New Holland TS-100A Assembly & Instruction Manual Download Page 1

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Published 01-05

Part No. 02982279

ASSEMBLY MANUAL

BOOM ARM MOWER

ALAMO INDUSTRIAL

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

Assembly Instruction Manual

New Holland - Cab 2 WD / 4 WD

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

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.

Summary of Contents for TS-100A

Page 1: ...Manual New Holland Cab 2 WD 4 WD TS 100A TS 115A TS 125A TS 135A 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 ...

Page 2: ......

Page 3: ...nce of accidents BEFOREYOUSTART 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...

Page 4: ...NOTES ...

Page 5: ...e 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 Assem...

Page 6: ... Reinstall Engine Guards Covers 3 8 Section 4 Hydraulic Tank Control Valve Installation Install Hydraulic Tank to Tank Mount Rails 4 2 TankHoseRouting 4 2 to 4 3 ControlValveFittingIdentification 4 4 to 4 5 HeadTiltLockValve 4 5 ValveHoseMarkingCodes 4 6 DiverterValve 4 6 to 4 8 Oil Cooler Cooling Fan Assembly 4 9 Section 5 Battery Exhaust Fuel Tank Modification Main Frame Installation BatteryRelo...

Page 7: ...s 8 14 to 8 16 CabDecals 8 17 Section 9 Boom Head Installation BoomMounting 9 2 to 9 5 Boom Lift Cylinder Pin Installation 9 2 to 9 3 Boom Cylinder Schematic 9 6 ValveHoseSchematic 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 Elec...

Page 8: ...Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Index 4 NOTES ...

Page 9: ... 2005 Alamo Group Inc Section 1 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 Model Specifications Maverick Boom 24 30 Section 1 ...

Page 10: ...hiscould alsoapplytothetractorcomponents CheckTractorsrepairguideforspecificinstruction 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 ha...

Page 11: ...rt Stop Time Approximate 6 Seconds Cutting Diameter Rotary Head 58 Inch Spindle 4 5 by 9 Heat Treated Alloy BladeBarType Stacked 3 Leaf BladeBarSize 1 1 4 Thick X 5 Wide Ea Leaf BladeBarMaterial T1 Steel bottom HRFB Steel top Middle BladeSwing 360 Deg Swing BladeMaterial High Carbon Alloy Steel Cutter Weight Approximate w Rotary Head 950 lbs Cutter Deck Opening Closing Hyd Operated Door Recommende...

Page 12: ...ill 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 0296...

Page 13: ...o 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 RATES CylinderType 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 029820...

Page 14: ...elief 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 F...

Page 15: ...8 105 142 140 189 200 271 280 379 355 481 430 583 700 949 1000 1355 1700 2304 2300 3118 3000 4067 ALWAYS CHECK MARKINGS ON TOP OF BOLT HEAD OR OTHER BOLT DESCRIPTIONS PlainHead 3 Dashes 6 Dashes Bolt Dia inch 2 B 5 D 8 F 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 Not Used Not Used Not Used 35 47 55 75 75 102 105 142 185 251 160 217 250 339 330 447 480 651 10 14 20 27 35 47 55 75 85 115 1...

Page 16: ... 2005 Alamo Group Inc Section 1 8 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 NOTES ...

Page 17: ... 2005 Alamo Group Inc Section 2 1 Maverick NH TS 115A 125A 135A Asy Man 01 05 Maverick Boom New Holland Tractor TS 100A 115A 125A 135A Tractor Preperations Section 2 ...

Page 18: ...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 assem...

Page 19: ...r 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 Remember to follow each step closely and cautiously Be aware of all support personnel at all times Ke...

Page 20: ...ing 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...

Page 21: ...rk 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 wor...

Page 22: ...ld 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 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...

Page 23: ... 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 compo nents that could be damaged by welding Before doing any welding ALL ELEC TRONIC...

Page 24: ... 2005 Alamo Group Inc Section 2 8 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 NOTES ...

Page 25: ... 2005 Alamo Group Inc Section 3 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 MAVERICK New Holland Tractor TS 100A 115A 125A 135A Pump Driveshaft Installation Section 3 ...

Page 26: ...bolted under the After Cooler that will have to be removed Existing Holes have rubber Plugs in them Figure 1 AirAfter Cooler Tractor Bolster Cover removed to gain access to inner hole when the four bolts that retain after cooler are removed the plate will slideout Whilethisplateisoutcheck thehosesfor the Oil Cooler and Air Conditioning condenser these hoses need to be tied up in such away that the...

Page 27: ... 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 combinationuntiltheshaftispointedtowardthefrontofthetractor andtheflangeyokeisoverfarenough to align with the four threaded pulley adapter holes 5 Alignthefourhol...

Page 28: ...hetractorbolsterusingfour20mmX45mmlong 2 RemoveBoltonCoverInfrontofAfterCooler Thisisanimportantstep TheAirConditionerHoses and the Oil Cooler Hoses are under this cover See Figure6 11 Thesehosesmustbetiedandrouted 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 RemovePumpSh...

Page 29: ... 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 Pump Drive Assembly Instructions Installing Driveline Half to Pump 1 InstallDrivelineHalf toPump Installtheclampyokeofthetubehalfofdrivelineontothe 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 fa...

Page 30: ...all Pump MountingBolts Tighten Clamp Yoke leave 1 8 to 1 4 gap btween yoke pump Align Splines on Pump Shaft with Driveshaft clamp yoke Push Pump into Pump Mount until flush Driveshaft Pump Mount Weldment installed Figure 11 Figure 13 Figure 14 Figure 15 Figure 16 Pump Shipped w Hyd Tank Valve is bolted to Tank Figure 12 ...

