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Maverick/NH TS-100A,115A,125A,135A

1. Assembly Instruction Manual New Holland Cab 2 WD 4 WD TS 100A TS 115A TS 125A TS 135A INDUSTRIAL Published 01 05 Part No 02982279 ASSEMBLY MANUAL Tractors ERR wih additional ions equipment tractor manufacturer medie ne 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 MEMBER OF THE 210 379 1480 A HET RE 2005 Alamo Group Inc ALWAYS ON THE CUTTING EDGE TO THE OWNER OPERATOR DEALER All implements with moving parts are potentially hazardous There is no substitute for a cautious safe minded operator who recognizes the potential hazards and follows reasonable safety practices The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents BEFOREYOUSTART Read the safety messages on the implement and shown in your manual Observe the rules of safety and common sense 44 DANGER FAILING TO FOLLOW SAFETY MESSAGES AND OPERATING INSTURCTIONS CAN CAUSE SERIOUS BODILY INJURY OR EVEN DEATH TO OPERATOR AND OTHERS IN THE AREA 2 NO RIDERS NO CHILDREN 3 USE SAFETY SHOES HARD 4 BLOCK UP SECURELY OPERATORS HAT SAFETY GLASSES BEFORE WORKING UNDER SEAT BELTS amp ROPS ee aS a Ome 1 Study and unders
2. GENERAL INFORMATION The tools you will need at the assembly site are as follows Welding equipment including correct head gear eye shields and protective clothing Impact wrench or socket and ratchet set Rubber mallet Box end Allen and crescent wrenches Alignment pins Phillips and plain head screwdrivers Forklift or hydraulic floor jacks with rolling back boards Over head hoist and floor jacks Jack Stands and or other support devices that are strong enough to support tractor and components 10 Multidirectional Levels 11 Paint Scraper 12 Hydraulic Filter Buggy or Cart 13 Safety shoes safety glasses and gloves A hard hat should be worn by anyone working under any raised component dza z w Remember to follow each step closely and cautiously Be aware of all support personnel at all times Keep the assembly area as clean as possible clean up all spills when they occur An uncluttered assembly area and a crew that is sensitive to the hazards involved in putting this implement together will help prevent accidents Keep all unauthorized personnel from the area Do not allow children near the assembly site nor allow them on or near the tractor after assembly There is no safe place for anyone except the operator on the tractor and those assisting with the assembly Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 2 3 General Information Installation Requirements
3. 12 Hose Red Plastic Tie B 4 8 Hose G 20 Hose Blue Plastic Tie Suction Hose No Plastic Tie 4 Hose amp Tee Tank Return Blue Plastic Tie H 12 Hose Orange Plastic Tie nm F 4 Hose Figure 2 E 4 Hose 90 Elbow 90 Elbow Red Plastic Tie Blue Plastic Tie NOTE Hoses are not shown in drawing above this is for clarity The hose routing is for the hoses which connect from one point to the other Use the instructions and hose description listed to follow hose routing 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 Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05
