadvertent

starting or movement of the tractor.

Q Place wheel blocks in front and behind the tractor wheels to prevent the tractor

from moving.

Q Never attempt to start the tractor unless properly seated in the tractor seat

with the seat belt fastened around you.

Q Never attempt to operate the tractor and mower controls unless seated in

the tractor seat with the seat belt fastened around you.

Securely block up and support the tractor before attempting to loosen and move the tires. Failure to properly block up the tractor can result in the tractor to suddenly move or fall, crushing you or another worker. Q Never work under any raised component or any component that is not

securely blocked up or supported.

WARNING!

Many components of this mower are very heavy and must be handled by proper material handling equipment. Do not lift components that weight over 50lbs by yourself. Q Use an overhead crane, forklift, or other coworkers to lift heavy items. Ensure

lifted components are securely supported.

Q Never walk or work under a lifted component.

Use extreme care when moving, handling or adjusting the tractor tires. The tires are extremely heavy and could fall and crush you

Q Use an overhead crane or forklift to move the tires. Q Properly fasten the tires to the material handling equipment to prevent the tire

from falling. The hydraulic oil is under high pressure and a hydrauli leak can cause oil to be injected under the skin.

Q Before starting the tractor ensure all hydraulic connections have bee tightened Q Never check for leaks with your hands. Use a piece of wood or cardboard to

check for the leak making sure your hands and face are kept away from the

leak area.

Q Repair any leaks before operating the equipments Q Clean up all oil that has leaked according to the requirements of the oil supplier.

Oil residue on the ground can result in unjury from slipping or falling.

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 2 - 5

General Information / Installation Requirements

TRACTOR PREPARATION (FIGURE 1 & 2)

1. Temporally remove ROPS and fenders from tractor axle. Move left rear tire out so that it is 50 inches

from the outside of left rear tire to the center of tractor. Then move the right rear tire out so that it is 96 inches between the outside of the left and right rear tires. Refer to your tractor’s Operator’s Manual for instructions on Rear Wheel Adjustment for your particular tire. FIGURE 1. Hydraflate rear left tire as much as needed for stability but stay in factory-recommend limit.

FIGURE 1

50"

96"

WARNING: Never operate the tractor with a loose wheel rim or disc. Always tighten nuts

to the specified torque and at the recommended intervals.

2. Extend front wheels out so that it is 55" inches between the inside of the tires. This will allow no interference between tire and front mount bracket. FIGURE 2.

FIGURE 2

55"

Tractor, Area Cleanliness

The Tractor, all tools and work area must be clean of dirt and debris when assembling any hydraulic components. DO NOT leave any hydraulic component open to the elements. DO not use any containers for fluids that are not clean and free of any other liquids. DO NOT use rags/cloth that has lint or fuzz on them when working on hydraulic components. Keep all hoses capped until you are ready to connect them.

Maverick Cleaning

The Maverick Components are designed to be water resistant. But the sealing can be damaged by Pressure Washers, Steam Cleaners, Solvents or any other harsh chemical that would be used to clean the units components. It is important to keep all electrical connections and components sealed and dry. When washing and cleaning this unit it should be done with a non corrosive soap and low pressure spray of water. It is recommended that all exposed electronic components be covered and protected from excess moisture.

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Section 2 - 6

General Information / Installation Requirements

Lay Out Components in Display. It is helpful to lay out the component in as neat a display

as possible. Lay out the Bolts according to size and length. Lay out the Nuts and washer by size. This will allow you to see how many of each part as you use them and help to identify any missing parts. (See figure 6) See Mount Kit Specification and Component Identification Section to help ID Components.

All the component that are received should be check and sorted as to what they are. Shown below is a general example of the components laid out, this is not a lay out of the components in this mount kit.

WARNING

DO NOT WELD On This Unit During or After Installation:

DO NOT WELD any components or items on this unit after the installation of the maverick Boom has begun. The Maverick Boom uses electronic modules and components that could be damaged by welding. Before doing any welding ALL ELECTRONIC MODULES AND DISPLAY COMPONENTS MUST BE UNPLUGGED. Check the Tractors Opertion, Repair, Service or any other manual from the tractor manufacturer of the tractor to find any special electronic or special proedures about the tractor electronics. Taking a few minutes to check could save you from a major damage to the electronics.

Maverick (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 2 - 7

NOTES

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Section 2 - 8

Section 3

MAVERICK

New Holland Tractor

TS-100A,1 15A,125A & 135A

Maverick (NH TS-100A,115A,125A,,135A Asy. Man) 01/05

Pump & Driveshaft

Inst allation

Section 3 - 1

Pump / Drive Assembly Instructions

Installing Pump, Pump Drive Components and Hydraulic Tank:

This Section covers the installation of Pump Drive Components, Pump Assembly and the Hydraulic Tank. Some precautions must be followed during the Assembly Process and before unit is ever started for the first time.

1. Tractor must be disabled to prevent accidental engine start and prevent damage to components.

2. All Fittings, Hose, Cylinders, Tank must be kept plugged at all times, No part of the Hydraulic

System can be left open at any time during mounting process, this will keep system clean.

3. All Tools, Work Area, Components and Workers Hands must remain Clean when working on

any part of the Hydraulic System.

4. All components should be rechecked for tightness at least twice, Hose routing also double

checked.

Preparing Tractor Front Plate (Bolster) to Slide Driveline in From Engine Side :

1. Preparing Tractor, On the Left side of Tractor there are some engine protective shields that will

have to be removed to install pulley adapter and driveshaft half (See Figure 2). The shaft half of driveline will have to be slid down and through the bolster from the engine side of radiator. The driveshaft has to slide in from the engine side because the hole (2 holes) in bolster are to small for driveline flange yoke to slide through. There is a plate that is bolted under the After Cooler that will have to be removed

to gain access to inner hole, when the four bolts that retain after-cooler are removed the plate will slide out. While this plate is out check the hoses for the Oil Cooler and Air Conditioning condenser, these hoses need to be tied up in such away that they will not rub on driveshaft after it has is installed.

Installing Pump Drive Components:

1. With Front Bolster as shown (See Figure

1), Remove any plastic plugs that are located in the threaded holes in the front and discard them, they will not be needed. The Casting will have two Driveline Hole in it. (See Figure 1).

Installing Pulley Adapter:

1. Install Pulley Adapter. The Pulley adapter

(P/N 02980699) is a round plate with 4 threaded holes and four non-threaded holes in it. Notice this pulley adapter will not have a center hole in it (See Figure 3). The four non-threaded holes are used to mount the Adapter to the Crankshaft Pulley using bolts (P/N 02980967) 12 mm X 60 mm long and lockwashers (P/N 00754566) 12 mm that are supplied in mount kit. The four threaded holes are used to install the flange yoke of driveline to pulley adapter Do not use longer bolts to mount Pulley Adapter to Pulley or Flange yoke to adapter than are supplied with mounting kit, if longer bolts are used they could go through adapter and pulley causing damage. Tighten the four bolts that retain the pulley adapter to the pulley now, it will be easier than trying to tighten them later. (See Figure 3 & 3A)

Cover removed

LH Side Engine

Guards Removed

From Tractor

Air After-Cooler

Tractor Bolster

Figure 1

Figure 2

Existing Holes

have rubber

Plugs in them

Maverick (NH TS-100A,115A,125A, 135A Asy. Man) 01/05

Section 3 - 2

Pump / Drive Assembly Instructions

2. Install Shaft Half of Driveline with Flange Yoke. Note the driveline universal joints should be timed

(See Figure 4). Slide the two driveline half assemblies apart and lay the tube half aside for now. Make certain that the four retaining bolts for the Pulley adapter to the crankshaft pulley have been tightened.

3. Check the length of the spline shaft of the driveline is a must. The shaft should be 12-1/

2" long (Measure Shaft Only). on some drivelines this shaft will have to be cut. The correct way to cut this shaft is with a saw, after cutting use a file & grinder to chamfer the cut end and clean the splines.

DO NOT cut shaft with a Torch as this will change the hardness of the shaft.

4. From the side of the tractor (LH side) slide the Shaft Half of driveline shaft end first down into the

opening below the radiator from engine side, insert it through the existing hole and/or cut hole combination until the shaft is pointed toward the front of the tractor, and the flange yoke is over far enough to align with the four threaded pulley adapter holes.

5. Align the four holes in the flange yoke of driveline with the four threaded holes in the pulley adapter.

Install the four retaining 7/16" X 1-1/4" long bolts (P/N 02976344) and 7/16" lockwasher (P/N 00022200) into flange yoke into adapter, tighten them at this time. These four bolts can be tightened by using a long socket extension run through along side the driveline shaft.

6. Set the tube end of driveshaft aside for now as it will be installed later. But always remember the

driveline universal joint must be aligned (timed) when assembling the driveline halves.

4 Non-Threaded Holes

Pulley Adapter

Figure 3

P/N 02980699

4 Threaded

Holes

Splined Clamp Yoke

/ Tube End

Figure 4

Flange Yoke

/ Shaft End

Drive Shaft

Assembly

Figure 3A

Maverick (NH TS-100A,115A,125A,,135A Asy. Man) 01/05

Figure 4A

Section 3 - 3

Pump / Drive Assembly Instructions

Install Tank Rail Weldments:

1. Install Tank Rail Welments . P/N 02981405 LH

and P/N 02981404 RH. These will bolt on using the two holes to the front of the frame rail supports. This will need to be done so the hydraulic tank can be mounted.

Tractor

RH Side Shown,

tighten these two bolts (two each side) now. NOTE: There is a left hand and a right hand weldment, the best way to determine which is LH and RH is theway they fit. The bend is bolted on to make the distance between the two tank rails the same as the width of the hyd tank.

Installing Pump Mntg Weldment :

1. Install Pump Mounting Weldment. The Pump

Mount Weldment (P/N 02980719) bolts to the front of the tractor bolster using four 20 mm X 45 mm long bolts (P/N 02975959) and 20 mm lockwashers (P/N 02971158) . Install the Pump Mounting Weldment (P/N 02980719) with the opening for the driveline cover up. Tighten the four mounting bolts now. (See Figure 8)

Bolt on Cover on

Figure 5

RH Tank Rail

LH Tank Rail

Figure 6

Figure 7

2. Remove Bolt on Cover In front of After Cooler.

This is an important step. The Air Conditioner Hoses and the Oil Cooler Hoses are under this cover (See Figure 6 & 11). These hoses must be tied and routed so the driveshaft will not rub them when engine is running. The hose can be tied with a sturdy plastic tie or other means sufficient to hold the hoses away from driveshaft

3. Remove Pump Shipping Bracket. The pump

is shipped using a bracket that bolts to the pum and the tank assembly. Before pump can be installed it will have to be unbolted from pump and tank. The shipping bracket is for shipping only and will not be used. When unbolting pump from tank assembly there are hoses that will have to be disconnected from pump as tank to pump hoses (filters are connected when assembly is shipped. Caution must be taken when disconnecting these fittings and/or hoses to keep the capped to keep contamination out of them.

Pump Shipping

Bracket

Figure 8

Maverick (NH TS-100A,115A,125A, 135A Asy. Man) 01/05

Section 3 - 4

Pump / Drive Assembly Instructions

123456

Installing Driveline Half to Pump :

1. Install Driveline Half to Pump. Install the clamp yoke of the tube half of driveline onto the

pump, slide the clamp yoke on pump shaft until you have about 1/8" to 1/4" gap between yoke and pump. Do not install yoke so far on pump shaft that yoke will rub against pump in anyway. Tighten the two bolts and nuts on clamp yoke at this time. (See Figure 9 & 14)

Figure 9

Driveline Tube Half with

Clamp Yoke

Installing Pump to Pump Mount Weldment :

1. Install Pump to Pump Mount Weldment. The Pump has the tube half of driveline attached

and clamp yoke tightened. To install the pump and driveline half it is best to use an assistant or overhead hoist to help you align the drivelines halves as they are slid together, the Driveline must be timed (universal joints aligned the same) as shown in the pump & driveline schematic on (See Figure 10 thru 17). Slide Driveline half and pump together until the shoulder on the pump slide in the hole on the pump mount weldment.

When installing the pump always keep ports sealed to keep them clean and free of contamination. The pump MUST be turned correctly. This can be done by making certain that the pressure filter that is mounted on top of the pump is up.

Install the two 1/2" X 1-1/2" long pump mount bolts (P/N 02892000) and two 1/2" lockwashers (P/N 00001300). Tighten the two pump mounting bolts.

Install Pump Driveline cover here

P/N 02980666 Pump Mount Weldment

Figure 10

Pump Mntg Bolts

Maverick (NH TS-100A,115A,125A,,135A Asy. Man) 01/05

2345678

Mounting Bolts

Section 3 - 5

234567890

2345678901

Bolts To Tractor Bolster

Mounting Bolts

Pump / Drive Assembly Instructions

Driveshaft & Pump

Mount Weldment

Figure 11

Align Splines on Pump Shaft

with Driveshaft clamp yoke.

Pump Shipped w/ Hyd. Tank, Valve

is bolted to Tank

installed

Figure 12

Tighten Clamp Yoke, leave

1/8" to 1/4" gap btween

yoke & pump

Figure 13

Push Pump into Pump

Mount until flush

Figure 15

Maverick (NH TS-100A,115A,125A, 135A Asy. Man) 01/05

Figure 14

Install Pump

Mounting Bolts

Figure 16

Section 3 - 6

Pump / Drive Assembly Instructions

12345

Installing Pump Driveline Cover :

1. Install Pump Driveline Cover. The Pump Driveline will have a cover (P/N 02980398) which

retained by four 1/4" X 3/4" bolts (P/N 00021400), four 1/4" flatwashers (P/N 00024100) and four 1/4" lockwashers (P/N 00017000), install and tighten these now (See Figure 6).