Page 31: ...34 PumpMounting Bolts P N 02980666 Pump Mount Weldment Figure 17 Pump Reference 123456789012 123456789012 123456789012 123456789012 12345678901 12345678901 12345678901 12345678901 MountingBolts Bolts To TractorBolster 123456789 123456789 123456789 123456789 MountingBolts 1234 1234 12 12 12 12 12 12 12 12 1 1 1 1 1 1 1 1 1 1 Installing Pump Driveline Cover 1 InstallPumpDrivelineCover ThePumpDriveli...

Page 32: ...haft 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 3 InstallPumpMountDriveshaftCover The Pump Mount has a bolt on cover on top of it See Figure17 21 Thecoverandboltsarefurnished with kit In figure 21 is shown without pump in stalled this is for illustration only Do not install cover before ...

Page 33: ... 2005 Alamo Group Inc Section 4 1 Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05 MAVERICK New Holland Tractor TS 100A 115A 125A 135A Hydraulic Tank Control Valve Installation Section 4 ...

Page 34: ...bolts tightened 3 Rotate Fittings to make better access to Valve and tank connections The fittings in the pump and valve may have to be rotated to make it more accessable whenconnecting the hoses 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 Inner M...

Page 35: ...h 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 Hydraulic Tank Hose...

Page 36: ... 2005 Alamo Group Inc Section 4 4 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 Directional Control Valve Fittings Pump Pressure Port Tank Return Port A Ports B Ports FIGURE 3 ...

Page 37: ...rageortransportation 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 f...

Page 38: ...wivel CCW Base End Yellow Y SAE 4 C3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Motor Circuit Hoses to Boom Connections Listed as reference Color Tie Code Hose Size Hyd Function Red R SAE 16 Pressure Flow to Motor Orange OR SAE 16 Return Flow From Motor Blue B SAE 8 Case Flow From Motor to Boom Blue B SA...

Page 39: ...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 Diverter Valve FIGURE 5 Pressure Supply Port P Return To Tank T B A A A A A A B B B B B Swing Lift Telescope Head Tilt Head Swivel Door To Diverter Valve Dipper G G W OR R W Y W B W OR W Y R B G W G Six Spool Control Valve External Wire Connec tionsforvalvearemarked...

Page 40: ...ime then stop re verse 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 exteriorwireharnessismarkedwithcodeR1 The connection from the fan will have two wires a Blue connection and a black connection See Figure 8 Exterior wire harness con nection marked R1 connects here FIGURE 8 Swivel Cyl Bas...

Page 41: ...Inc Section 5 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 Maverick Boom New Holland Tractor TS 100A 115A 125A 135A Battery Modification Exhaust Modification Fuel Tank Modification Main Frame Installation Section 5 ...

Page 42: ...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 ...

Page 43: ...he factory mounting bracket The replacement bracket moves the ex haust inward towards the engine by about 5 to 6 inches This is to give clearance of the boom and exhaust system See Figure 7 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 o...

Page 44: ...eed 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 F...

Page 45: ... will have 1 hole in the outer end same as the tank See Figure 12 13 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 send ing unit See Figure 14 7 Bolt Tank to the Mounting Brackets Bolt the tank to t...

Page 46: ...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...

Page 47: ...l only SwingCylinders Swing Cylinder Pivot Bushings SwingCylinderTrunnionMountWeldment Swing Cylinder Cover TurretCylinderLink BoomMount Machined Boom Mount Attaching Pin Short Pin Boom Mount Attaching Pin Medium Pin Boom Mount Attaching Pin Long Pin Lift Cyl Pin Turret Boom Mount Pin TurretAsy Machined LH Counter Weight Weight Attaching Pin Long Pin Center Section Frame Weldment ...

Page 48: ...g 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 Frame Installation Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Cente...

Page 49: ...2 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 t...

Page 50: ... 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 ch...

Page 51: ...he 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 Figure 28 Boom Rest Support...

Page 52: ... large cotter pins install cotter pins and bend end of them to secure them See Figure 32 33 34 2 AdditionalCounterWeight CWT Installation The30footboommodelhasanadditionalboltonweight at the counter weight This additional weight bolts to the weight weldment on the 30 foot model only See Figure 32 3 Wheel Counter Weight CWT Installation The Wheel counter weight is in addition to the frame mounted c...

Page 53: ...n 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 theboltheadsunterframeweldmentandnutsare ontopvisiblelookingdown iftheyareinwrongthe swing cylinders will hit the bolts causing damge to cylinde...

Page 54: ...ee 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 fo...

Page 55: ...et 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...

Page 56: ... 2005 Alamo Group Inc Section 5 16 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 NOTES ...

Page 57: ... 2005 Alamo Group Inc Section 6 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 MAVERICK New Holland Tractor TS 100A 115A 125A 135A Optional RH Lexan Door Installation Section 6 ...

Page 58: ...tected surface for the disassembly of the latch and brace components See Figure 2 Item 1 This is the 1 2 3 Figure 1 Figure 2 4 5 6 plastic cover for the latch and will snap off Item 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 pulle...

Page 59: ...e fastener untill the shoulder of the fastener is into the hole in the door DO NOT Tighten Fastener at this time 7 InstallOuterDoorHandleandfasteners Item 9 This is the outer door handle before it can be installed Item 10 must be modified Item 10 This is the upper mountofhandlerubberpad Thereisashoulderonitthat must be cut off before it can be used using a sharp knife cut this shoulder off The tub...