4. 2005 Alamo Group Inc Section 4 3 Directional Control Valve Fittings A B Ports Ports L Port Load Sense Signal k gas P1 Port Z ON y IY TO 1135 MB EC swine fi IOONE Ol Dipper ETE a OO CRC Telescope Se tig Pr Stickers nai Head al DP 186000 a Head Swivel Door y F I R 4 Tank Return Port CTI al FT 3 gt TEJ A T B CS 07 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 4 4 Directional Control Valve Fittings Valve Fittings and Location See Figure 3 Item Part No Qty Description 02981888 Valve amp Fittings Asy 6 Spool 1 02981370 1 Valve Asy w o Fittings 2 02090800 2 Adapter Hyd Elbow 12MB 12MJ 90 3 02972177 11 Adapter Hyd Straight 10MB 6MJ 4 03200284 1 Adapter Hyd Straight 6MB 4MJ 5 02981889 1 Adapter Hyd Straight 10MB 6MJ 6 02972208 1 Valve Solenoid Asy 7 02975438 1 Adapter Hyd Straight 8MB 8FJX 8 02981890 1 Adapter Hyd Straight 8MB 6MJ HYDRAULIC LOCK VALVE Head Tilt Function An Electric Solenoid Operated Hydraulic Lock Valve Figure 4 is incorporated in the Head Tilt Function to prevent excessive Head Lift Cylinder leak down during storage or transportation The Solenoid which operates this valve is normally inthe Locked position until Head Lowering function is actuated at Joystick When Joystick is actuated to lower Head an electric signal is sent to solenoid to open Lock valv
5. Continued Next Page Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 5 Common Box Component List 02981781 Common box Consist of the Following Items Contiuned from previous page PART NO ITEM 26 21 28 29 30 31 32 33 34 35 36 37 38 00011400 00023100 00017000 00776031 00776481 02977417 107079 02982339 D377 02981822 00019600 02892000 02981992CA QTY DESCRITION BOLT HEX HEAD 3 8 NC X 1 BOLT HEX HEAD 3 8 NC X 1 1 2 PL GR5 LOCKWASHER 1 4 PL STD CANISTER F MANUALS DECAL SHEET CANNISTER MANUAL DECAL OPERATORS MANUAL INSIDE WIRE BLACK 14 GA X 24 LONG OVAL SLEEVE 5 32 DIA BOOKLET DECAL BOOM MOWER HOSE BRACKET WELDMENT LOCKWASHER 1 2 HEAVY PL BOLT HEX HEAD 1 2 13NC X 1 1 2 PL GR8 MANUAL CANNISTER ASSEMBLY Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 6 Mounting Component ID 24 ft Cab amp 2wd New Holland TS 100A 115A 125A 135A Cab 2wd IMPORTANT NOTICE The following Part Assembly Numbers are for reference and should not be ordered as replacement parts unless all the components in that assembly are wanted These will break down to bills of material of the components Some of numbers listed are NOT individual Parts but complete assemblies and or box of assemblies Check before ordering 24 foot Maverick 2wd Mount Kit 2wd tractors
6. H bolts through Weight and Wheel Rotate Wheel to align holes if Wheel Weight Mnig needed Install a Hex Lock Nuton PA E Locknuts inside Insert the other two Bolts gs LE E j through Weight and Wheel and See VA Cy start the other two Locknuts Do not tighten yet See Figure 2 i il di wa Wal 5 Looking at the outside make sure the three special Wash Wheel Weight ers Figure 1 Item 2 are aligned _ with the Slots in the Wheel Weight Special Washers f Tr 1400 Ibs Tighten the three Bolts now You Part 02971569 MN will need an assistant to hold the other Side while you are tightening the Bolts While tightening Bolts check to make sure the three spe cial washers are seated correctly If these Bolts are tightened and washer are not seated into the recess on Wheel Weight dam age will occur See Figure 3 6 Remove forklift away from Wheel and Weight Recheck tight ness of Wheel Weight retaining Bolts Bolts should torque to 500 Figure 3 ft Ibs Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 7 3 Auxiliary Rear Wheel Counter Weight Installing Auxiliary Wheel Weight Kit 1 The Auxiliary Wheel Weight is made up of three steel plates and mounting hardware Each Auxiliary Weight weighs approx 136 lbs When all three are installed on the existing 1400 Ib weight it will increase the wheel weight by 408 lbs This makes the total bolt on wheel weig