Pump End Clamp Yoke

P/N 02980398 Driveline Cover

Time Universal Joints

Driveline Asy

P/N 02980666 Pump Mount Weldment

Mounting Bolts

Tractor Engine Pulley

Pulley Adpater w/ Mounting Bolts & Washers (4 bolts)

4 Driveline Mounting Bolts

Driveline Cover Mounting Bolts,

2345678901

Flatwashers & Lockwashers (4)

Pump Mounting Bolts

Maverick (NH TS-100A,115A,125A,,135A Asy. Man) 01/05

2345678

234567890

Mounting Bolts

Pump (Reference)

Section 3 - 7

Bolts To Tractor Bolster

Figure 17

Pump / Drive Assembly Instructions

Install Tractor Guards & Covers:

1. Reinstall LH Side Engine Guards. The left

hand side engine guards need to be reinstalled using the original hardware (See Figure 18). These guard are to gain access so the pulley adapter could have been installed as shown (See Figure

19).

2. Reinstall Top Cover. There is a top cover

that bolts onto the front of the tractor that is removed to make certain that the hoses that run underneath (See Figure 20) are tied back to prevent them from rubbing on the driveshaft that was installed, this is very important to prevent damage to the hoses (See Figure 21). The front cover plate will be installed using the original hardware.

LH Side Engine

Guards Removed

From Tractor

Figure 18

3. Install Pump Mount Driveshaft Cover. The

Pump Mount has a bolt on cover on top of it (See Figure 17 & 21). The cover and bolts are furnished with kit. In figure 21 is shown without pump installed, this is for illustration only. Do not install cover before pump is installed.

4. Review this section and make certain all

components are installed and tightened to specification (Bolt Toque Chart) and hoses are secured so as not to interfere with another component.

Figure 19

Air Conditioner & Oil Cooler Hoses

Pump Mount

Cover Bolts

Here

Air Conditioner &

Oil Cooler Hoses

Figure 20

Maverick (NH TS-100A,115A,125A, 135A Asy. Man) 01/05

Front Cover

Figure 21

Section 3 - 8

Section 4

MAVERICK

New Holland Tractor

TS-100A, 115A, 125A, 135A

Hydraulic Tank &

Control Valve

Installation

Maverick (NH TS-100A,115A , 125A, 135A Asy. Manl) 01/05

Section 4 - 1

Hydraulic Tank & Control Valve Installation

Hydraulic Tank and Control Valve installation:

This Section covers the installation of the Hydraulic Tank and Control Valve Assembly. The Tank and valve are shipped as an assembly.

1. Locate Tank and Valve Asy, this will need to be lifted with a hoist, the front bumper wldmnt

is welded to the front of the tank from the factory.

2. All Tools, Work Area, Components and Workers Hands must remain Clean when working on any

part of the Hydraulic System. All hoses and fittings should remain plugged till ready to install them to keep them clean.

3. All components should be rechecked for tightness and Hose routing also double checked.

Install Hydraulic Tank to Front of Tractor:

1. Hydraulic Tank and Valve Assembly, The Hydraulic Tank, Control Valve and Pump are shipped

together (See Figure 1). The Pump should have already been mounted.

2. Install Hyd. Tank & Control Valve Asy. To

install the tank and valve assembly you should use an over head hoist to lift Tank and Valve Assembly, as it is heavy and can be damaged if dropped. The hoist will also assist when aligning the mounting holes. There are three mounting tabs in the rear of the tank. Mount the three rear bolts, Three on each side. The hydraulic tank slide under pump and between the LH & RH Tank rails. Do not remove from hoist until tank has been bolted on and bolts tightened

Inner

Mounting

Tabs

3. Rotate Fittings to make better access to

Valve and tank connections, The fittings in the pump and valve may have to be rotated to make it more accessable whenconnecting the hoses.

Figure 1

Hose Connections To Pump And Hyd Tank: (See Figure 2)

Item Part No. Qty. Description A 02981427 1 Hose, 8FJX - 8FJX 90° - 24" Lg. w/Red Tie (Charge Filter to Pump)

B 02981428 1 Hose, 8FJX - 8FJX 90° - 21" Lg. w/ Blu Tie (Case Drain to Tank) C 02981429 1 Hose, 12FJX - 12FJX - 23" Lg. (Pump to Suction Filter) hose under

pump and cannot be seen in drawing. D 02981430 1 Hose, 12FJX - 12FJX - 31" Lg. w/ Red Tie (Pressure Filter to Supply) E 02981431 1 Hose, 4FJX - 4FJX 90° - 35" Lg. w/ Red Tie (Pump Load Sense to Valve (PX)

Connects to top side of pump as shown. F 02981432 1 Hose, 4FJX - 4FJX 90° - 20" Lg. w/ Blu Tie (Pump Regulator to Tank)

Connects to bottom side of pump not seen. F ------------- 1 Hose #4, Connects here w/ Tee Fitting (Connect to Base End Stabilizer Cyl) G 02981433 1 Hose, 20FJX - 12FJX - 24" Lg. (Pump to Suction Filter) H 02981462 1 Hose, 12FJX - 12FJX 90° - 20" Lg. w/ Org Tie (Valve Return to Tank) J ------------- 1 Hose, # 16 w/ Red Tie (Pressure from Pump to Motor) Bottom Port K ------------- 1 Hose, # 16 w/ Orange Tie (Oil Return from Motor) Top Port L ------------- 1 Hose. w/ Blue Tie (Oil Return from Oil Cooler to Tank)

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 4 - 2

Hydraulic Tank Hose Routing

"J" # 16 Hose

(Red Plastic Tie)

"K" # 16 Hose

(Orange Plastic Tie)

"C" # 12 Hose

Suction Hose

(No Plastic Tie)

"G" # 20 Hose

Suction Hose

(No Plastic Tie)

"A" # 8 Hose

(Red Plastic Tie)

"L" # Hose

(Blue Plastic Tie)

"B" # 8 Hose

(90° Elbow)

(Blue Plastic Tie)

"A" # 8 Hose

(90° Elbow)

(Red Plastic Tie)

"E" # 4 Hose

(Red Plastic Tie)

"D" # 12 Hose

(Red Plastic Tie)

"H" # 12 Hose

(90° Elbow)

(Orange Plastic Tie)

"D" # 12 Hose

(Red Plastic Tie)

"G" # 20 Hose

Suction Hose

(No Plastic Tie)

"H" # 12 Hose

(Orange Plastic Tie)

Figure 2

NOTE: Hoses are not shown in drawing above, this is for clarity. The hose routing is for the hoses which connect from one point to the other. Use the instructions and hose description listed to follow hose routing. Example: Hose - A connects to one end marked A and the other end of hose connects to the other item marked A. This is done with the other letters as well, the hose must connect to the same letter markings on each end as in drawing. Some hose will be marked with a colored plastic tie. Some hose will have a straight fitting or a 90° fitting. This is to allow hoses to be routed to where they clear other items, when connecting hose put the end on that has the correct fitting as noted in drawing with (90°) or the straight fitting if note marked hose routing that is to make hoses clear other items. Do Not connect hose to different letter items, all hose end must connect to the same letter on both ends. TO ID HOSES: Always check Size, Length, Fittings and Color Plastic Tie to identify the hoses. Some hoses will have the same color tie but the size, length or fittings will be different.

"E" # 4 Hose (90° Elbow)

(Red Plastic Tie)

"F" # 4 Hose & Tee

(Blue Plastic Tie)

"F" # 4 Hose

(90° Elbow)

(Blue Plastic Tie)

"B" # 8 Hose

(Blue Plastic Tie)

Tank Return

Maverick (NH TS-100A,115A , 125A, 135A Asy. Manl) 01/05

Section 4 - 3

Directional Control Valve Fittings

Pump Pressure

Port

"A"

Ports

FIGURE 3

"B"

Ports

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Tank Return Port

Section 4 - 4

Directional Control Valve Fittings

Valve Fittings and Location: (See Figure 3)

Item Part No. Qty Description

02981888 -- Valve & Fittings Asy, 6 Spool

1 02981370 1 Valve Asy w/o Fittings 2 02090800 2 Adapter Hyd, Elbow 12MB - 12MJ 90° 3 02972177 11 Adapter Hyd, Straight 10MB - 6MJ 4 03200284 1 Adapter Hyd, Straight 6MB - 4MJ 5 02981889 1 Adapter Hyd, Straight 10MB - 6MJ 6 02972208 1 Valve Solenoid Asy 7 02975438 1 Adapter Hyd, Straight 8MB - 8FJX 8 02981890 1 Adapter Hyd, Straight 8MB - 6MJ

HYDRAULIC LOCK VALVE: (Head Tilt Function)

An Electric Solenoid Operated Hydraulic Lock Valve (Figure 4) is incorporated in the Head Tilt Function to prevent excessive (Head Lift Cylinder) leak down during storage or transportation. The Solenoid which operates this valve is normally in the Locked position until Head Lowering function is actuated at Joystick. When Joystick is actuated to lower Head an electric signal is sent to solenoid to open Lock valve. When the function to raise the Head is activated there is no electric signal from Joystick. The pressure against the valve when head is being raised will force Valve open like a relief Valve allowing Oil to pass through it. If this valve will not open it could stop head from lifting or dropping. The valve is plumbed into the Hydraulic Circuitry of the Head Tilt Function and is located near the Control Valve.

Maverick (NH TS-100A,115A , 125A, 135A Asy. Manl) 01/05

Hydraulic Lock Valve

Item Part No. Qty. Description

02972208 -- Solenoid Valve Asy 1 02971425 1 Seal Kit, f/ solenoid Valve 2 02975198 1 Coil, 12V- DC w/Dual

8-32NF Studs 3 02975199 1 Cartridge, Solenoid Valve 4 02975438 1 Adapter Hyd, Straight 8MB-6FJX 5 02981890 1 Adapter Hyd, Straight 5MB - 6MJ

FIGURE 4

Section 4 - 5

Hydraulic Hose Connections

HYDRAULIC HOSE CODES AT VALVE

Hydraulic Hose Band Mark Color Codes: Hose's and/or fittings are marked with a

Color Coded Plastic Band around it. Some Bands are a solid Color and some are Colored with a Stripe. The purpose of the colored bands are to provide a quick reference for hose and port connection. A metal band is also attached to the hose, on that band is an Alamo Industrial Part Number for reference if needing a replacement hose.

& Part Number (See Figure 5)

Boom Cylinder Circuit Hoses:

Color Tie (Code) Hose Size Port Diverter Hyd. Function

Green G SAE # 6 A --- Swing, Back (Rod End) Green / White G / W SAE # 6 B -- - Swing, Forward (Base End) Orange OR SAE # 6 A --- Lift, Down (Rod End) Orange / White OR/W SAE # 6 B --- Lift, Up (Base End) Blue B SAE # 6 A --- Dipper, In (Rod End) Blue / White B/ W SAE # 6 B --- Dipper, Out (Base End) Yellow Y SAE # 6 A --- Telescope, In (Rod End) Yellow / White Y/W SAE # 6 B --- Telescope, Out (Base End) Red R SAE # 6 B --- Head Tilt, Up (Rod End) Red / White R/W SAE # 6 A --- Head Tilt, Down (Base End) Green G SAE # 4 A P2 Control Valve tor Diverter valve Green / White G/W SAE #4 B P1 Control Valve to Diverter Valve Green G SAE # 4 - -- C4 Swivel, CW (Rod End) Green / White G/W SAE # 4 - -- C 1 Swivel, CCW (Base End) Yellow Y SAE # 4 - - - C3 Door, Open (Rod End) Yellow / White Y/W SAE # 4 -- C 2 Door, Closed (Base End) Orange OR SAE#12 T --- Valve Return To Tank Red R SAE#12 P -- Pressure to Valve.

Always Check Hose Size, Color Code

Motor Circuit Hoses to Boom Connections: (Listed as reference)

Color Tie (Code) Hose Size Hyd. Function

Red R SAE # 16 -- Pressure Flow to Motor Orange OR SAE # 16 -- Return Flow From Motor Blue B SAE # 8 -- Case Flow From Motor to Boom Blue B SAE # 12 -- Case Flow at Boom to Tank

Diverter Valve.:

The Diverter Valve bolts onto the front frame mount bracket on the LH side of the tractor, the holes are in the bracket (See Figure 5 , 6 & 7). The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two (or more if valves are stacked) functions with a single pressure supply. This valve is strictly a diverter valve and is designed to direct the pressure, not regulate the flow or pressure.

The Port openings on this diverter valve are marked with letter number codes which show which port is connected to which hose and where that hose connect on other end (See Figure 5, 4 & 7))

Port Function & Connection

P1 Hose Hydraulic Pressure from Door / Swivel (B) Port on Control Valve (G/W Tie) P2 Hose Hydraulic Return to Door / Swivel (A) Port on Control Valve (G Tie) C1 Hose to Head Swivel Cylinder Base End (G/W Tie) C2 Hose to Door Cylinder Base End (Y/W Tie) C3 Hose to Door Cylinder Rod End (Y Tie) C4 Hose to Head Swivel Cylinder Rod End (G Tie)

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 4 - 6

Hydraulic Hose Connections

Six Spool Control Valve

External Wire Connections for valve are marked "A" and "B" on Valve & AA1 thru AA12 on wire harness connections

Swing

Lift

Dipper

Telescope

Head Tilt

Head Swivel / Door

(To Diverter Valve)

Pressure

Supply

Port "P"

Diverter V alve

Valve "B" Port to

Diverter valve P1 Port

4 Through holes are

mounting holes

Valve "A" Port to

Diverter valve P2 Port

FIGURE 5

(G/W Tie)

(G Tie)

"B"

G/W

"A"

OR/

"A"

"B""B"

B/W

Y/W

"B""B"

"B"

G/W

Return

To Tank

"T"

"A""A"

R/W

"A""A"

Diverter Valve "C1" Port

to Swivel Cyl Base End Port (G/W Tie)

Diverter Valve "C4" Port

to Swivel Cyl Rod End

Port (G Tie)

VS . 125/F

Diverter Valve "C2" Port

to Door Cyl Base End

Port (Y/W Tie)

SAE 4

Diverter Valve "C3" Port

to Door Cyl Rod End

Port (Y Tie)

Maverick (NH TS-100A,115A , 125A, 135A Asy. Manl) 01/05

Section 4 - 7

Oil Cooler / Fan Assembly

Connecting Oil Cooler And Fan Assembly to Exterior Wire Harness

1. Oil Cooler / Fan Assembly. The Oil cooler / fan assembly is for cooling the oil being returned from the Motor Case Drain. The fan is connected to the control box and is turned on & off automatically. It set to run on a program that will run the fan in the cooling rotation for a designated time, then stop, reverse the rotation (cycle to clean debris off of cooler, then stop and reverse the fan again and begin the cycle all over again.