Page 60: ...e 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 origi nal 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 wi...

Page 61: ... 2005 Alamo Group Inc Section 7 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 MAVERICK Standard Wheel Weight Auxiliary Wheel Weight Installation New Holland Tractor TS 115A 125A 135A Section 7 ...

Page 62: ...ra long in drawing for illustration only 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 Chlori...

Page 63: ...to align holes if needed InstallaHexLockNuton inside Insert the other two Bolts through Weight and Wheel and start the other two Locknuts Do not tighten yet See Figure 2 5 Looking at the outside makesurethethreespecialWash ers Figure 1 Item 2 are aligned withtheSlotsintheWheelWeight Tighten the three Bolts now You will need an assistant to hold the otherSidewhileyouaretightening the Bolts While ti...

Page 64: ... 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 ...

Page 65: ... 2005 Alamo Group Inc Section 8 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 MAVERICK New Holland Tractor TS 100A 115A 125A 135A Joystick Wire Harness Valve Installation Section 8 ...

Page 66: ...e 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 Figu...

Page 67: ... being pinched See Figure 9 12 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 ...

Page 68: ...1 H7 H6 H9 H10 H11 H12 H1 H2 H3 T2 H4 T3 H5 T4 H6 T5 9 7 8 6 5 4 3 2 1 Wire Harness Side P4 P2 P3 JoystickSide Red Blk Wht Blu Red Wht Brn Blk V i o Blk Red P4 3 Yel Red Blk Red Blu Blk Wht Red Wht Vio Brn Blk Yel Red Blk Red Blk PCBAssembly Pin Numbers Locations Pin Numbers Locations Resistor Harness P N 02981990 Is attached to the Joystick when it is recieved J1 7 8 9 4 5 6 1 2 3 FIGURE 7 ...

Page 69: ...nterior 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 FIGURE 7A Joystick Electrical Mounting Knob Plug Knob Retaining Screw Knob Depth Control Clip Switch Mounting Nut Switch Wire Fasteners 4 Switch Asy Complete FIGURE 8 4 Resister Harness to Joystick The Joystick will be shipped with the...

Page 70: ...4 5 6 7 8 9 P 1 P2 P3 P4 PCB To Activate Trigger Push In Joystick P N 02981347 with Resister Harness J1 FIGURE 12 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 CAUTION The Harness has two wires that run under the floor mat the positive wire MUST connect to the ignition key switch of the tractor for...

Page 71: ...Pin Remove console cover tie strap XS Module P N 02981533 inside console 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 J...

Page 72: ...listings in the illustrations to identify the connection location FIGURE 18 FIGURE 17 Display Control Box Connections Cut Notch in Small cover panel to allow harness to fit through Can1 Can2 C1 XS Module P N 02981533 FIGURE 15 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 Wh...

Page 73: ...ck NH TS 100A 115A 125A 135A Asy Man 01 05 Interior Wire Harness Schematic P N 02981375B CAN 2 XS MODULE CAN 1 XS MODULE K3 X1 G1 CC2 CC1 Must connect to Key switch wire P1 J2 M1 M2 D FIGURE 20 NOTE See Figure 11 for listing of Code Locations ...

Page 74: ...ed 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 com pleted and all the other installations of unit have been done DO NOT reconnect battery cables at this ...

Page 75: ... 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 boltontheLHsideinfrontofthe 6spoolvalve SeeFigure25 27 28 Theexteriorwiringharnesss...

Page 76: ...nder Up AA11 Swing Door AA12 Swing Door BB SolenoidValveConnectionforDiverterValve E ConnectorXT2Module F ConnectorXP2Module G2 Exterior Harness to G1 Interior Harness H1 LockValveConnection H2 LockValveConnection R1 CoolerFanConnection S1 TemperatureConnectionSensor T1 Pump Solenoid 1 Connection V1 Pump Solenoid 2 Only on Timbercat Head W1 ChargeFilterconnection X1 ReturnFilterConnection Y1 Commo...

Page 77: ... If valve has not been mounted it can be mounted now See Figure 27 28 31 38 Exterior Wire Harness Schematic P N 02981375A Pressure Supply Port P Return To Tank T B A A A A A A B B B B B Swing Lift Telescope Head Tilt Head Swivel Door To Diverter Valve Dipper G G W OR R W Y W B W OR W Y R B G W G Six Spool Control Valve FIGURE 28 External Wire Connec tionsforvalvearemarked A and B on Valve AA1 thru...

Page 78: ...nection BB of exterior harness connects here FIGURE 32 Connecting Oil Cooler And Fan Assembly to Ex terior Wire Harness 15 Oil Cooler Fan As sembly The Oil cooler fan assembly is for cooling the oil beingreturnedfromtheMotor Case Drain The fan is con nected to the control box and is turned on off automati cally Itsettorunonaprogram thatwillrunthefaninthecool ing rotation for a designated time then...

Page 79: ...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 5...

Page 80: ...t the operator for a filter element change WARNING This filter does not have a by pass Theelementmustbechangedattheappropri ate 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 brack ets See Figure 37 There wi...

Page 81: ...n Boom Swing 02965093 Proper Engine Operating 02965262 Warning Hose Burst 02967827 Multi Hazard 3 Multi Hazard Danger Decal This is in stalled on the Left Side Window of Cab on the inside to Drivers Left P N 02967827 See Figure 39 4 Warning Hose Burst Decal This installs on the Right Side Window of Cab on the Inside to Drivers Right P N 02965262 See Figure 40 5 Notice To Owner Decal This installs ...