7. 2005 Alamo Group Inc Section 8 18 Section 9 MAVERICK New Holland Tractor TS 100A 115A 125A 135A Boom amp Head Installation Boom Head Installation Boom Installation Boom Hoses 1 Turret Assembly The turret assembly has ESMRTeN Hosa Swing Cyl Hose the cylinders connected and the hoses are con jaro pres o Lie 1021 100 nected 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 White Tie 2 Booms Are recieved from the factory with the Sections of Boom Assmebled to together The Boom Sections are assembled with the hy draulic lines and cylinder connected The hose will be connected to the boom that are routed to the control valve and diverter valve and bundled together See Figure 4 The Boom Hoses are Lifting protruding out the turret mount end of the boom Point The Hose connections on the head end will be shipped with metal caps on them these are to protect the lines from contamination and should not be removed until the hoses are being in stalled See Figure 5 The hose that attaches to the boom are sent installed on the head assem bly and the hose will also have plugs in them 1 Figure 2 3
8. Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Index 2 INDEX ASSEMBLY INSTRUCTION Page Section 6 Lexan Door Installation Lexan DOOPINSIANATIOES SR dm sa 6 2 to 6 4 Section 7 LH Wheel Weights Standard Wheel W igAt 408 un 7 2 to 7 3 Auxiliary Wheel Wed cscs sccatecesensestessonenndiedsoassetscectededdedancecetocsshedieds 7 4 Section 8 Joystick Wire Harness Valve Installation Wire Harness tractor Preparation 8 2 Replace Tractor Seat Arm Rest 8 3 E S Switch ne AA dON mibesesues 8 4 Jo SSN 8 4 to 8 6 STENEN 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 GP 8 17 Section 9 Boom Head Installation OOM VOUMUNG EEE lie nn aie 9 2 to 9 5 Boom Lift Cylinder Pin Installation nn 9 2 to 9 3 Boom Cylinder Schematic o nnrnvnnn nn 9 6 Valve 0 510 110 1 sol asilog cko in ciou nia 9 6 Hose Routing ARNO ola lg 10 1 no ME 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 FN es 9 11 to 9 12 Section 10 Fill Oil Tank Setting Electronic Display Controls PU Wel EEE 10 2 to 10 3 PANG tr PL e reg 10 3 Setting Electric Display Control Box 10 4 to 10 11 Joystick Operation 10 12 front Pump amp Tank Cover Installation 10 13 Section
9. Oil Cooler Fan As sembly The Oil cooler fan assembly is for cooling the oil being returned from the Motor Case Drain The fan is con nected to the control box and is turned on amp off automati cally Itsetto run on a program that will run the fan in the cool Exterior wire ing rotation for a designated harness connec time then stop reverse the tion marked R1 rotation cycle to clean debris off of cooler then stop and reverse the fan again and be CE gin the cycle all over again j The connection to the cooler onthe exterior wire har ness is marked with code R1 The connection from the fan will have two wires a Blue connection and a black con nection See Figure 32 connects here Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 14 Exterior Wire Harness Schematic P N 02981375A Maverick Sensor Connections 1 Instrumentation The Maverick Boom utilizes instrumentation for certain decision making activi ties Listed below are the sensors included on this unit Tank Temperature Sensor Charge Pressure Filter Switch Valve Pressure Filter Switch and Re turn Filter Switch 2 Tank Temperature Sensor The tank tem perature sensor monitors the fluid temperature in the area of the pump suction screens the tempera ture is real time and is used on the network to accomplish certain objectives The first is to display on the interface while the cutter circ