The connection to the cooler on the exterior wire harness is marked with code R1. The connection from the fan will have two wires, a Blue (+ connection) and a black (connection) (See Figure 8).

Diverter Valve

FIGURE 6

Swivel Cyl. Base End C1 Port (G/W Tie)

From Valve "A"

Port to P1 Diverter

Port (G / WTie)

Valve "A" Port to

P2 Diverter Port

Port (G Tie)

FIGURE 7

Swivel Cyl. Rod

End C4 Port (G Tie)

Door Cyl.

Base End

C2 Port

(Y/W Tie)

Door Cyl. Rod End

C3 Port (Y Tie)

Exterior wire harness con-

nection marked R1 connects

FIGURE 8

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

here

FIGURE 9

Section 4 - 8

Section 5

Maverick Boom

New Holland Tractor

TS-100A,1 15A,125A & 135A

Exhaust Modification

Fuel Tank Modification

Main Frame Installation

Maverick (NH TS-100A,115A,125A,135A Asy. Man) 01/05

Battery Modification

Section 5 - 1

Battery Holder Relocation

Battery Holder Relocation:

1. The Battery Relocation. The battery holder is

located on the RH side of the tractor (See Figure 1) . It will have to be relocated. The mount kit will include a battery relocation kit. The battery relocation kit includes a mounting bracket (See Figure 2) that will relocate the battery tray farther to the rear. This is done so the Boom Swing will not hit battery when in the transport position. The RH Step Will need to be removed to allow access to relocate battery.

2. Remove Factory Battery Cover, Battery,

Battery Tray and Battery Tray mount. Remove the battery cover (See Figure 3), Remove the battery cables from the battery. Remove the battery from the battery tray. Unbolt the battery tray from the tractors factory mount bracket. Remove the factory mounting bracket from the tractor (See Figure 4).

3. Install Replacement Battery Tray Bracket.

Install the replacement battery tray bracket (See Figure 2) using the same bolts and holes as the original bracket. This Bracket is designed to move battery further back. Install original battery tray using original hardware. Reinstall battery into batter tray (See Figure 3). DO NOT reconnect battery cables at this time, leave them off and make certain they do not make contact with the battery connections as you do not want the battery connected during installation. Replace the battery cover (See Figure 1) for now this will protect battery and cover.

Figure 1

Battery

Relocation

Bracket

P/N

02981725

Figure 2

Figure 3

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Figure 4

Section 5 - 2

Exhaust / Muffler Relocation

Exhaust / Muffler Relocation:

1. Remove The Exhaust . The Exhaust reloca-

tion kit will include a new mounting bracket, Bolting hardware, replacement exhaust pipe from turbo to muffler. The Muffler needs to be removed first (See Figure 5). Remove the Exhaust pipe to turbo (See Figure 5). Remove the tractors factory Exhaust pipe mounting bracket (See Figure 6).

2. Install Exhaust Replacement Mounting

Bracket. The replacement exhaust mounting bracket will bolt in the place of the factory mounting bracket. The replacement bracket moves the exhaust inward towards the engine by about 5 to 6 inches. This is to give clearance of the boom and exhaust system (See Figure 7).

Tractor Factory Exhaust pipe to

Turbo

Figure 5

3. Install Replacement Exhaust Pipe. Install

the replacement exhaust pipe using the new clamp furnished in kit. Fasten the new exhaust pipe to the new exhaust bracket using the two factory u-Bolts that were used on the original exhaust pipe (See Figure 8).

4. ing the factory bolts and hardware. Check all the bolts and components to the exhaust for tightness and fit.

Reinstall the muffler to the exhaust pipe us-

Factory Exhaust

Mount Bracket

Figure 6

Figure 7

Maverick (NH TS-100A,115A ,125A/,35A Asy. Man) 01/05

Exhaust Bracket

Replacement

P/N 02980933

Figure 8

Section 5 - 3

New Exhaust Pipe

P/N 02980917

Fuel Tank Replacement

Fuel Tank Replacement:

1. Remove RH Rear Tire and Wheel. Use

proper Floor jack to lift the RH Rear Wheel, Support the tractor with proper jack stands rated appropriately for the tractors weight. The RH rear tire and wheel should be removed for this installation by using a hoist to support and lift the wheel and tire assembly. The tractors factory fuel tank is mounted behind the RH rear tire and wheel (See Figure 9).

2. Remove Tractors Factory Fuel Tank and

Mounting Brackets. The LH factory step will have to be removed from the tractor before attempting to remove the fuel tank, the step will not be reused. The factory fuel tank will need to drained of fuel. Use an appropriate and safe method for pumping out tank and for the storage of the fuel removed. The Tank is removed by loosening and removing the retaining straps that you will see around the tank from the out side. DO NOT Attempt to remove tank with fuel in it. Store the fuel tank in an appropriate safe place away from flames, extreme heat and or dusting dirty conditions. The Fuel Pickup and Gauge sending unit will need to be removed from the factory tank to be installed in the new replacement tank later (See Figure 10).

3. Install Replacement Fuel Tank Mounting

Brackets. Remove the factory fuel tank mounting brackets, there are two new mounting brackets that will be supplied to mount the new tank. There is a front and a rear bracket (See Figure 11 & 12).

Remove RH

Rear Tire &

Wheel

Figure 9

Figure 10

Front Fuel Tank

Bracket P/N

02982206

Figure 11

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Holes

Here

Rear Fuel Tank

Bracket P/N

02982207

Hole

Here

Figure 12

Section 5 - 4

Fuel Tank Replacement

4. Install Pick Up Tube & Gauge Sending Unit in

new Tank. The Pickup gauge sending unit from the factory tank will be installed into the new tank. This is recommended to be done before mounting the new tank to the tractor (See Figure 13). The new tank will have a fuel capacity of 51 gallons

5. Install the new mount brackets to the tractor

frame. The tank mounting brackets will bolt to the tractor the same as the factory brackets that were removed. Make certain that the brackets are installed correctly, the front bracket will have 2 outer holes (same as the tank see Figure 11 & 13). The rear bracket will have 1 hole in the outer end (same as the tank, See Figure 12 & 13)

Mounting

Tabs

Front

P/N 02982198

Pick Up Tube Unit

Tank

6. Install The new Fuel tank onto Tractor. The

new fuel tank with the gauge sending unit slide in on top of the new mounting brackets with the fuel cap to the front (See Figure 14). Connect lines to fuel pick up connections, connect wiring to fuel gauge sending unit. (See Figure 14)

7. Bolt Tank to the Mounting Brackets. Bolt the

tank to the mounting brackets, there are two bolts in the front bracket and one bolt in the rear bracket. (See Figure 15)

8. Install New replacement Step. The new Re-

placement step is a bolt on weldment that will bolt to the new fuel tank with four bolts, note: below the step is painted yellow for clarity only (See Figure

16).

Rear

Bracket

(1 Bolt)

Figure 13

Figure 14

Rear

Figure 15

Maverick (NH TS-100A,115A ,125A/,35A Asy. Man) 01/05

Front

Bracket

(2 Bolts)

Figure 16

Section 5 - 5

Frame Installation

Under Mount frame Asy:

1. Before beginning any repairs on this section make certain the boom is extended outward to

full extend and laying on the floor. Before removing the Boom Pivot Pin support the boom with an overhead hoist so as when Pie is removed boom can be lifted out of the way. NEVER REMOVE ANY PINS OR BOLTS unless boom is supported at pivot end and head end is resting on the floor.

2. The under mount frame asy is made up of the Turret, Center Section Frame Weldment,

Boom Mount, Swing Cylinders, Swing Cylinder Trunnion Mount, Turret Cylinder Link and Counter Weight.

3. The Turret Asy will be shipped assembled to the Boom mount with the hoses and cylinders

plus attaching hardware assembled to it.

4. The Swing Cylinders have replaceable mounting bushing which can be replaced by

removing the bottom cover and trunnion mount weldment. The Cylinders can be dropped down enough to replace the bushing. The replace the Trunnion Mount weldment. Also by removing the cylinders the Turret Cylinder link can be removed.

5. The Turret assembly has a large bearing assembly bolted to it and then bolted to the Boom

Mount. This Bearing CANNOT be removed (or replaced ) unless the Boom is disconnected from it first. When disconnecting boom make certain the boom is supported as not to fall (See Step 1). The Bolts retaining the turret to the bearing and the bolts connecting bearing to the Boom Mount MUST be torqued to the required specification, This is very critical. See the Bolt Torque Chart in the beginning of this manual.

6. DO NOT remove any mount pins and/or bolts unless the components are supported properly

to prevent them from falling

7. The Turret Bearing Assembly has 3 grease fittings, each 120° apart. All three of these grease

fittings must be greased because of the diameter of the bearing this to ensure an even distribution of grease though out the diameter of the bearing assembly.

8. If the hoses for the swing cylinders are disconnected or replaced make certain that they are

reconnected correctly as shown in this section (Swing Cylinder Hose Routing). If the hoses are not connected correctly the swing will not function correctly.

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Section 5 - 6

Under Mount Frame Asy

(24 & 30 ft are the same except for the LH weight)

Turret Asy, Machined

Turret / Boom Mount Pin

Frame Installation

30 ft model only

LH Counter Weight

Lift Cyl Pin

Weight Attaching Pin, Long Pin

Boom Mount Attaching Pin, Long Pin

Turret Cylinder Link

Center Section Frame Weldment

Boom Mount Attaching Pin, Medium Pin

Boom Mount Attaching Pin, Short Pin

Boom Mount, Machined

Swing Cylinders

Swing Cylinder Pivot Bushings

Swing Cylinder Trunnion Mount Weldment

Swing Cylinder Cover

Maverick (NH TS-100A,115A ,125A/,35A Asy. Man) 01/05

Section 5 - 7

Frame Installation

Frame Installation:

1. Frame Components. The frame will include

the rear axle mounts, a LH & RH Frame rail. Two front frame mounts, a LH & RH. One center frame weldment. (See Figure 17, 18, 19, 20 & 21)

2. Install Frame Components. The Frame

components will only fit one way. The Frame components are a Bolt together assembly no welding will be required. The Frame components will bolt together and to the tractor using mostly 3/4" and/or 20 mm bolts. Each 3/4" & 20 mm bolt will use hardened flat washers, one on the head side when bolts go into the tractor castings. Two washers used when bolts use a nut and go through the frame. These hardened washers are important.

LH Rear Frame

Mount Weldment

P/N 02982006

Figure 17

Figure 18

RH Rear Frame

Mount Weldment

P/N 02982005

RH Front Frame Mount Weldment

P/N 02982015

Figure 19

Center Frame

Weldment

P/N 02981168

LH Front Frame

Mount Weldment

P/N 02982014

Figure 20

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Figure 21

Section 5 - 8

Frame Installation

3. Install Rear Frame Mount Rails. Rear frame

rails consist of a LH & RH. We have started with the Left Hand Rail. The three point lift stabilizer brackets will need to be unbolted on both sides. In the illustration for the LH side we installed the frame with the LH rear tire and wheel still removed, this was done for clarity not because the wheel needs to be removed. Using a floor jack to lift the rail up under the rear axle (Stabilizer brackets for three point have been unbolted). Install the bolts up and into the three point stabilizer bracket and the tractors rear axle housing and snug the bolts down. Support the frame rail with a jack stand (or leave the floor jack under it). (See Figure 17 & 22).

The RH Rear Frame Rail will basically install the same, bolts up under the tractor axle housing with the three point stabilizer bolt back up under frame rail (See Figure 18 & 23). The RH Rail looks different at the rear because the boom rest will bolt here later.

4. Install Front Frame Mount Rails. The Front

Frame mount rails will consist of a RH & LH (See Figure 19, 20, 24 & 25) These will only fit one way as they have a gusset reinforcement on one side that will be showing to the outside when installed. These can be lifted by the technician installing them. The LH and RH will install the same way, Using 4 bolts each that screw into tractor casting on the side of the tractor (See Figure 24). Make certain that all 3/4" and 20 mm bolts have hardened flatwashers on them.

LH Rear Frame

Mount Weldment

P/N 02982006

Figure 22

RH Rear Frame

Mount Weldment

P/N 02982005

Figure 23

3 Point Stabi-

lizer Bracket

RH Front Frame Mount Weldment

P/N 02982015

Figure 24

Maverick (NH TS-100A,115A ,125A/,35A Asy. Man) 01/05

LH Front Frame

Mount Weldment

P/N 02982014

Figure 25

Section 5 - 9

Frame Installation

5. Install Center Frame Weldment. The Center Frame Weldment has a front and a back side (LH

& RH side). The Center frame must be installed with the two openings (See Figure 26) toward the front of the tractor. These openings are to allow for the movement of the swing cylinders when moving the boom to the boom rest position.