Page 82: ... 2005 Alamo Group Inc Section 8 18 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 NOTES ...

Page 83: ... 2005 Alamo Group Inc Section 9 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 MAVERICK New Holland Tractor TS 100A 115A 125A 135A Boom Head Installation Section 9 ...

Page 84: ...nd 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 in stalled See Figure 5 The hose that attaches to the boom are sent installed on the head assem bly and the hose will als...

Page 85: ...er 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 ex tending or collapsing cylinder always put the opened end of the hoses into a clean drain pan as oil will run out of the cylinder when ...

Page 86: ...ee 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 ho...

Page 87: ...l 4 Hose Green Tie Door Cyl 4 Hose Yellow Tie Motor Pressure 16 Hose Red Tie Motor Tank Return 16 Hose Orange Tie Motor Case Drain 12 Hose Blue Tie Door Cyl 4 Hose Yellow White Tie Boom Head Installation HeadMount Pin Hole Head Lift Link Pin Hole Figure 9 Figure 10 50 Inch Head w o Swivel Hitch Mount 50 Inch Head w o Swivel Hitch Mount ...

Page 88: ...a n g e T i e Dipper Cyl 6 Hose Blue Tie Blue White Tie Telescope Cyl 6 Hose Yellow White Tie Yellow Tie Head Tilt Cyl Red Tie Red White Tie P1 P2 C1 C2 C3 C4 Swivel Cyl 4 Hose 4 Hose Door Cyl Green White Tie G re e n T ie Ye llo w W hit e Tie Y e ll o w T ie G r e e n W h i t e T i e G r e e n T i e DiverterValve 6 Spool Control Valve 6 Hose Swing Cyl No Colored Ties only Hose Bands P N 02981825 ...

Page 89: ... 12 Figure 13 Figure 14 Figure 15 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...

Page 90: ...Swivel CCW Base End Yellow Y SAE 4 C3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Motor Circuit Hoses to Boom Connections Listed as reference Color Tie Code Hose Size Hyd Function Red R SAE 16 Pressure Flow to Motor Orange OR SAE 16 Return Flow From Motor Blue B SAE 8 Case Flow From Motor to Boom Blue B S...

Page 91: ...yl 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 Diverter Valve FIGURE 17 Pressure Supply Port P Return To Tank T B A A A A A A B B B B B Swing Lift Telescope Head Tilt Head Swivel Door To Diverter Valve Dipper G G W OR R W Y W B W OR W Y R B G W G Six Spool Control Valve External Wire Connec tionsforvalvearemarked...

Page 92: ...Tie F Oil Cooler to Tank Second is the 20 hose with the orange plas tic tie the upper connection at boom See Figure 17 This is the Return hose from the motor upper connec tion at pump See Figure 20 Third is the 16 Hose with the blue plastic tie the middle connection at the boom See Figure 17 which is the case drain from the motor This hose connects to the Oil Cooler Fan Assembly which is mounted u...

Page 93: ... 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 Hydraulic Tank Hose ...

Page 94: ...g 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 12FJ...

Page 95: ... 2005 Alamo Group Inc Section 10 1 New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 MAVERICK Fill Oil Tank Electronic Controls Setting New Holland Tractor TS 100A TS 115A TS 125A TS 135A Section 10 ...

Page 96: ...ntamination by filtering the hy draulic oil while filling the hydraulic tank Filter buggies or carts are commercially available for Pre cleaning oil before it is installed or hydraulic system cleanup These consist of a high efficiency high capacity filter a circu lating pump a drive motor and hoses for connecting to oil supply See Figure 2 3 When adding hydraulic oil use only new oil from a sealed...

Page 97: ...ic tank filling Fill the cavity completely full up to plug threads IMPOR TANT This must be done before the unit is ever started Make cer tain that the O Ring Seal is on plug and reinstall it after cavity is full of oil now the pump is primed The Unit still will not operate until the next step of setting the electronics to operate the system Remove This allen head plug to Prime Pump Figure 5 ATTENT...

Page 98: ...ystem 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 elec...

Page 99: ...oinsthenetwork Thatinformationistransferredviathenetworktothevalvesolenoid 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 D Item C Item B Item A 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 selectin...

Page 100: ...ming software for the system control and provide an interface between the operator and the Maverick Boom The interface is utilized through a multi screen function that allows the operator to set individual parameters for customized control functions The display also provides tools such as an on board measurement device useful for determin ing short circuits component loss and or power supply issue...

Page 101: ...de of the tank The function of this component is to provide a gateway for incoming and outgoing infor mation This module receives input from instrumen tation then provides that information to the network for further utilization See Figure 10 REFER ENCE PRODUCT MANUAL FOR MDM DISPLAY THISMANUALISAVAILABLEFROMTHEMANU FACTURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT ...

Page 102: ...ns activated until fluid temperature drops to or below the desired temperature See Figure 12 The Charge Pressure Filter Switch The charge pressure filter switch is located at the filter in thechargelooponthehydrostaticpump SeeFigure 13 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and promp...

Page 103: ...LVE INSTRUMENTATION FIGURE 15 Maverick Operator Interface The Operator Interface The operator selects parameters provided by a menu system in the MDMdisplaycontrolbox Theparametersareusedtoestablishhowtheboomunitfunctions Themenu system is comprised of two sections The first section is setup the second section powers up the boom control circuit and cutter head circuit The following steps outline h...