10. Qty 1 1 2 4 2 1 1 Description LEXAN DOOR NEW HOLLAND TS A TRIM PUSH ON WEATHER SEAL 199 BOLT HEX HEAD 5 16 NC X 1 3 4 PL GR5 LOCKNUT TOPLOCK 5 16 NC PLB BOLI HEX HEAD 5 16 NC X 1 1 2 CARTON NH TS A LEXAN DOOR INSERT LEXAN DOOR INSTALLATION Lexan Door Kit P N 02980888 is in Mount Kit P N 02982341 02980916 Exhaust Relocation Kit Consist of the following Item No em OonRWN F Part No 02980917 02980728 701513C 00754566 02980933 02959132 Qty 1 3 3 3 1 2 Description PIPE EXHAUST NH TS115A BOLT HEX HEAD M12 P1 75 X 30mm PL GR10 9 M12 FLATWASHER LOCKWASHER 12MM WLDMT EXHAUST BRACKET CLAMP 3 1 2HD MUFFLER CLAMP Exhaust Reloctaion Kit P N 02980916 is in Component Box P N 02981893 which is in Mount Kit P N 02982341 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 14 Mounting Component ID 24 ft Cab amp 4wd 02981750 Battery Relocation Kit Consist of the following Item No tem Part No Qty Description 1 02981725 1 WLDMT BATTERY BRACKET 2 00011400 3 BOLT HEX HEAD 3 8 NC X 1 3 00012101 3 LOCKWASHER 3 8 PL 4 00013901 3 NUT HEX 3 8 NC PL Battery Reloctaion Kit P N 02981750 is in Component Box P N 02981893 which is in Mount Kit P N 02982341 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
11. The Unit still will not operate until the next step of setting the electronics to operate the system Figure 9 New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 3 CONTROL VALVE BOOM amp MOTOR CONTROL Maverick Boom and Motor Control Circuits It is advised that this section be read before proceeding with any repairs or test with the 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 currentfrom 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
12. harness connections To Diverter Valve O O c 2 s U D L Pressure Supply Port P XT2 Expansion Transmission ER E Gr Bolts on LH side i Bolt RH side in front of Valve FIGURE 30 A A ie A FIGURE 29 29 i 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 8 38 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 13 Exterior Wire Harness Schematic P N 02981375A Diverter Valve Wire Harness Connection BB of exterior harness connects here Diverter Valve Diverter Valve C1 Port to Swivel Cyl Base End Port G W Tie Valve B Port to Diverter valve P1 Port Diverter Valve C4 Port G W Tie to Swivel Cyl Rod End Port G Tie 4 pie kr are Diverter Valve C2 Port mounting NOIES to Door Cyl Base End Port Y W Tie Valve A Port to Diverter valve P2 Port G Tie Diverter Valve C3 Port to Door Cyl Rod End FIGURE 31 Port Y Tie Connecting Oil Cooler And Fan Assembly to Ex terior Wire Harness 15
13. lu Disconnect the negative lead ground from the battery terminal to prevent any us ELT low fe Y KA ga 1 M p X uly fad ip X H SPE 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
14. 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 02981893 which is in Mount Kit P N 02981892 02981750 Battery Relocation Kit Consist of the following Item No tem Part No Qty Description 1 02981725 1 WLDMT BATTERY BRACKET 2 00011400 3 BOLT HEX HEAD 3 8 NC X 1 3 00012101 3 LOCKWASHER 3 8 PL 4 00013901 3 NUT HEX 3 8 NC PL Battery 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 tem 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 amp 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 GRB 11 7B101128 2 BOLT HEX HEAD 5 8 NC X 3 1 2 PL GR8 12 00695100 2 LOCKNUT TOPLOCK 5 8 13 00001800 2 LOCKNUT TOPLOCK 1 2 NC PLB 14 02975669 4 BOLT HEX HEAD M20 P2 5 X 60MM PL GR10 9 15 02971158 4 LOCKWASHER 20MM TS A Front Axle Stabilizer Kit P N 02981895 is in Component Box P N 02981893 which is in Mount Kit P N 02982341 Maverick NH TS 100A 115A 125A 135A