IMPORTANT NOTE: When bolting the center frame up to the front and rear frame mounting rails the bolts on the RH turret side must have the bolts installed from the bottom with the bolt heads on bottom under center under frame and the nuts on top (See Figure 27 showing nuts on top). The reason the nuts must be on top is mounted. The Bolts that are used to mount center frame are not the same lentgh. The 8 bolts for the rear fame bracts (bolts that face the rear of the tractor) will be 3/4" X 3-1/2" long. The other twelve bolts will be 3/4" X 2-1/4" long. All 20 Bolts that at are used to mount center frame MUST have hardened flat washers install on both sides, one under Bolt Head and one under Nut (See Figure 26 & 27)

Using floor jacks (or Fork lift) position the center frame weldment up under the tractor (See Figure

27). The center frame weldment will bolt to the front and rear mounting rails on both sides. Make Certain to use hardened flatwashers on all 3/4" and 20 mm bolts, when using nut on bolts it will need two hardened washers, one on each side (See Figure 27) . Double check the frame mounting bolt tightness.

so the bolts will not hit the swing cylinders when the turret assembly has been

RH Side of Tractor

Front Mounting

Holes use 3/4" X

2-1/4" bolts in

these 8 places

Install with these openings to front of tractor

Front of Tractor

Rear Mounting Holes use 3/4" X

3-1/2" bolts in these 8 places

Rear Top Mounting Holes use 3/4" X 2-1/

4" bolts in these 4 places

Rear of Tractor

LH Side of Tractor

P/N 02981168 Center Section Under Mount Frame Wldmnt

Rear View

Figure 26

6. Install Boom Rest Weldment. The boom rest weldment for the 24 foot boom and the 30 ft.

boom are not the same (See Figure 29). The boom rest weldment bolts to the RH Side on the Rear Frame mount weldment behind the tractor axle weldment (See Figure 30). It is recommended that this be installed using an overhead hoist and supported by the hoist until boom rest and support brace (See Figure 28 & 30) are completely installed. The Boom Rest Support also serves as the top axle strap for the RH Axle mount (See Figure 30).

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Section 5 - 10

Frame Installation

7. Install LH Axle Strap. The Axle Strap bolts

down over the top of the Axle (LH Side) and bolts run through the Rear Frame rails. The RH Side the axle strap is part of the boom support brace weldment and also bolts down over the axle with the bolts through the rear frame rail (See Figure 30 & 31)

Make certain that all the bolts mounting the frame components and the boom rest are properly torqued, see the bolt torque chart.

8. Reinstall LH Rear Tire and Wheel. Reinstall

the LH rear Tire and Wheel now if it has not already been done. Use a hoist to lift and secure the rear tires is recommended as they are very heavy.

Boom Rest

Support Weldment

P/N 02982022

(f/24 ft or 30 ft.. boom)

Bolts to

boom rest

Shown from LH

side of tractor

Front

Rear

Figure 27

Boom Rest

Weldment

P/N 02982314

(f/24 ft. boom)

P/N 02982025

(f/ 30 ft. boom)

Figure 28

Bolts to top of

Boom Rest Support

& Axle Strap

Weldment

Figure 30

Maverick (NH TS-100A,115A ,125A/,35A Asy. Man) 01/05

tractor axle

Boom Rest

Figure 29

LH side of tractor Upper

axle strap

P/N 02980694

Figure 31

Section 5 - 11

Frame Installation

Counter Weight Installation 24 & 30 Foot Boom:

1. Counter Weight (CWT) Installation. The Counter weight (See Figure 1 ) mounts on the LH side Under

Frame Weldment. Its is retained with three pins, the long pin on top, the short pin at the rear and a short pin at the front. Using a hoist or other sufficient lifting device align the weight with the frame. The Frame for the weight will slide over the under frame until the upper long pin is aligned with the mounting tube of the weight and the mounting tubes of the under frame. Install the long mounting pin. The front and rear pin holes should be aligned, install the short pins front and rear. The short pins are retained using a nut and bolt. The long pin uses two large cotter pins, install cotter pins and bend end of them to secure them. (See Figure 32 , 33 & 34)

2. Additional Counter Weight (CWT) Installation: The 30 foot boom model has an additional bolt on weight

at the counter weight. This additional weight bolts to the weight weldment on the 30 foot model only (See Figure 32)

Weight Attaching Pin, Short Pin Rear side

Weight Mount Attaching Pin, Long Pin

Center Section Under Frame Weldment

Figure 32

LH Counter Weight 24 or 30 Foot Boom

Weight Attaching Pin, Short Pin front side

Additional bolt on Weight Used on 30 ft boom models only

3. Wheel Counter Weight (CWT) Installation: The Wheel counter weight is in addition to the frame

mounted counter weight, they both must be used together, the 30 foot boom will have an additional frame counted counter weight bolted on, (See Figure 32). All these weight are in addition to adding liquid weight into the Left rear tire. The proper amount of counter weight is not complete until all these weight have been installed.

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Section 5 - 12

Frame Installation

Figure 33

Figure 34

Turret Assembly Installation 24 & 30 Foot Boom:

1. Turret Assembly. Theturret assembly is

shipped assembled with the hydraulic swing cylinders, hoses, pivot bearing assembly, boom mount weldment and mounting pins installed (See Figure 35 & 36).

2. Under Frame Weldment. The Under frame

weldment center section is designed for the turret assembly to mount on the RH side. Remove the one long mounting pin and the front and back short mounting pins (See Figure 36 & 37). Check to make certain the mounting bolts mounting the center ubder frame weldment are installed with the bolt heads unter frame weldment and nuts are on top visible looking down, if they are in wrong the swing cylinders will hit the bolts causing damge to cylinders and bolts. (See Figure 37)

Turret Mount Attaching Pin, Long Pin

Center Section Under Frame Weldment

Turret Mount Attaching Pin, Long Pin

Figure 35

Maverick (NH TS-100A,115A ,125A/,35A Asy. Man) 01/05

Turret Attaching Pin, Short Pin, one Front side and one rear side.

Figure 36

Section 5 - 13

Frame Installation

3. Turret Assembly Installation. Theturret assembly mounts on the RH side onto the center section

under frame (See Figure 36 & 37) . Using a hoist (or other lifting device) lower the turret assembly until it is level with the underframe. Slide the turret assembly inward toward the under frame until the retaining pin tube on under frame an turret assembly align. Installthe long upper retaining pin and then the two small front and rear pins. The long upper pin is retained with two cotter pins that need to be bent over on the ends. The short pins are retained with nuts and bolts (See Figure 36 & 38).

Figure 37

Figure 38

4. Turret Assembly Grease Fittings. The turret assembly has three grease fittings around the OD of

it. The grease fittings are 120° apart, this is to make certain that the bearing will be greased all the way around because of the large diameter of the bearing. This bearing must be greased before unit is put into service. It is easier to get to grease fittings now than after boom has been installed. On the under side of the turret assembly are the grease fittings for the swing cylinder pivot mounts, these need to be greased before operating the unit. Also there is a bolt on cover on the under side of turret that will be installed (See Figure 40) at a later time. Greasing the cylinder pivots will need to be done before the cover is installed (See Figure 39) and the boom swing stop will need to be adjusted, but this cannot be done until a later time making it best to leave this cover of until then. After greasing components at assembly of unit operator should consult the operators manual for maintenance requirements.

Figure 39

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Figure 40

Section 5 - 14

Front Axle Stabilizer Installation - 30 FT Model (Standard)

Front Axle Stabilizer Kit Installation:

1. Install Front Axle Stabilizer Kit (Kit P/N 02981895). The front axle stabilizer kit is standard on the

30 foot model. The front axle stabilizer kit will consist of all brackets and hardware to install to front RH side of 4 wheel drive axle RH side of tractor frame

This kit is tied to the oil supply at the Lift Cylinder for the boom, the upper pressure supply hose (# 4 hose with blue plastic tie) is tee'd to the "B" port of valve for the lift cylinder and connected to the Base end of the stabilizer cylinder. The lower Hose is connected to the rod end of the cylinder and is connected to the tank return hose at the tank. Install the cylinder with the rod end toward the axle and the base end of cylinder up to the bracket (item 3) bolted to tractor frame. Number 4 hose with a blue plastic tie at the front side of tank (See Figure 41 through 48).

The Brackets bolt to the tractor axle and form a clamp around front axle housing (item 1 & 2). The Stabilizer cylinder is charged only when the boom lift cylinder is activated and is controlled automatically with the boom lift controls.

The three axle brackets are as follows Item Part No Qty Description

1 02983143 1 Top Axle Bracket 2 02983144 1 Bottom Axle Bracket 3 02982330 1 Stabilizer Support Bracket 4 02981316 1 Hydraulic Cylinder See Mount Kit & Component ID section for Axle Stabilizer complete component and hardware kit list.

2. When installed correctly the three components

should be aligned as show (See Figure 44). The upper and lower bracket should have the same gap between them in front as in the back to make certain brackets are even. Check the hose connections and all mounting bolts for the axle stabilizer kit.

P/N 02983143 New front axle bracket (top)

Back side

P/N 02983144 New front axle bracket (bottom)

RH Front Tire side

Figure 41

P/N 02982320 Cyl Support Weldment (Included in Front Axle S tabilizer Kit Only)

Figure 42

Engine side

P/N 02981316 Cylinder Assembly

(Included in Front Axle S t abilizer Kit Only)

Pressure Hose End

Return Hose End

Support Bracket End

Figure 43

Maverick (NH TS-100A,115A ,125A/,35A Asy. Man) 01/05

Axle End

Upper Cyl

Mount Bolt

Lower Cyl

Mount Bolt

Upper Clamp

Mount Bolt

Figure 44

Section 5 - 15

NOTES

Maverick (NH TS-100A,115A ,125A,135A Asy. Man) 01/05

Section 5 - 16

Section 6

MAVERICK

New Holland Tractor

TS-100A,115A,125A,135A

Maverick (NH TS-100A,115A , 125A, 135A Asy.Man) 01/05

Optional

RH Lexan Door

Inst allation

Section 6 - 1

Optional Lexan RH Door Kit Installation

New Holland "TS" Series Optional Door Kit No. 02980888

RH Lexan Door Kit. Option P/N 02980888

Remove & Dis-Assembly of Factory Stock Glass Door.

that you use enough help to remove it safely. It is recommended to use three people as shown (see figure 1) Use some type of container to hold all removed components and hardware, some will be reused & some will not. The Assembly procedure and the dis-assembly procedure is the same except in reverse. The RH Door is a mirror image of the LH Door which can always be used for reference.

2. Disconnect the gas shock (it is inside) from

the door pipe brace, disconnect it at the door end.

3. With someone supporting the door at the

bottom and some one to hold the nuts inside loosen the upper hinge bolts and the lower hinge bolts (See figure 1) CAUTION! The lower hinge bolts also hold the Pipe brace to the window, with these hinge bolts removed DO NOT lift or hold window by using this brace, it could put glass window under stress causing it to break. When Removing Bolts from hinges make a note of the large rubber washer and the large steel washer and there location as they will be reused in the same location and order they are in. (See Figure 1).

4. Lay Removed door on a soft protected

surface for the disassembly of the latch and brace components (See Figure 2). (Item 1) This is the

2) This is the Latch and retaining bolts, nuts & washers for the latch assembly, remove them. When removing the latch you will need to lift and turn it in away that you can get the inside handle rod (connected to item 5) pulled out of its hole in the latch not the handle item 5. (Item 3) Remove the upper retaining nut and flat washer (this flat washer will not be reused) (Item 4) Remove the lower handle retaining bolt , there will be rubber washer (that will not be reused) under the steel washer. (Item 5) The outer door handle can be removed now, there will be rubber pad at the upper (larger portion) end between the glass and the handle that will have a thin pipe type spacer in it. Also the lower handle mounting bolt will have a smaller rubber pad with a metal insert in it that is between the glass and handle. (Item 6) This is the inner door handle and WILL NOT be removed from the pipe brace weldment. (Item 7) This is the pipe brace weldment and extends from latch / door handle to the lower hinge bolts. At the lower hinge bolts there will be a rubber pad between glass and metal plate, this pad will be reused. (Item 8) This is the lower mount for the pipe brace (See Figure 4 & 5 for fastener) and will be the last fastener removed, this fastener takes a special tool to remove it. See your New Holland Dealer for instruction & Removal Tool.

To remove the factory door make certain

plastic cover for the latch and will snap off. (Item

Figure 1

Figure 2

Maverick (NH TS-100A,115A , 125A, 135A Asy.Man) 01/05

Section 6 - 2

Optional Lexan RH Door Kit Installation

New Holland "TS" Series Optional Door Kit No. 02980888

5. Lay the New Lexan Door (P/N 02980803) on a

protected surface (here we used Bubble Wrap Packing material). Install the push-on weather seal material (P/ N 02980889) with the soft rubber side up as shown. This weather seal is designed to push-on with out adhesive, but you can use adhesive if you wanted. Where the two end meet an adhesive should be used to jion the two end. Use an adhesve that is rubbery and dries to the touch. The 3M Co. makes a good Black weather strip adhesive that will work well for this (See Figure 3)

6. Install the pipe brace on top of door.( Item 8)

This is the lower fastener (See Figure 4 & 5) and will need to be installed first, make certain to put the rubber washer back on fastener, install the fastener untill the shoulder of the fastener is into the hole in the door. DO NOT Tighten Fastener at this time.

7. Install Outer Door Handle and fasteners. (Item

9) This is the outer door handle, before it can be installed

Item 10 must be modified (Item 10) This is the upper mount of handle rubber pad. There is a shoulder on it that must be cut off before it can be used, using a sharp knife cut this shoulder off, The tube Spacer shown with item 3 goes through the hole of item 10 and then slide over threads of item 9.

8. Push the lower rubber (with steel insert in it)

into the hole of the door, holding the handle in place fron the bottom start the bolt & washer item 4, there was a rubber washer used under item 4 bolt. In some cases it can not be reinstalled, check bolt engage ment to see if it can be used.