Page 104: ... for standard directional flow Key F 1 to activate Joystick the Boom will not move until the joystick is activated The Boom function Set up is now complete the boom speed the head attachment has been chosen and the joystick has been activated Key F 1 to power motor This is best done when the engine RPM is at idle speed Doing this a t high RPM will cause the system pressure to surge sending fluid o...

Page 105: ...ctly If the Boom will not lift The Pump for the Cylinder supply may have to be adjusted This is a simple process that will require a 7 16 wrench for this adjustment and a 1 2 wrench for the locking nut Looking on the LH side of the pump there are two adjustments one has a 7 16 hex headandtheotheraridgedroundhead Onlyadjust the one with the hex head DO NOT adjust or change the round ridged adjustme...

Page 106: ...nal to the Electronic Controller which indicates the position of the Spool 4 The Electronic Controller will continue to adjust the Valves 1 4 in order to maintain an equilibrium between the Joystick signal and the feedback signal 5 Reaction time from the time the Joystick is moved until the Spool moves is approximately 300 milliseconds Joystick Functions Push Buttons Only Top Left Swivel CW Top Ri...

Page 107: ...madeonthetankmountbracket Therearetwobolts one each hinge that bolt the two hinge halves together The is a safety cable that will bolt to the cover and the tank mount bracket this is to prevent the cover from opening to far forward and hitting the ground Thereareretaininglatchesthatwillbolttothetank mount bracket and the cover The holes for the fasteners willhavetodrilledbytheinstallationtechnicia...

Page 108: ...ee Figure 27 Loosen the bolt and locking nut turn the bolt outward 3 Swinging Boom DO NOT Swing Boom until the boom has been run with it sticking out away from tractor and all electronic control adjustments have been done The boom must be working smoothly Slowly with low engine RPM with some one guiding you swing boom inward toward cab until the boom rest lug is aligned with the boom rest pin See ...

Page 109: ...and NH TS 100A 115A 125A 135A Asy Man 01 05 Adjust Boom Swing Stop Swing Stop Lug Built onto the Turret Cylinder Link Weldment Turret Assembly as seen from the bottom Turret Swing Stop Lug with Adjusting Bolt Locking Nut Swing Cylinders Figure 27 ...

Page 110: ... 2005 Alamo Group Inc Section 10 16 New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 NOTES ...

Page 111: ... 2004 Alamo Group Inc 11 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 Maverick New Holland Tractor TS 100A 115A 125A 135A Mounting Specifications Section 11 ...

Page 112: ...nly due to front axle spindle loading Options Extra Maverick Installation Manual 02982279 Standard Features 1 Modified exhaust pipe for boom transport clearance 2 Replacement arm rest with joystick console 3 NeapcostyledrivelinewithdoubleU joints 4 1400 wheelweightplus408 auxiliaryweightkit 5 Right hand replacement Lexan door 3 8 Lexan replacement door right side only See Figure 4 6 51gallonreplac...

Page 113: ...Replacement Exhaust Pipe Elbow Bracket Figure 2 Seat Mounted Joystick Figure 3 Battery Box Clearance Mounting Specifications Figure 4 Lexan Door Replacement Kit Figure 5 Electronic Module mounted unseen behind cab panel Figure 6 Electronic Display Screen mounted in Cab in Operator view ...

Page 114: ...00 2 CABLE CLAMP 9 02981377 1 OIL COOLER ASY W FAN 10 00015800 8 LOCKNUT TOPLOCK 3 8 NC 11 00011100 12 FLATWASHER 3 8 STD 12 02981383 1 COOLER MOUNT RH 13 02981384 1 COOLER MOUNT LH 14 02090800 2 ADAPTER HYD ELBOW 12MB 12MJ90 15 02962181 6 ADAPTER HYD STRAIGHT 16 02977622 1 DIVERTER SOLENOID VALVE 17 02981803 1 VALVE AND HYD TANK ASY Includes the Next 47 Items 02981373 1 INDICATOR ELEC W PACKARD 0...

Page 115: ... WARNING HOSE BURST 02971943 1 DECAL ALAMO IND YELLOW 02981888 1 ASY VALVE FITTINGS 02968896 1 PLASTIC TIE ORANGE 11LG 02968894 1 PLASTIC TIE RED 11LG 02971943 1 DECAL ALAMO IND YELLOW 02982347 1 ADAPTER HYD 16MB 10MJ STRAIGHT 02972064 1 ADAPTER HYD ELBOW 16MB 8MJIC 90 18 02981805 1 ELECTRONIC KIT includes the following 9 items 02981374 1 CONTROLLER 3 AXIS 5 BUTTON 02981375 1 HARNESS WIRE CONTROLS...

Page 116: ... PL GR5 28 00017000 2 LOCKWASHER 1 4 PL STD 29 00776031 1 CANISTER F MANUALS 30 00776481 1 DECAL SHEET CANNISTER MANUAL 31 02977417 1 DECAL OPERATORS MANUAL INSIDE 32 107079 1 WIRE BLACK 14 GA X 24 LONG 33 02982339 2 OVAL SLEEVE 5 32 DIA 34 D377 1 BOOKLET DECAL BOOM MOWER 35 02981822 1 HOSE BRACKET WELDMENT 36 00019600 1 LOCKWASHER 1 2 HEAVY PL 37 02892000 1 BOLT HEX HEAD 1 2 13NC X 1 1 2 PL GR8 3...