Figure 3

Figure 4

The two ends meet here

Figure 5

Maverick (NH TS-100A,115A , 125A, 135A Asy.Man) 01/05

Inner Latch Actuater Rod

3 9

Figure 6

Section 6 - 3

Optional Lexan RH Door Kit Installation

New Holland "TS" Series Optional Door Kit No. 02980888

9. Insert Handle into door from bottom, make

certain item 3 tube spacer is inserted through hole of door and through hole of pipe brace, there is a rubber pad to reinstall between pipe brace plate at upper latch and door (See Figure 6) Install item 3 Nut onto handle, Note when disassembled there was a large flat washer here. The flat washer WILL NOT be used in reassembly. Snug the item 3 nut but DO NOT tighten.

10. Lifting the Latch and turning to the correct

angle slide the latch actuated rod through the hole on the latch. Turn and lower latch in place. Using the original Bolts, Washers and nuts bolt on the latch to pipe brace (See Figure 7). These can be tightened at this time.

11. Prepare the Door Hinges which are still on

tractor (See Figure 8) by making certain the round rubber washers are in place, the ID of washer will have the shoulder of the hinge sticking through it as shown (See Large Rubber Washers Figure 8). The lower hinge uses a two hole oblong rubber pad between door and pipe brace.

12. Install new door, make certain all rubber

pads are in place, Holding door push the lower hinge up to door. Install the new 5/16" NC X 1-3/4" Gr. 5 Bolts P/N 00021900 from kit, Use the old small OD structural flatwashers that were removed from original door. The Top Hinge on the inside will have a round rubber washer pad and a large round steel washer. The lower hinge should have the oblong rubber pad with two holes in it. Put the New 5/16" NC locknuts with any washers that were remove form original door. While supporting the door (see Figure

9) tighten the hinge mounting bolts, Do this slowly and carefully making certain the shoulder oh hinge goes through hole in door. DO NOT over tight these bolts. Tighten the other fasteners on the door brace and latch handle. If Door is not fitting right the door striker bolt on the inner cab frame is adjustable by loosing it up and moving it in or out as needed. USE CAUTION when cleaning the Lexan door, DO NOT use any cleaner that is harmful to plastic, Read all directions for cleaner use befor using it, if using it for the first time on the Lexan door, test it in a small out of the way place. DO NOT use rough material such as paper towels to clean Lexan Door.

Latch Retaining Bolt, Washer & Nut

Inner Rubber Pad

Figure 7

Large Rubber Washers

Lower Hinge

Figure 8

Figure 9

Latch

Inner Latch Actuater Rod

Large Rubber Washers

Upper Hinge

Maverick (NH TS-100A,115A , 125A, 135A Asy.Man) 01/05

Section 6 - 4

Section 7

MAVERICK

Standard Wheel Weight

Auxiliary Wheel W eight

Inst allation

New Holland Tractor

TS-1 15A,125A & 135A

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 7 - 1

Rear Wheel Counter Weight

Fill Left Rear Wheel with Liquid:

The Left Rear Wheel must be filled with liquid. Alamo Industrial recommends a Calcium Chloride Water Mixture. The recommended Ratio of a 30 / 70 mix (30% Calcium Chloride and 70% Water), this mixture will add weight at about 10.5 lbs per gallon. Follow the Mixture procedures furnished by the Manufactured of the Brand of Calcium Chloride that you are using. It is also recommended that a trained person installs the calcium Chloride. Calcium Chloride must be added in addition to the Steel Wheel Weight and the Counter Weight that hangs on the Left Side. It is Not recommended to use straight Water in the Wheel as this would not provide protection against freezing. A 30/70 Calcium Chloride Water mixture provides antifreeze to approx -50 deg. F. below 0.

Rotate Washer to Match Bolt

Circle dia. and Washer fits into

Wheel Weight Slot.

Bolt is shown extra long in

drawing for illustration only

Item Part No. Qty Description

1 02979603 3 Hex Head Bolt, 7/8" NC X 16" 2 02971569 3 Wheel Weight Washer, Special 3 02970758 1 Wheel Weight Casting, 1400 lbs. 4 5JRC1490 3 Locknut, Top Lock 7/8" NC

Note: some Older Units used a All Thread Rod with Hex Nuts Lock Nuts, with Flat Washer and Lock washer. This was replaced with the Bolt Type shown above. These Bolt and Nut combinations will replace the old All Thread type.

Figure 1

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 7 - 2

Rear Wheel Counter Weight

Installing Wheel Weight

1. This Wheel Weight is 1400

lbs. Always use caution when working with it.

2. Locate the three Holes in

LH Rear Wheel. Make sure these holes are 15/16" dia. if not, they must be reamed out.

3. Lift Left Rear Tractor

Wheel till it just clears the ground. This will allow the Wheel to be rotated when aligning mounting holes for Weight.

4. Using a forklift, lift Wheel

Weight into Wheel. When Wheel Weight is centered in Wheel Secure Forklift and Set Parking Brake on Forklift. Insert one of the three bolts through Weight and Wheel (Rotate Wheel to align holes if needed). Install a Hex Lock Nut on inside. Insert the other two Bolts through Weight and Wheel and start the other two Locknuts. Do not tighten yet. (See Figure 2)

Wheel Weight Mntg

Locknuts

Figure 2

5. Looking at the outside

make sure the three special Washers (Figure 1 Item 2) are aligned with the Slots in the Wheel Weight. Tighten the three Bolts now. You will need an assistant to hold the other Side while you are tightening the Bolts. While tightening Bolts, check to make sure the three special washers are seated correctly. If these Bolts are tightened and washer are not seated into the recess on Wheel Weight, damage will occur. (See Figure 3)

Wheel Weight

Special Washers

Mounting Bolts

Part # 02971569

(3)

6. Remove forklift away from

Wheel and Weight. Recheck tightness of Wheel Weight retaining Bolts. Bolts should torque to 500 ft. lbs.

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Figure 3

Wheel Weight

1400 lbs.

Section 7 - 3

Auxiliary Rear Wheel Counter Weight

Installing Auxiliary Wheel Weight Kit.

1. The Auxiliary Wheel Weight is made up of three steel plates and mounting hardware. Each

Auxiliary Weight weighs approx 136 lbs. When all three are installed on the existing 1400 lb. weight it will increase the wheel weight by 408 lbs. This makes the total bolt on wheel weights equal 1800 lbs. This will not include the amount of weight to the tire from the installed liquid which, will vary with the size of the tire and the liquid that is added.

Auxiliary. Wheel Weight Kit No. 02976671 Qty Part No. Description 2 00012200 Lockwasher, 7/8"

2 00012300 Nut, 7/8" NC 2 00760266 Bolt, 7/8"-NC X 5-1/2 GR8 3 02976644 Auxiliary Wheel Weight Plate, 136 lbs Each

2. Install Auxiliary Wheel Weights. The Auxiliary Wheel Weight bolt to the larger 1400 lb. wheel

weight. There are two slots in the large weight that the 7/8" bolt heads will slide into. It is recommended that the tractor wheel is in position so these two slots has one facing front and one to the rear. Slide the two 7/8" bolts into the slots, the slots will prevent the heads of the bolts from turning. The Bolts in the large wheel weight will have to be aligned to the proper distance apart, to match the distance of the holes in the auxiliary weights. Slide the auxiliary weight over the two bolts, do this with all three weight for this kit. Install the lockwashers and hex nuts. Tighten the bolts to required tightness. See bolt torque charts in tractor preparation section.

Wheel Weight P/N 02970758

Figure 4

Auxillary Weight

Attaching Stots

Figure 5

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 7 - 4

Section 8

MAVERICK

New Holland Tractor

TS-100A,1 15A,125A & 135A

Joystick - Wire Harness

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

& Valve Installation

Section 8 - 1

Joystick / Electrical Mounting

Installing Wiring Harness and Joystick:

1. Preparing Tractor Floor Mat. First thing to do is remove the Battery Cables from Battery, Do

Not perform any work on Tractor or Boom Electronics unless this has been done. Raise the Floor Mat up on the RH Side by the RH Door, You will need to fold it back approx. 12 to 14 inches (See Figure 1 & 2).

DO NOT Tear or Cut any Holes in Rubber Floor Mat, as it will NOT be required. You may find a rubber plug or you may have to cut a hole with a hole saw, this will have to be decided during installation. If you need to cut a hole, check the under side of cab for any obstruction or any component that might be damaged before you cut the hole. The hole is going to have to be oblong in order for the plug to go through it. Measure Wire Harness plug Coded G1 to determine the size hole. In Figure 2 below the tractor had two holes from the tractor manufacturer, technician removed the rubber plugs and cut the space between the two holes to open it into one oblong hole. Check to make certain the installation will not interfere with the operators normal functions. (See Figure 1 & 2). Floor mat can be reinstalled by over wire harness with out cutting any holes in floor mat..

Pull Floor Mat

loose here

Cut Hole in flor of

cab if not one

already in it.

FIGURE 1

FIGURE 2

2. Remove Tractor RH Side Panel. Remove the side panel on the RH side of the cab so the wire

harness can be run down through and under top panel and will be covered when the panel is put back on (See Figure 3). Isert the end of the interior wire harness with the pug coded G1 down into the panel from top and out bottom of panel (See Figure 3 & 4).

FIGURE 3

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

FIGURE 4

Section 8 - 2

Joystick / Electrical Mounting

Locating Joystick and electrical components:

1. Joystick Assembly with Resister Harness. The joystick has the resister wire harness

attached to it when you received the joystick.

2. Emergency Stop Switch. The emergency Stop (E-Stop) Switch will be sent with the knob and

mounting nuts installed onto it. These will need to be removed when mounting switch.

3. Replacement Seat Arm Rest. The Tractor seats Rh arm rest will be replaced with a fabricated

one to mount E-Stop Switch and Joystick.

4. exterior harness connecting to the interior harness and running outside the cab to the pump and tank area at the front of the tractor.

5. the floor of the cab on the RH side. Lift Floor mat and check, if no hole (possible with rubber plug in it) a hole will need to be cut with a hole saw. If cutting holes in floor of cab always check under side of floor to make certain there are no components that will be hit and damaged by saw. DO NOT use a torch to cut holes in cab floor.

6. to gain access to connections and/or mounting of components. Do not remove any panels until instructed to do so.

Wire Harness. The Wire harness is in two piece, The interior harness inside the cab and the

Wire Harness through Floor of Tractor Cab. Some tractors may have a hole all ready through

Access Panels of Tractor interior. Panels in the cab will need to be loosened and/or removed

Installing Seat Replacement Arm Rest:

1. Replace RH Factory Arm Rest. The fac-

tory seat RH arm rest will be replaced with a weldment designed to serve as the armrest and mount for the emergency stop switch and the joystick assembly (See Figure 5, 6 & 7). Unbolt the factory arm rest and bolt on the replacement arm rest. The Arem rest is retained using the same type method as thr factory arm rest, this is what allows the arm rest to be raised up and down (See Figure

6) See the bottom of the welded replacement arm rest. It may be required to use a die grinder in slotted hole th help with alignment of retaining bolt. (See Figure 6).

2. Install Emergency Stop Switch. The emer-

gency Stop (E-Stop) Switch mounts into the arm rest in the smaller of the two holes. The Knob and mounting nut will need to be removed and the switch installed from the bottom of the arm rest. Replace mounting nut and knob (See Figure 5 , 7 &

3. Locate Joystick Assembly. The joystick

assembly has a flange around the bottom, it uses 4 screws to mount joystick to the arm rest. Lower the wiring of joystick down through hole in arm rest. Make certain the three plugs are in the hole and not being pinched. (See Figure 9 & 12).

Arm Rest Weldment

P/N 02981415

FIGURE 5

Under Side of

Welded Arm

Rest with

Slotted Hole

FIGURE 6

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 8 - 3

Joystick / Electrical Mounting

Resistor Harness P/N 02981990 Is attached to the Joystick when it is recieved.

Pin Numbers & Locations

Blk

Yel/Red

Blk/Red

Wire Harness Side

Brn/Blk

Vio

Red/Wht

Blk/Wht

Blu

Red

Joystick Side

FIGURE 7

P4-3

P4-2

Yel/Red

Blk/Red

Blk

Z AXIS

P4 P2

H2(-)

H12

P2-2

P2-3

Vio

Y AXIS

H5(T4)

H6(T5)

H10

H11

P4-1

Brn/Blk

H3(T2)

H4(T3)

P2-1

Red/Wht

H1(+)

P3-2

P3-3

Blk/Wht

Blu

X AXIS

PCB Assembly

P3-1

Red

Pin Numbers & Locations

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

Section 8 - 4

Joystick / Electrical Mounting

4. Resister Harness to Joystick. The Joystick will be shipped with the resister Harness

connected to it as an assembly. (See Figure 7 & 8) The Interior wire harness plug has 2 connectors on it A 9 Pin Connector (labeled J1) and a 6 Pin Connector (labeled P1) . These two connections will plug into the interior wire harness with the same code

when the interior harness is installed. (See Figure 7 &

8). The Interior harness is run under the RH side Panel and along the rear panel. You will need to cut a notch in the rear panel to allow the harness to pass between the two panels where they meet near the bottom.

5. Interior Wire Harness. The interior wire har-

ness has all the connections needed to connect interior components. The RH side interior panel of cab will need to be loosened and/ or removed, this allows mounting of the XS module (See Figure 6 & Next pages for wiring schematics) continued in step 6

Switch

Rear

Panel

FIGURE 7A

Switch Mounting Nut

Depth Control Clip

Knob

Knob Plug

FIGURE 8

Wire Fasteners (4)

Switch Asy Complete

Knob Retaining

Screw

FIGURE 9

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

FIGURE 10

Section 8 - 5

Joystick / Electrical Mounting

6. Interior Wire Harness (continued). The interior wire harness schematic (See Figure 11 & 12)

shows the wire harness as it is run through the cab. The XS Module will need to be mounted inside the cab, the best place is behind the RH side panel (See Figure 6, 9 & 12). The wire harness will need it be put under this panel, also with the connectors in the

appropriate place to connect with the interior components. The harness to the joys stick will need to be run along the panel at the back of the cab.

two wires that run under the floor mat, the positive wire MUST connect to the ignition key switch of the tractor for a power source. DO NOT Connect the positive wire anywhere else (See Step 9 & Figure 14 wire CC1).. The plug (G1) will need to run through the floor

to the exterior of the cab, it will connect to the plug (G2) of the exterior harness. (See figure 11, 12, 13 & 14). Secure wires under arm rest.

Joystick P/N 02981347 with Resister Harness

CAUTION: The Harness has

FIGURE 11

FIGURE 12

PCB

7. XS Module P/N 02981533. The XS module

(See Figure 13) mounts in side the tractor cab behind the right hand side panel (See Figure 13 &

14). The Connections (Three Separate Pugs, Can 1, Can 2 & D) will be inside the side panel after it is reinstalled and will not be visible unless you remove the side panel (See Figure 14 , 16, 17 & 18 ). The XS Module does not have a mount bracket, it will need to be mounted by the assembly technician inside panel where it will be out of the way, not interfere with any tractor components and be secured. It can be tied in or bolted. The Only Plugs protruding from behind RH Interior panel shoud be the plugs for the display control box (See Figure 14, 16, 17 & 18).

P-1

FIGURE 13

To Activate Trigger Push In

3 2

6 5

XS Module

P/N 02981533

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

Section 8 - 6

Interior Wire Harness Schematic P/N 02981375B

Remove console cover, tie strap

XS Module P/N 02981533 inside

console

D ( XS Module

Connector)

Can 1 ( XS

Module

Connector)

Can 2 ( XS

Module

Connector)

J1 Joystick Connection (9 Pin)

P1 Joystick Connection (6 Pin)

CC1 +Pos.

Key Switch

Connection

CC2 - Neg.

Chasis

Ground

Code Connection

Can 1 XS Module Can1 Connection (2 of 3 Connections) Can 2 XS Module Can 2 Connection (3 of 3 Connections) CC1 + Positive Key Switch Connection (MUST Connect to key switch wire) CC2 - Negative Chasis Ground D XS Moudule C1 Connection (1 of 3 Connections) G1 Exterior Harness G2 Plug (coonnects Interior & exterior Harness) J1 Joystick Resister Harness (9 Pin Plug) K3 Control Box Display Connection (1 of 2 Connections) M1 E-Stop Switch (use A or B of Switch) M2 E-Stop Switch (use A or B of Switch) X 1 Control Box Display Connection (2 of 2 Connections

FIGURE 14

K3 ( Control Box Display

Connection

X1 ( Control Box Display

Connection

G1 (Connects to G2 Plug

of Exterior Wire Harness)

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 8 - 7

Joystick / Electrical Mounting

8. Wire Exterior & Interior Harness Schematic. The wire harness schematics and instructions

will need to be used together to install the wire harness. The interior Harness and the exterior harness will connect together with one plug connection. Figure 14, 16,17, 18 & 19) pertain to the interior harness, Plugs have codes on them to identify where they connect, the connections will have codes on them to identify where the connection goes. The code on the plug and the code on the connection may not be the same, see the code connection listings in the illustrations to identify the connection location.

9. Plugs for Display Control Box. The wire plugs for

the display control box will come up through the small cover on top of the right hand side panel (See Figure 16, 17, 18 & 19). When the small cover is replaced the plugs and wires need to be moved to the back of the panel near the RH rear cab post (See Figure 17 & 18). Cut a notch in the panel at the rear so the cover will fit down around the wire harness plugs (See Figure 17 & 18). Also the rear tractor panel will need a notch cut in it to allow the wire harness to be installed between the side and rear panel. Cut this notch near the bottom of the rear panel (See Figure 19)

Display Control

Box Connections

Can2

Can1

XS Module

P/N 02981533

FIGURE 15

Cut Notch in Small cover panel to

allow harness to fit through

FIGURE 16

Display Control

Box Connections

FIGURE 18

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

FIGURE 17

Rear

Panel

Wire Harness to Joystick

FIGURE 19

Section 8 - 8

Interior Wire Harness Schematic P/N 02981375B

CAN 1 XS

MODULE

NOTE: See Figure 11 for

listing of Code Locations

CAN 2

XS MODULE

FIGURE 20

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 8 - 9

CC2

CC1

connect to Key switch

(Must

wire)

Interior XS Module & Display Control Box

9. Connect Wires to Key Switch. There are two wires on the interior Harness that connects to the

key switch (Wires CC1 and CC2) these need to be routed under floor mat and in behind dash panels.

CAUTION:The positeve wire (CCI) MUST be connected to the wire from the key ignition switch of tractor for an electrical power supply. DO NOT connect the power supply wire (CC1) to any other power supply as it could cause interference with the electronic components due to a power surge

10. Tractor RH Side Panel reinstalled. When the

tractor side panel is reinstalled the plugs (2 Plugs K3 & X1) for the Display control box will be sticking up out from be hind the panel (See Figure 21), Run the wiring harness in from behind panel, use caution to not let wire harness interfere with or be in a position to damage or be damaged by other tractor components behind panel.

11. Install Display Control Box Mount Bracket. The

display mount control box mount to the Rh rear cab post (See Figure 22 & 23) . There are two plastic plugs in the plastic cover over cab post. Remove these two plug to expose two 10 mm bolt holes in cab post. Position the mounting bracket with the bent end at the post and using the 10 mm bolts furnished bolt the bracket to the post.

12. Install Display Control Box. The display control

box will bolt to the mount plate P/N 02982324 that is mounted to the RH Rear Cab corner post (See Figure 22, 23 & 24). There is a wire setion on disply control box that will pug into the two plugs on the interior harness plug KS & X1 (See Figure 21 & 22) The display control box cannot be tested until the interior and exterior wiring harness installation has been completed and all the other installations of unit have been done. DO NOT reconnect battery cables at this time, the electrical wiring is NOT done.

Display Control

Box Connections

FIGURE 21

P/N 02982324 Mount Plate - (Iqan) Display Control Box Mount

Cab RH Rear

Corner Post

FIGURE 22

Bend Upward 60° Here

P/N 02982324 Mount Plate - (Iqan) Display Control Box Mount

FIGURE 23

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

Display

Control Box

FIGURE 24

Section 8 - 10

Exterior Wire Harness Schematic P/N 02981375A

13. Exterior Wire Harness. The exterior wire harness will run from the cab of the tractor to the front.

It will include the wiring for the sensors at the pump. The connections for the valve actuator assemblies. The electronic modules that are mounted to the right side of the tank and the module on the front of the valve. The plugs have codes labeled on them, there is a matching code on them where the plugs are connected. Some plugs have instructions and/or color codes. Read the next pages of this manual to become familiar with the wire harness connections. There are two electronic modules bolt on the tank assembly in the front of the tractor. The XT2 module bolted on the right hand side of the tank and the XP2 bolt on the LH side in front of the 6 spool valve. (See Figure 25, 27 & 28). The exterior wiring harness should be laid out and connections need to be start at the first connection coming from the tractor cab connection, this allows the harness to be moved around and under components as needed. NOTE; V1 Pump Solenoid 2 is only used when the Timbercat Head is installed and will be installed into plug next to Pump solenoid 1 which is used with all heads. Note: Unless the timbercat head is used only Solenid 1 will be installed which is Plug V1, leave plug T1 tie to othrer plug out of the way.

H1 & H2 ( Lock Valve Connection)

Y1 Connect to White Wire & Y2 Connect

to Black Wire ( Valve Filter)

W1 (Charge Filter)

G2 (Plug to Interior

Wire Harness)

R1 (Cooler Fan)

S1 (Temp Sensor)

E (XT2 Module)

FIGURE 25

Plug Valve Valve Label Function Label

AA1 Swivel B AA2 Swivel A AA3 Tilt A AA4 Tilt B AA5 Telescope A AA6 Telescope B AA7 Dipper A AA8 Dipper B AA9 Lift A AA10 Lift B AA11 Swing / Door A AA12 Swing / Door B

X1 & X2

(Return Filter)

Decal Below shows the Hose location and Plastic tie color on hose. Also the markings for the wire harness plugs on valve ("A" or "B") See Figure 18 & 18A)

FIGURE 26

Pump Solenoid

T1 (Sol 2) & V1(Sol1)

BB (Diverter Valve)

AA (See

Below)

F (XP2 Module)

NOTE; Decal, Stripes to Base and Solid to Rod end refers to the plastic ties on hoses only &

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

not electricl connections

Section 8 - 11

Exterior Wire Harness Schematic P/N 02981375A

AA1 Swivel Cylinder, CCW AA2 Swivel Cylinder, CW AA3 Tilt Cylinder, Down AA4 Tilt Cylinder, Up AA5 Telescope Cyl, IN AA6 Telescope Cylinder, Out AA7 Dipper Cylinder, Down AA8 Dipper Cylinder, Up AA9 Lift Cylinder, Down AA10 Lift Cylinder, Up AA11 Swing / Door AA12 Swing / Door BB Solenoid Valve Connection for Diverter Valve E Connector XT2 Module F Connector XP2 Module G2 Exterior Harness to G1 Interior Harness H 1 Lock Valve Connection H 2 Lock Valve Connection R1 Cooler Fan Connection S1 Temperature Connection Sensor T 1 Pump Solenoid 1 Connection V1 Pump Solenoid 2 (Only on Timbercat Head) W1 Charge Filter connection X 1 Return Filter Connection Y1 Common, Connect to White Wire at Filter Y2 Signal, Connect to Black Wire at Filter Z 1 Negative Chasis Ground

Connection Markings on Exterior Wire Harness:

AA11

AA9 AA7

AA5

AA3

AA12

AA10

AA8

AA6

AA4

AA2

FIGURE 27

AA1

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

Section 8 - 12

Exterior Wire Harness Schematic P/N 02981375A

Six Spool Control Valve

External Wire Connections for valve are marked "A" and "B" on Valve & AA1 thru AA12 on wire harness connections

Swing

Lift

Dipper

Telescope

Head Tilt

Head Swivel / Door

(To Diverter Valve)

Pressure

Supply

Port "P"

FIGURE 28

XP2 (Expansion, Power)

"B"

G/W

"A"

OR/

"A"

"B""B"

B/W

Y/W

"B""B"

"B"

G/W

Return

To Tank

"T"

"A""A"

R/W

"A""A"

XT2 (Expansion, Transmission)

Bolts on LH side

in front of Valve

FIGURE 29

14. Diverter Valve Wiring Connection: The plug for the diverter valve is at the end of the exterior

wiring harness and will be marked with code BB. The plug and wire will run down the LH side of tractor from the front mounted hydraulic pump / Tank. The diverter valve is bolted the the LH front Frame Mount bracket. The holes are already in the bracket and the diverter valve should have already been mounted. If valve has not been mounted it can be mounted now (See Figure 27, 28 , 31 & 38).

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

FIGURE 30

Section 8 - 13

Bolts on RH side

on side of Tank

Exterior Wire Harness Schematic P/N 02981375A

Diverter Valve Wire Harness Connection BB of

exterior harness connects here

Diverter V alve

Diverter Valve "C1" Port

to Swivel Cyl Base End Port (G/W Tie)

Valve "B" Port to

Diverter valve P1 Port

4 Through holes are

mounting holes

Valve "A" Port to

Diverter valve P2 Port

FIGURE 31

(G/W Tie)

(G Tie)

VS . 125/F

SAE 4

Diverter Valve "C4" Port

to Swivel Cyl Rod End

Port (G Tie)

Diverter Valve "C2" Port

to Door Cyl Base End

Port (Y/W Tie)

Diverter Valve "C3" Port

to Door Cyl Rod End

Port (Y Tie)

Connecting Oil Cooler And Fan Assembly to Exterior Wire Harness

15. Oil Cooler / Fan Assembly. The Oil cooler / fan assembly is for cooling the oil being returned from the Motor Case Drain. The fan is connected to the control box and is turned on & off automatically. It set to run on a program that will run the fan in the cooling rotation for a designated time, then stop, reverse the rotation (cycle to clean debris off of cooler, then stop and reverse the fan again and begin the cycle all over again.

The connection to the cooler on the exterior wire harness is marked with code R1. The connection from the fan will have two wires, a Blue (+ connection) and a black (- connection) (See Figure 32).

Exterior wire

harness connec-

tion marked R1

connects here

FIGURE 32

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

Section 8 - 14

Exterior Wire Harness Schematic P/N 02981375A

Maverick Sensor Connections:

1. Instrumentation The Maverick Boom utilizes

instrumentation for certain decision making activities. Listed below are the sensors included on this unit. Tank Temperature Sensor, Charge Pressure Filter Switch, Valve Pressure Filter Switch and Return Filter Switch.

2. Tank Temperature Sensor. The tank tem-

perature sensor monitors the fluid temperature in the area of the pump suction screens. the temperature is real time and is used on the network to accomplish certain objectives. The first, is to display on the interface while the cutter circuit is operating. The second, is to be used to control the electric fan on the hydraulic cooler. At any time the fluid level reaches 150° F. the fan is activated and remains activated until fluid temperature drops to or below the desired temperature (See Figure 33).

FIGURE 33

3. The Charge Pressure Filter Switch The

charge filter pressure switch has three wire coming out of it, a white , black and Blue wire. The Blue wire will not be used and will be cut off. The charge pressure filter switch is located at the filter in the charge loop on the hydrostatic pump (See Figure

34). The sensor monitors the back pressure created by the filter element when in use. When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operator for a filter element change of filter element.

4. The Valve Pressure Filter Switch The Valve

pressure filter switch is located at the pressure filter in the valve pressure circuit, between the closed center load sense pump and the control valve (See Figure 35). The sensor monitors the back pressure created by the filter element when in use. When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operator for a filter element change.