Page 117: ...H TS 100A 115A 125A 135A Cab 2 wd Consist of the Following Items Item Part No Qty Description 1 02980888 1 LEXAN REPLACEMENT DOOR KIT RH SIDE 2 02971789 1 WHEEL WEIGHT KIT 1400 LBS 3 02976671 1 AUXILLARY WHEEL WEIGHT KIT 408LBS 4 02980938 1 REPLACEMENT FUEL TANK KIT 5 02982005 1 RAIL WELDMENT RH REAR 6 02982006 1 RAIL WELDMENT LH REAR 7 02982014 1 RAIL WELDMENT RH FRONT 8 02982015 1 RAIL WELDMENT ...

Page 118: ...HER 7 16 PL 5 02975692 18 BOLT HEX HEAD M20 P2 5 X 50MM PL GR10 9 6 02971158 18 LOCKWASHER 20MM 7 00059500 4 NUT HEX 1 NC PL 8 02032200 4 LOCKWASHER STD 1 9 02980723 8 BOLT HEX HEAD M18 P1 5 X 80 PL GR10 9 10 02970066 8 LOCKWASHER 18MM 11 02959587 2 BOLT HEX HEAD 3 4 10NC X 6 PL GR8 12 00037200 26 LOCKNUT 3 4 NC 13 02960521 4 BOLT HEX HEAD 3 4 NC X 2 3 4 PL GR8 14 5312316 70 WASHER 3 4 20 MM HARDE...

Page 119: ...GR8 4 02976644 3 PLATE WHEEL WELDMENT Auxilary Wheel Weight Kit P N 02976671 is in Mount Kit P N 02982343 02980938 Fuel Tank Consist of the following Item No Item Part No Qty Description 1 00011100 3 FLAT WASHER 7 8 PL STD 2 00015800 3 LOCKNUT TOPLOCK 3 8 3 00037200 2 LOCKNUT 3 4 NC 4 00001800 4 LOCKNUT TOPLOCK 1 2 NC PLB 5 02776600 4 BOLT HEX HEAD 1 2 13NC X 1 1 4 PL GR8 6 03200285 1 DECAL WATCH ...

Page 120: ...following Item No Item Part No Qty Description 1 02980917 1 PIPE EXHAUST NH TS115A 2 02980728 3 BOLT HEX HEAD M12 P1 75 X 30mm PL GR10 9 3 701513C 3 M12 FLATWASHER 4 00754566 3 LOCKWASHER 12MM 5 02980933 1 WLDMT EXHAUST BRACKET 6 02959132 2 CLAMP 3 1 2HD MUFFLER CLAMP Exhaust Reloctaion Kit P N 02980916 is in Component Box P N 02982344 which is in Mount Kit P N 02982343 02981750 Battery Relocation...

Page 121: ...up Inc 11 11 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 New Holland TS 100A 115A 125A 135A Cab 4wd Page 1 8 thru 1 11 24 foot Maverick 4wd MountKiTOnly Mount Kit P N 02982341 Mounting Component ID 24 ft Cab 4wd ...

Page 122: ...1 RAIL WELDMENT RH FRONT 7 02982015 1 RAIL WELDMENT LH FRONT 8 02982314 1 BOOM REST WELDMENT 9 02981893 1 COMPONENT BOX 02981893 Component Box Consist of the following Item No Item Part No Qty Description 1 02980699 1 PULLEYADAPTER NH TS A 2 02980719 1 ASSY TS A PUMP MOUNT W COVER 3 02980694 1 PLATE BOOM REST STABILIZER 4 02980916 1 KIT EXHAUST RELOCATION TS115A 5 02981750 1 KIT BATTERY RELOCATION...

Page 123: ...R8 16 00748547 7 FLATWASHER 1 1 32 X 2 3 16 X 22 HARDENED 17 02981985 8 WASHER 18MM HARDENED 18 02966556 3 BOLT HEX HEAD 1 NC X 11 PL GR8 19 02972088 8 BOLT HEX HEAD 3 4 NC X 3 1 2 PL GR8 20 02980721 1 BOLT HEX HEAD 1 8UNC X 10 1 2 PL GR8 21 02918600 8 BOLT HEX HEAD 3 4 10UNC X 2 PL GR8 22 00759457 4 BOLT LAG 5 16 X 2 PL GR5 23 00011700 4 LOCKWASHER 5 16 PL STD 24 00762398 2 BOLT HEX HEAD M10 P1 5...

Page 124: ...k Kit P N 02980938 is in Mount Kit P N 02982341 02980888 Lexan Door kit RH Door Consist of the following Item No Item Part No Qty Description 1 02980803 1 LEXAN DOOR NEW HOLLAND TS A 2 02980889 1 TRIM PUSH ON WEATHER SEAL 199 3 00021900 2 BOLT HEX HEAD 5 16 NC X 1 3 4 PL GR5 4 00750940 4 LOCKNUT TOPLOCK 5 16 NC PLB 5 02766400 2 BOLT HEX HEAD 5 16 NC X 1 1 2 6 02981016 1 CARTON NH TS A LEXAN DOOR 7...

Page 125: ...1 CYLINDER ASY 2 02981896 1 ADAPTER HYD REDUCER 6FJX 4MJ 3 02965166 1 ADAPTER HYD TEE 6MJ 6MJ 6FJX 4 02960018 1 ADAPTER HYD ELBOW 5 02960054 1 PLUG 4 MB W T VENT O RING 6 001845 1 HOSE 4 4FJX 4FJX90 70LG 7 02983143 1 BRACKET WELDMENT TOP 8 02983144 1 BRACKET WELDMENT BOTTOM 9 02982320 1 CYLINDER SUPPORT WELDMENT 10 00752716 2 BOLT HEX HEAD 1 2 NC X 3 1 2 PL GR8 11 7B101128 2 BOLT HEX HEAD 5 8 NC X...