WARNING! This filter does not have a bypass. The element must be changed at the appropriate time to avoid element damage and system contamination.

FIGURE 34

FIGURE 35

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 8 - 15

Exterior Wire Harness Schematic P/N 02981375A

5. The Return Filter Switch. The return filter

switch is located at the return filter mounted on to the tank top. The fluid returning from the cylinder control valve is filtered before returning to tank at this location (See Figure 36). The sensor monitors back pressure created by the filter assembly while cylinder circuit is in operation. When the back pressure reaches 25 psi the switch will trigger and prompt the operator for a filter element change.

WARNING! This filter does not have a bypass. The element must be changed at the appropriate time to avoid element damage and system contamination.

6. Oil Cooler & Fan Assembly. The oil cooler /

fan assembly bolts to the tank rail mount bracket between tractor front axle and hydraulic tank. The mounting holes are in the tank rail mounting brackets (See Figure 37). There will be two hose connected to the cooler, one from the motod case drain to the cooler and one from the cooler to the tank return, These hose will have blue plastic ties on them.

FIGURE 36

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

FIGURE 37

Diverter Valve

Diverter Valve Plug

FIGURE 38

Section 8 - 16

Decal Mounting

Installing Warning and Instruction Decals:

1. Always clean windows before installing

decals. Windows must be dry and free of any oil, after cleaning do not touch windows before decals are installed. Take precaution to make sure decals are right side up and straight when installing them, they cannot be taken off and redone.

2. Identify Decals. Lay all the Decals out and ID

each one so you will know which is installed where. The Decals will have the Part Number on them in the lower corners. Decal No. Description 00763977 Notice to Owner 02964677 Important - Boom Rest 02963524 Attention - Boom Swing 02965093 Proper Engine Operating 02965262 Warning - Hose Burst 02967827 Multi - Hazard

02967827

FIGURE 39

3. Multi-Hazard - Danger Decal. This is in-

stalled on the Left Side Window of Cab on the inside to Drivers Left. P/N 02967827 (See Figure 39)

4. Warning Hose Burst Decal. This installs on

the Right Side Window of Cab on the Inside to Drivers Right P/N 02965262 . (See Figure 40)

5. Notice To Owner Decal. This installs on the

inside top rear of Right Door Glass P/N 02964677 (See Figure 41)

6. Attention Boom Swing Decal. This installs on the

inside top rear of Right Door Glass P/N 02963524 (See Figure 41)

7. Important Boom Rest Decal. This installs on the

inside top rear of Right Door Glass P/N 02964677 (See Figure 41)

8. Proper Engine Operating Decal. This installs on

the inside top rear of Right Door Glass P/N 02965093 (See Figure 41)

FIGURE 40

00763977

02964677

02965262

02963524

02965093

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

FIGURE 41

Section 8 - 17

NOTES

Maverick (NH TS-100A,115A , 125A, 135A Asy. Man) 01/05

Section 8 - 18

Section 9

MAVERICK

New Holland Tractor

TS-100A,1 15A, 125A, 135A

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Boom & Head

Inst allation

Section 9 - 1

Boom / Head Installation

Boom Installation / Boom Hoses:

1. Turret Assembly, The turret assembly has

the cylinders connected and the hoses are connected to the cylinders. The end of the hoses will be sticking up through the turret mount weldment between turret and tractor. The hoses will need to be connected there and routed to the hydraulic control valve. One hose will have a Green Tie and one a green and white tie where the come up throught the turret mount weldment. (See Figure

3).

2. Booms Are recieved from the factory with

the Sections of Boom Assmebled to together. The Boom Sections are assembled with the hydraulic lines and cylinder connected. The hose will be connected to the boom that are routed to the control valve and diverter valve and bundled together. (See Figure 4). The Boom Hoses are

protruding out the turret mount end of the boom. The Hose connections on the head end will be shipped with metal caps on them, these are to protect the lines from contamination and should not be removed until the hoses are being installed (See Figure 5). The hose that attaches to the boom are sent installed on the head assembly and the hose will also have plugs in them.

Swing Cyl. Hose

with Green Tie

Figure 1

Lifting

Point

Swing Cyl. Hose

with Green /

White Tie

Rear of Tractor

3. Boom Lift Cylinder. The boom lift cylinder

will be connected to the boom at the rod end of the cylinder (See Figure 2 & 4) when it is shipped from factory. The hoses will also be connected to the cylinder. The retaining pin for the lift cylinder will be located in the turret assembly. The Lift Cylinder will be fastened to boom with tie wire. It will not be required to remove this tie wire before mounting boom on turret assembly.

Figure 2

4. Booms & Lift Cylinder Mounting Pins.

The Boom and lift cylinder mounting pins are shipped installed in the turrert assembly. Remove both pins in preparation to mounting the boom. (See Figure 3)

Figure 3

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Main Boom

Mount Pin

Lift Cyl. Base

End Mount Pin

Section 9 - 2

Boom / Head Installation

5. Lower Boom onto Turret Assembly. Us-

ing an over head hoist lift the boom by placing a lift strap at the boom hinge point (See Figure

2), the boom assembly will be shipped with the two boom end tie wired together (See Figure 3A). The wire tie will need to be removed as it is tied through the boom hinge pin hole. Lift the boom above the turret assembly and lower it back down onto the turret assembly aligning the boom with the mounting pin hole. Install the Mount Pin through the turret and into the boom. Make certain the pin is installed correctly as one side of the pin is self locking in design. Tighten the pin retaining nut and install cotter pin. (See Figure 3C)

6. Connect lower end of Lift Cylinder. The

Base end (lower end) of lift cylinder will mount into the turret under the boom mount. The Cylinder will have to be extended to connect, If cylinder has to be extended the best way is to unplug the ends of the lift cylinder hoses where they come out of the boom, these will be the # 6 hose with the Orange Tie and the # 6 hose with the orange / White Tie. When pulling (extending or collapsing cylinder) always put the opened end of the hoses into a clean drain pan as oil will run out of the cylinder when extended or collapsed. After installing the cylinder lower mounting pin re-plug the hoses that were in the drain pan until ready to connect hoses.

Turret End

Of Boom

Boom Mounting

Pin Hole

Figure 3A

Lift Cylinder

Mount Pin

Figure 3B

7. Connect Head to Boom. The mounting

pins to install the head onto the boom will be shipped installed in the mount weldment. Remove the mounting pins. Use the hoist to lower boom down over head to connect head, Align the upper head mount pin. The lower mount pin is the connect the lift link. (See Figure 4 &

5). The Door Cylinder and the Swivel Cylinder are shipped installed on the head with the hoses connected to the cylinder.

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Figure 3C

Section 9 - 3

Boom / Head Installation

8. Heads Are received from the Factory with

the Cylinder and Head hoses Attached to Head. The head will be received with the door cylinder, swivel cylinder and Motor attached to the head. The Hoses for the cylinders and the motor will connect to the boom. There is a decal that is installed on the side of the boom that shows where the hoses connect to the fitting that have the metal caps on them. The fittings for the head are located on the side of the main Boom. The hoses must be connected in the correct order to make certain of correct operation (See Figure 4, 5, 6, 7, 8, 9 & 10).

9. Two Head Options. There are two heads

available, 60" (See Figure 4,5 & 6) which has the head Swivel attachment on it. The 50" Head which will not have the swivel attachement (See Figure 9 & 10) If using the 50" head leave the ports for swivel cylinder on boom capped (See Figure 8)

10. Connect Hose From Boom to Control

Valve. The cylinder hoses will connect to the control valve mounted on the front of the tractor with the exception of the Door and Swivel Cylinder hoses they will connect to the diverter valve and then there are two hoses that connect to thediverterr valve to the 6 spool control valve (See Figure 11). The hoses for door and swivel will be routed under the tractor along the center under frame weldment to the diverted valve which will be mounted on the LH side of the tractor on the front frame mount bracket.

60 Inch Head with

Swivel Hitch Mount

Figure 4

60 Inch Head with

Swivel Hitch Mount

Figure 5

Figure 6

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

60 Inch Head with

Swivel Hitch Mount

Figure 7

Section 9 - 4

Motor Case Drain

#12 Hose

(Blue Tie)

Door

Cyl. # 4 Hose

(Yellow / White Tie)

Boom / Head Installation

Motor Tank Return

#16 Hose

(Orange Tie)

Motor Pressure

# 16 Hose

(Red Tie)

Door

Cyl. # 4 Hose

(Yellow Tie)

Swivel

Cyl. # 4 Hose

(Green / White Tie)

Figure 8

Figure 9

Swivel

Cyl. # 4 Hose

(Green Tie)

50 Inch Head w/o

Swivel Hitch Mount

Head Lift Link

Pin Hole

Head Mount

Pin Hole

50 Inch Head w/o

Swivel Hitch Mount

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Figure 10

Section 9 - 5

Boom / Valve Hydraulic Schematic

Stabilizer Cyl

# 4 Hose

Returns to same port on

tan as Oil cooler Hose

"B" Ports

"A" Ports

Pressure Supply

(Red Tie)

Tees into Lift ("B" Port)

Hose (No Plastic Tie)

Swing

Dipper

Boom Lift

Head Tilt

Telescope

Figure 11

6 Spool Control Valve

Swivel / Door

Tank Return

(Orange Tie)

No Colored Ties only Hose

Bands P/N 02981825

Swing Cyl

# 6 Hose

Swing Cyl

# 6 Hose

Boom Lift Cyl

# 6 Hose

Dipper Cyl

# 6 Hose

Orange / White Tie

Blue / White Tie

Blue Tie

Green / White Tie

Green Tie

Orange Tie

Green Tie

Green / White Tie

Diverter Valve

Yellow Tie

Green Tie

Yellow / White Tie

Telescope Cyl

# 6 Hose

Red / White Tie

Head Tilt Cyl

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Yellow Tie

Red Tie

Section 9 - 6

Yellow / White Tie

# 4 Hose

Swivel Cyl

# 4 Hose

Green / White Tie

Door Cyl

Boom / Head Installation

11. Routing Cylinder Hoses from Boom to Valve The Hose from the boom to the valve will be

split, the four hoses to the door cylinder and swivel cylinder will run together through a section of sleeving material to the RH side of the tractor (See Figure 12). On the Right hand side of the tractor the four hoses will connect to the diverter valve in the coded locations (See Figure 11). Tie the hoses to the frame under the tractor (See Figure 13). The two hoses from the diverter valve will continue along the LH side of tractor with sleeving material over them (See Figure 13) to the front of the tractor. They will have hose support brackets on them that bolt to the side of the tractor (See Figure 13) where they will be connected to the valve at the Door / Swivel Ports in the correct order (See Figure 16 & 17).

The other cylinder hoses from the boom will be inserted into sleeving material and also be routed under the tractor to the LH side (See Figure 14). They will continue up the LH side to the front of the tractor where they will connect to the valves ports. The hoses will be held to the frame with metal hose holders bolted to the tractor frame (See Figure 15).

NOTE: the hoses must be run through the sleeving material. On the LH side there is a hole in the center frame weldment the hoses can be run through it if wanted. Connect the hoses to the valve as shown (See Figure 11 & 17)

Figure 12

Figure 13

Hose Support

Bracket

Sleeving Material

for Hoses

Figure 15

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Figure 14

Figure 16

Section 9 - 7

Hydraulic Hose Connections

HYDRAULIC HOSE CODES AT VALVE

Hydraulic Hose Band Mark Color Codes: Hose's and/or fittings are marked with a

& Part Number (See Figure 4)

Boom Cylinder Circuit Hoses:

Color Tie (Code) Hose Size Port Diverter Hyd. Function

Green G SAE # 6 A --- Swing, Back (Rod End) Green / White G / W SAE # 6 B -- - Swing, Forward (Base End) Orange OR SAE # 6 A --- Lift, Down (Rod End) Orange / White OR/W SAE # 6 B --- Lift, Up (Base End) Blue B SAE # 6 A --- Dipper, In (Rod End) Blue / White B/ W SAE # 6 B --- Dipper, Out (Base End) Yellow Y SAE # 6 A --- Telescope, In (Rod End) Yellow / White Y/W SAE # 6 B --- Telescope, Out (Base End) Red R SAE # 6 B --- Head Tilt, Up (Rod End) Red / White R/W SAE # 6 A --- Head Tilt, Down (Base End) Green G SAE # 4 A P2 Control Valve tor Diverter valve Green / White G/W SAE #4 B P1 Control Valve to Diverter Valve Green G SAE # 4 - -- C4 Swivel, CW (Rod End) Green / White G/W SAE # 4 - -- C 1 Swivel, CCW (Base End) Yellow Y SAE # 4 -- - C3 Door, Open (Rod End) Yellow / White Y/W SAE # 4 -- C 2 Door, Closed (Base End) Orange OR SAE#12 T --- Valve Return To Tank Red R SAE#12 P -- Pressure to Valve.

Always Check Hose Size, Color Code

Motor Circuit Hoses to Boom Connections: (Listed as reference)

Color Tie (Code) Hose Size Hyd. Function

Red R SAE # 16 -- Pressure Flow to Motor Orange OR SAE # 16 -- Return Flow From Motor Blue B SAE # 8 -- Case Flow From Motor to Boom Blue B SAE # 12 -- Case Flow at Boom to Tank

Diverter Valve.:

The Diverter Valve bolts onto the front frame mount bracket on the LH side of the tractor, the holes are in the bracket (See Figure 5 & 6). The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two (or more if valves are stacked) functions with a single pressure supply. This valve is strictly a diverter valve and is designed to direct the pressure, not regulate the flow or pressure.