Page 126: ...5A Asy Man 01 05 New Holland TS 100A 115A 125A 135A Cab 4wd Page 1 12 thru 1 15 30 foot Maverick 4wd MountKiTOnly Mount Kit P N 02981892 30 Maverick booms must be mounted on 4wd tractors only due to front axle spindle loading Mounting Component ID 30 ft Cab 4wd ...

Page 127: ...IL WELDMENT LH REAR 7 02982014 1 RAIL WELDMENT RH FRONT 8 02982015 1 RAIL WELDMENT LH FRONT 9 02982025 1 BOOM REST WELDMENT 10 02981893 1 COMPONENT BOX 02981893 Component Box Consist of the following Item No Item Part No Qty Description 1 02980699 1 PULLEYADAPTER NH TS A 2 02980719 1 ASSY TS A PUMP MOUNT W COVER 3 02980694 1 PLATE BOOM REST STABILIZER 4 02980916 1 KIT EXHAUST RELOCATION TS115A 5 0...

Page 128: ...R8 16 00748547 7 FLATWASHER 1 1 32 X 2 3 16 X 22 HARDENED 17 02981985 8 WASHER 18MM HARDENED 18 02966556 3 BOLT HEX HEAD 1 NC X 11 PL GR8 19 02972088 8 BOLT HEX HEAD 3 4 NC X 3 1 2 PL GR8 20 02980721 1 BOLT HEX HEAD 1 8UNC X 10 1 2 PL GR8 21 02918600 8 BOLT HEX HEAD 3 4 10UNC X 2 PL GR8 22 00759457 4 BOLT LAG 5 16 X 2 PL GR5 23 00011700 4 LOCKWASHER 5 16 PL STD 24 00762398 2 BOLT HEX HEAD M10 P1 5...

Page 129: ...405 2 BOLT HEX HEAD 3 4 NC X 5 1 2 PL GR8 8 108693 1 GAS CAP 9 02976633 1 WLDMT STEP 10 00753642 3 BOLT HEX HEAD 3 8 NC X 1 1 4 PL GR5 11 02980996 6 BOLT SOCKET HEAD 10 24 X 1 12 63121800 6 LOCKWASHER 10 STD PL 13 31001000 6 FLATWASHER 3 16 PL STD 14 02982198 1 WLDMT FUEL TANK 15 02982206 1 WLDMT FRONT BRACKET 16 02982207 1 WLDMT REAR BRACKET Replacement Fuel Tank Kit P N 02980938 is in Mount Kit ...

Page 130: ...tery Reloctaion Kit P N 02981750 is in Component Box P N 02981893 which is in Mount Kit P N 02981892 02981895 TS A Front Axle Stabilizer Kit Consist of following Item No Item Part No Qty Description 1 02981316 1 CYLINDER ASY 2 02981896 1 ADAPTER HYD REDUCER 6FJX 4MJ 3 02965166 1 ADAPTER HYD TEE 6MJ 6MJ 6FJX 4 02960018 1 ADAPTER HYD ELBOW 5 02960054 1 PLUG 4 MB W T VENT O RING 6 001845 1 HOSE 4 4FJ...

Page 131: ...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 Mounting Component ID Control Valve Fittings ...

Page 132: ...ty 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 Mounting Component ID Hydraulic Lock Valve ...

Page 133: ...c Pressure from Door Swivel B Port on Control Valve P2 Hose Hydraulic Return to Door Swivel A Port on Control Valve C1 Hose to Head Swivel Cylinder Base End C2 Hose to Door Cylinder Base End C3 Hose to Door Cylinder Rod End C4 Hose to Head Swivel Cylinder Rod End VS 125 F C2 C3 SAE 4 P1 P2 C1 Port this side Not Seen to head swivel cyl base end C4 Port this side Not Seen to head swivel cyl rod end ...

Page 134: ...0 30 ft model only SwingCylinders Swing Cylinder Pivot Bushings SwingCylinderTrunnionMountWeldment Swing Cylinder Cover TurretCylinderLink BoomMount Machined Boom Mount Attaching Pin Short Pin Boom Mount Attaching Pin Medium Pin Boom Mount Attaching Pin Long Pin Lift Cyl Pin Turret Boom Mount Pin TurretAsy Machined LH Counter Weight Weight Attaching Pin Long Pin Center Section Frame Weldment ...

Page 135: ... 2004 Alamo Group Inc 11 25 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 Mounting Component ID Hyd Hose Connections 24 FT Boom ...

Page 136: ...02981840 1 Z MJ X FJX Hose 4 4MJ 4FJX 176 Lg Grn Tie Swivel Dipper Sect n 02981841 1 Z MJ W FJX Hose 4 4MJ 4FJX 176 Lg Grn Wht Tie Swivel Dipper Sect n 02981842 1 Z MJ T FJX Hose 6 6MJ 6FJX 176 Lg Red Tie Tilt Dipper Sect n 02981843 1 Z MJ S FJX Hose 6 6MJ 6FJX 176 Lg Red Wht Tie Tilt Dipper Sect n 02981846 1 C FJX F FJX Hose 16 16FJX 16FJX90 102 Lg Red Tie Motor P Lift Sect n 02981847 1 A FJX D F...