The Port openings on this diverter valve are marked with letter number codes which show which port is connected to which hose and where that hose connect on other end (See Figure 4, 5 & 6))

Port Function & Connection

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 9 - 8

Hydraulic Hose Connections

Six Spool Control Valve

External Wire Connections for valve are marked "A" and "B" on Valve & AA1 thru AA12 on wire harness connections

Swing

Lift

Dipper

Telescope

Head Tilt

Head Swivel / Door

(To Diverter Valve)

Pressure

Supply

Port "P"

Diverter V alve

Valve "B" Port to

Diverter valve P1 Port

4 Through holes are

mounting holes

Valve "A" Port to

Diverter valve P2 Port

FIGURE 17

(G/W Tie)

(G Tie)

"B"

G/W

"A"

OR/

"A"

"B""B"

B/W

Y/W

"B""B"

"B"

G/W

Return

To Tank

"T"

"A""A"

R/W

"A""A"

Diverter Valve "C1" Port

to Swivel Cyl Base End Port (G/W Tie)

Diverter Valve "C4" Port

to Swivel Cyl Rod End

Port (G Tie)

VS . 125/F

Diverter Valve "C2" Port

to Door Cyl Base End

Port (Y/W Tie)

SAE 4

Diverter Valve "C3" Port

to Door Cyl Rod End

Port (Y Tie)

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 9 - 9

Boom / Head Installation

12. Routing Boom Hoses to Pump The Boom hose to the pump will be routed on the RH Side

of tractor, They will be run through sleeving material and hose support bracket (See Figure 18). The Pump hoses must be connected correctly to the boom and pump. There are 2 Pump to motor hoses and 1 motor case drain return hose for a total of 3. (Note Motor Case Drain hose will be run through the Oil Cooler and then return to tank).

First is the # 20 hose with the red plastic tie the lower connection at Boom, (See Figure

17), this is the pressure supply from the pump lower connection at pump (See Figure 20) to the motor connection at the boom.

Second is the # 20 hose with the orange plastic tie the upper connection at boom (See Figure 17). This is the Return hose from the motor upper connection at pump (See Figure 20).

Third is the # 16 Hose with the blue plastic tie the middle connection at the boom (See Figure 17) which is the case drain from the motor. This hose connects to the Oil Cooler / Fan Assembly which is mounted under tractor bolster behind hydraulic tank (See Figure 19) . There is a short #16 hose (See Figure 19) which will not have a plastic tie on it that will connect to the oil cooler, and then goes to the tank to a return port (See Figure 20).

Blue Tie

Red Tie

Figure 17

Orange Tie

13. Pump Hose Routing at Tank. The hose routing

at tank is shown as reference to the Pump hose routing which most of will already be connected when the tank and pump assembly is shipped from the factory. All hoses that you must disconnect and reconnect during pump and/ or tank assembly, refer to this figure for the correct location of hose (See Figure

21). DO NOT start tractor before all steps of the installation is completed, if tractor is started damage to the hydraulic system will occur.

Hose From Boom

(Motor Case Drain)

Blue Platic Tie

Hose From Oil

Cooler to Tank

return, No Plastic

Tie

Sleeving Material

Hose Support

Bracket

Figure 18

Orange Tie

(Top Fitting)

for Hoses

Red Tie

(Bottom Fitting)

RH Side

of Tractor

Figure 19

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Figure 20

Section 9 - 10

No Tie (F/ Oil

Cooler to Tank)

Hydraulic Tank Hose Routing

"J" # 16 Hose

(Red Plastic Tie)

"K" # 16 Hose

(Orange Plastic Tie)

"C" # 12 Hose

Suction Hose

(No Plastic Tie)

"G" # 20 Hose

Suction Hose

(No Plastic Tie)

"A" # 8 Hose

(Red Plastic Tie)

"L" # Hose

(Blue Plastic Tie)

"B" # 8 Hose

(90° Elbow)

(Blue Plastic Tie)

"A" # 8 Hose

(90° Elbow)

(Red Plastic Tie)

"E" # 4 Hose

(Red Plastic Tie)

"D" # 12 Hose

(Red Plastic Tie)

"H" # 12 Hose

(90° Elbow)

(Orange Plastic Tie)

"D" # 12 Hose

(Red Plastic Tie)

"G" # 20 Hose

Suction Hose

(No Plastic Tie)

"H" # 12 Hose

(Orange Plastic Tie)

Figure 21

"E" # 4 Hose (90° Elbow)

(Red Plastic Tie)

"F" # 4 Hose & Tee

(Blue Plastic Tie)

"F" # 4 Hose

(90° Elbow)

(Blue Plastic Tie)

"B" # 8 Hose

(Blue Plastic Tie)

Tank Return

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 9 - 11

MOTOR & BOOM PUMP - HOSE ROUTING

Listed Below are the location, part number , hose size / type and function of the hoses at the tank, this list is to be used with figure 21 as a reference.

Item Part No. Qty. Description

A 02981427 1 Hose, 8FJX - 8FJX 90° - 24" Lg. w/Red Tie (Charge Filter to Pump) B 02981428 1 Hose, 8FJX - 8FJX 90° - 21" Lg. w/ Blu Tie (Case Drain to Tank) C 02981429 1 Hose, 12FJX - 12FJX - 23" Lg. (Pump to Suction Filter) hose under

Connects to top side of pump as shown. F 02981432 1 Hose, 4FJX - 4FJX 90° - 20" Lg. w/ Blu Tie (Pump Regulator to Tank)

Maverick (NH TS-100A,115A, 125A, 135A Asy. Man) 01/05

Section 9 - 12

Section 10

MAVERICK

Fill Oil Tank

Electronic Controls Setting

New Holland Tractor

TS-100A, TS-115A

TS-125A, TS-135A

New Holland (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 10 - 1

Hydraulic Oil Installation 2 WD & 4 WD

Hydraulic Tank Filling:

1. Filling With Recommended Hydraulic Oil. The oil

used MUST MEET the requirements as to type and cleanliness level, THIS IS A MUST. The oil must be type

ISO Grade Hydraulic Oil w/ protection wear grade based on abient temperature (See Decal Figure 4).

The grade of oil will vary with the ambient twmperature. The Fluid Cleanliness level MUST BE ISO 16/14/11 rating. MAKE CERTAIN that the oil you are using meets this requirement. If Oil does not test to cleanleness reguirement, it will have to be filtered to clean it before installing it into the maverick hydraulic system. NEVER install or add Oil that does not meet these stadand requirenments.

2. Remove the Filler Cap and fill the Hydraulic

Tank, Make certain the oil is ISO AW 100 Hydraulic Fluid with cleanliness level of ISO 16/14/11 is a must, however do not over fill or spill oil.

3. Check that all the hydraulic connections are

complete and tightened on the Motor Hydraulic System and the Cylinder Hydraulic System.

4. Avoid hydraulic contamination by filtering the hy-

draulic oil while filling the hydraulic tank. Filter buggies or carts are commercially available for Pre cleaning oil before it is installed or hydraulic system cleanup. These consist of a high-efficiency, high-capacity filter, a circulating pump, a drive motor, and hoses for connecting to oil supply. (See Figure 2 & 3)

When adding hydraulic oil, use only new oil from a sealed barrel. Used oil or oil from an open barrel may contain high levels of contamination. Transfer the new oil into the hydraulic tank by using a hydraulic filter pump unit equipped with a properly operating micron filter to achive rquired cleanleness level is a must. This will insure that the oil being added is safe to use. Do not just pour the oil directly into the hydraulic tank since most oils (even from a sealed barrel) have contaminants that should be removed, before operating the hydraulic system. (See Figure 2 & 3).

Fill

Cap

Figure 1

Figure 2

3/4 Full

1/2 Full

Sight

Gauge

4. Important: Change the return filter in tank and

suction filters at recommended hours of operation (See Operators Manual for maintenace schedule). The only hydraulic oil to be used is the AW

ISOAW Tractor Hydraulic Oil (See Figure 4 for oil Grade ) with a cleanliness level of ISO16/14/

11. Always use a good Filter Maintenance program and Oil cleaning system before adding any oil to system..

New Holland (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Figure 3

Section 10 - 2

Hydraulic Oil Installation 2 WD & 4 WD

ATTENTION

10°F

20°F

The correct hydraulic fluid is dependent upon ambient temperature. Refer to chart when selecting proper grade

30°F

AW ISO VG 32

Figure 4

Prime Hydraulic Pump:

1. The Hydraulic Pump

MUST be Primed. The hy-

draulic pump is primed by putting oil directly in to the pump. Looking at the pump, out near the end of the pump there is a Allen plug (See Figure 5). Remove this plug and install only approved hydraulic oil ( See Step 1 through 3 of hydraulic tank filling). Fill the cavity completely full up to plug threads. IMPORTANT! This must be done before the unit is ever started. Make certain that the O-Ring Seal is on plug and reinstall it after cavity is full of oil, now the pump is primed. The Unit still will not operate until the next step of setting the electronics to operate the system.

40°F 60°F 70°F

AW ISO VG 46

AW ISO VG 68

Figure 5

90°F

AW ISO VG 100

110°F

02982828

Remove This allen head

plug to Prime Pump

New Holland (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 10 - 3

CONTROL VALVE - BOOM & MOTOR CONTROL

Maverick Boom and Motor Control Circuits:

It is advised that this section be read before proceeding with any repairs or test, with the display and electronics used in this application the system will test many components for you. This is done by following the prompts on the display screen.

DO NOT pressure wash this system, while the components are sealed the soaps, acid and high water pressure used in the pressure washer can damage these seals and cause moisture to enter system causing damage.

DO NOT do any welding around these electronic components, If welding is required in a repair the electronic components MUST be disconnected (unplugged). Un plug all components, Joystick, Modules, Displays and any other electronic component. If not unplugged the current from the welded can cause serious damage to electronic components.

Additional repair and diagnostic procedures for the electrical system is available on the internet web site of the manufacture of this system at: REFERENCE PRODUCT MANUAL FOR

MDM DISPLAY. THIS MANUAL IS AVAILABLE FROM THE MANUFACTURER ON THE INTERNET AT www.iqan.com viewable and printable with ADOBE ACROBAT READER. If you do not have Adobe Acrobat Reader it can be obtained at www.adobe.com. Make certain

that the instructions you refer to is for the MDM system, the manufacturer has more than one system.

The boom and motor control is electronic over hydraulics. If these functions are not properly set or working properly the mower can not be operated. Also make certain that all fluid levels are OK and with in operating limits.

The first thing that should be checked is the main (electrical) power supply to the system, this can be checked on the display unit when power is on.

The set-up portion as shown in the next pages should be checked to make certain the joystick and motor functions are set correctly. Check all the connections if not operating properly. If the settings are not correct the system will not function properly.

Check the emergency stop (E-Stop) switch if it is in the off position the system will not operate and the system cannot be set properly.

Never short across any of these components as the type electronics used can be seriously damaged. Always use a volt / ohm meter to test any circuits.

New Holland (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 10 - 4

CONTROL VALVE - BOOM CONTROL

Maverick Boom Control System:

over hydraulic system. There are three main areas of that system, the electronic network, instrumentation and hydraulic components.

Operating the Boom Control functions is done so by means of a load sensing electronic

2. System components are, The hydraulic System, The electronic network, The instrumen-

tation and Operator Interface.

3. The Hydraulic System, The hydraulic components are responsible for transferring me-

chanical power into hydraulic power. There are two separate hydraulic circuits, the boom circuit and the mower head circuit.

4. How the boom is controlled, The system progression starts with operator input at the

joystick (Figure 6- Item A) or other instrumentation. Input is received at the CAN module (Figure 5- Item B) and joins the network. That information is transferred via the network to the valve solenoid (Figure 5- Item C) which activates and moves the spool sending hydraulic fluid pressure to the cylinder (Figure 5-Item D) and moves the load.

Item-BItem-A

Item -C

Item -D

FIGURE 6

Maverick Mower Head Circuit

1. The Motor Circuit. The motor circuit for the cutting head operation is operated through

display (Figure 6- Item A). By selecting the activation parameter the coil will shift the servo-piston at the hydrostatic pump (Figure 7-item B), stroking the pump into the "On" position. Flow will then be supplied to the hydraulic motor at the cutter head (Figure 6-Item C). Activate the motor circuit while the engine RPM is at idle. Once activated, the engine RPM can be raised to the 540 PTO required speed, if the 540 PTO engine speed is not noted on the tractors RPM gauge consult tractor owners manual to find what the required speed is. At any time the Emergency stop switch (Figure 7-Item D) located on the joystick will deactivate the cutter motor circuit. The blade will stop within 6 second when the emergency switch is shut "Off"

New Holland (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 10 - 5

CONTROL VALVE - ELECTRONIC NETWORK

Maverick Mower Head Circuit: (continued from Previous page)

Item -BItem -A

Item -C

Item -D

FIGURE 7

Maverick Electronic Network: (Figure 8)

Electronic Network. The electronic network is the control and communication network that receives and transmits data to certain components in the boom control system. Its purpose, is to manage the incoming and outgoing information.

There are five main components. The MDM is an operator Display that is located in the cab. The purpose of the display is to house the programming software for the system control and provide an interface between the operator and the Maverick Boom.

The interface is utilized through a multi-screen function that allows the operator to set individual parameters for customized control functions.

The display also provides tools such as an on board measurement device, useful for determining short circuits, component loss, and/or power supply issues. REFERENCE PRODUCT MANUAL

FOR MDM DISPLAY. THIS MANUAL IS AVAILABLE FROM THE MANUFACTURER ON THE INTERNET AT www.iqan.com viewable and printable with ADOBE ACROBAT READER. If you do not have Adobe Acrobat Reader it can be obtained at www.adobe.com.

Make certain to view the MDM section as this is the type used on the maverick boom, there are listings at the web site that will not apply to the maverick boom.

FIGURE 8

New Holland (NH TS-100A, 115A, 125A, 135A Asy. Man) 01/05

Section 10 - 6

New Holland TS-100A, TS-115A, TS-135A, TS-125A, ts110 Assembly Manual

Specifications and Main Features

Frequently Asked Questions

User Manual