Page 137: ... 2004 Alamo Group Inc 11 27 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 Mounting Component ID Hyd Hose Connections 30 FT Boom ...

Page 138: ...ect n 02981867 1 Z MJ X FJX Hose 4 4MJ 4FJX 214 Lg Grn Tie Swivel Dipper Sect n 02981868 1 Z MJ W FJX Hose 4 4MJ 4FJX 214 Lg Grn Wht Tie Swivel Dipper Sect n 02981869 1 Z MJ T FJX Hose 6 6MJ 6FJX 214 Lg Red Tie Tilt Dipper Sect n 02981870 1 Z MJ S FJX Hose 6 6MJ 6FJX 214 Lg Red Wht Tie Tilt Dipper Sect n 02981873 1 C FJX F FJX Hose 16 16FJX 16FJX90 140 Lg Red Tie Motor P Lift Sect n 02981874 1 A F...

Page 139: ...routingisforthehoseswhich 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 markedA Thisisdonewiththeotherlettersaswell thehosemustconnecttothesamelettermarkings on each end as in drawing Some hose will be marked with a colored plastic tie Some ...

Page 140: ... Plastic Tie Green White NOTE Hose are not shown in drawing this is for clarity The hose routing is for hoses which connect from one point to the other Use the instructions and hose descriptions listed to follow hose routing Example Hose A1 connects to one end marked A1 and the other end connects to the other connection marked A1 This is done with the other letters as well the hose must connect to...

Page 141: ...ection P1 Port Load Sense Signal PL Service Port Connection A Port A Tank Return Connection T2 Testing Port for Pilot Pressure Test PS Service Connection Port B Port B B B B B B B A A A A A A Swing Dipper Telescope Head Tilt Head Swivel Door Lift Mounting Component ID Cyl Cntrl Valve Connections ...

Page 142: ... Number Boom Cylinder Circuit Hoses connections from Control Valve Color Tie Code Hose Size Port 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 B Lift Down Rod End Orange White OR W SAE 6 A 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 B Telescope In Rod End Yellow White Y ...

Page 143: ...p Inc 11 33 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 IqanDisplayUnit XP2 Expansion Power XT2 Expansion Transmission XS Expansion Signal TankTemperature Sensor ChargePressureFilterSwitch Component Identification ...

Page 144: ...05 P N 02976633 LH Side Step Wldmnt P N 02980694 LH Rear TopAxle strap Component Identification P N 02981168 Center Section Under Mount FrameWldmnt Rear View Front of Tractor LH Side of Tractor RH Side of Tractor Rear of Tractor Install with these openings to front of tractor ...

Page 145: ...t Identification P N 02980933 Exhaust Relocation Bracket P N 02981404 Tank Rail Mount RH P N 02981405 Tank Rail Mount LH P N 02981415Arm Rest Controller Mount Weldment P N 02981725 Battery Relocation Bracket Weldment 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 12 12 12 12 12 12 RH Side Shown LH Bent opposite way Tractor End ...

Page 146: ...P N 02982324 Mount Plate Iqan Display Mount Component Identification P N 02982022 Boom Rest Stabilizer Wldmnt P N 02982014 Rail Weldment RH Front P N 02982015 Rail Weldment LH Front P N 02982198 Fuel Tank Weldment 51 Gals 02982206 Fuel Tank Brkt Weldment Front 02982207 Fuel Tank Brkt Weldment Rear ...

Page 147: ...Axle Stabilizer Kit Only for 4 WD Tractors P N 02983144 Front Axle Stabilizer Bottom Bracket Weldment Included in FrontAxle Stabilizer Kit Only for 4 WD Tractos P N 02982320 Cyl Support Weldment Included in FrontAxle Stabilizer Kit Only 123 123 123 123 123 123 123 1234 1234 1234 1234 1234 1234 1234 1234567 1234567 1234567 1234567 1234567 1234567 1234567 1234567 1234567 1234567 1234567 P N 02981316...

Page 148: ...8 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 Component Identification Oil Cooler FanAssembly P N 02981377 Two Wires in plug 1 Blue Wire Connection 1 Black Wire Connection Connecte to R1 Connec tion of Exterior Wire Harness ...

Page 149: ... 2004 Alamo Group Inc Section12 1 Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05 MAVERICK New Holland Tractor TS 100A 115A 125A 135A PRE DELIVERY INSPECTION CHECKLIST Section 12 ...

Page 150: ...rque to 120 ft lbs All Welds inspected toinsure proper welds and locations Hydraulic System Oil Level in Hydraulic Tank is within the sight gauge Hose connections are tight Hoses do not have any kinks or twist in them Front Pump Shaft adapter bolts are tight Front Pump Shaft Coupler Drive Shaft is lubricated and has an anti seize compound on the Splines of Pump and Shafts The Pump Drive Shaft has ...

Page 151: ... the boom and mower head throughout its full range of motion and check for hose s rubbing pinching or kinking ___ Make sure the Return Filter Gauge is reading in the Green after Oil is warm ___ Check the function of the Mower Head On Off Valve and switch for proper function ___ Make sure that the tractor will not start with the mower on off switch in the on position ___ Check the Blade Rotation fo...

Page 152: ... 2005 Alamo Group Inc Section 12 4 Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05 NOTES ...

Page 153: ......

Page 154: ...Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Maverick Assembly Manual New Holland TS 100A 115A 125A 135A 2005 Edition P N 02982279 ...

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