15. 02965166 1 ADAPTER HYD TEE 6MJ 6MJ 6FJX 4 02960018 1 ADAPTER HYD ELBOW 5 02960054 1 PLUG 4 MB W T VENT amp 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 GRB 11 7B101128 2 BOLT HEX HEAD 5 8 NC X 3 1 2 PL GR8 12 00695100 2 LOCKNUT TOPLOCK 5 8 13 00001800 2 LOCKNUT TOPLOCK 1 2 NC PLB 14 02975669 4 BOLT HEX HEAD M20 P2 5 X 60MM PL GR10 9 15 02971158 4 LOCKWASHER 20MM TS A Front Axle Stabilizer Kit P N 02981895 is in Component Box P N 02981893 which is in Mount Kit P N 02982341 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 15 Mounting Component ID 30 ft Cab amp 4wd New Holland T S 100A 115A 125A 135A Cab amp 4wd Page 1 12 thru 1 15 30 foot Maverick 4wd Mount KiT Only Mount Kit P N 02981892 30 Maverick booms must be mounted on 4wd tractors only due to front axle spindle loading Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 16 Mounting Component ID 30 ft Cab amp 4wd New Holland TS 100A 115A 125A 135A Cab amp 4wd IMPORTANT NOTICE The following Part Assembly Numbers are for reference and should not be ordered as replacement parts unless all the components in that assembly are wanted These will break down to bills of material of the com
16. 05 2005 Alamo Group Inc Section 8 15 Exterior Wire Harness Schematic P N 02981375A 5 The Return Filter Switch The return filter switch is located at the return filter mounted on to the tank top The fluid returning from the cylinder control valve is filtered before returning to tank at this loca tion See Figure 36 The sensor monitors back pressure created by the filter assembly while cylin der circuit is in operation When the back pressure reaches 25 psi the switch will trigger and prompt the operator for a filter element change WARNING This filter does not have a by pass The element must be changed at the appropri ate time to avoid element damage and system contamination 6 Oil Cooler amp Fan Assembly The oil cooler fan assembly bolts to the tank rail mount bracket between tractor front axle and hydraulic tank The mounting holes are in the tank rail mounting brack ets See Figure 37 There will be two hose con nected 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 di ora x FIGURE 37 Diverter ta Plug Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc 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 befo
17. 1 2 Maverick Boom SEE ONS as aa ara 1 3 to 1 6 Hose Fitting Torque NA ii 1 6 BT 1 7 Section 2 Tractor Preparation General GOUT NOD ae a ae sta ae 2 2 to 2 8 Section 3 Pump amp Driveshaft Installation Remove Engine Guards for Access to engine compartment 3 2 Pulley ATEN 3 2 Install Shaft Half of Drivesha t 3 3 Install Tank Mount Rails 3 4 WETS VM NTU sosna ajeho obojok tot EE 3 4 to 3 Reinstall Engine Guards amp Covers 3 8 Section 4 Hydraulic Tank amp Control Valve Installation Install Hydraulic Tank to Tank Mount Rails 4 2 TankAose ani an ce 4 2 to 4 3 Control Valve Fitting Id ntiticatiOn 2 s ssssenr 4 4 to 4 5 Me 4 5 Valve Hose Marking Codes 4 6 NTV Ne 4 6 to 4 8 Oil Cooler amp Cooling Fan Assembly nn 4 9 Section 5 Battery Exhaust Fuel Tank Modification amp Main Frame Installation Battery Relocation Modlification 5 2 Exhaustrelocation Modification 5 3 Fuel TankInstallation Modification 5 4 to 5 5 Under Mount Component Information 5 6 to 5 7 Frame EEE 0 a a 5 8 to 5 11 Boom RESTINS TAA ON Sa so in 5 11 Frame Counter Weight Installation 5 12 Boom Turret Assembly Installation 5 13 to 5 14 Front Axle Stabilizer S ann be temoin ab 5 15
18. 1 Hose 12FJX 12FJX 31 Lg w Red Tie Pressure Filter to Supply E 02981431 1 Hose 4FJX 4FJX 90 35 Lg w Red Tie Pump Load Sense to Valve PX Connects to top side of pump as shown F 02981432 1 Hose 4FJX 4FJX 90 20 Lg w Blu Tie Pump Regulator to Tank Connects to bottom side of pump not seen Fo 1 Hose 4 Connects here w Tee Fitting Connect to Base End Stabilizer Cyl G 02981433 1 Hose 20FJX 12FJX 24 Lg Pump to Suction Filter H 02981462 1 Hose 12FJX 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 lt 1 Hose w Blue Tie Oil Return from Oil Cooler to Tank Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 4 2 Hydraulic Tank Hose Routing J 16 Hose B 8 Hose Red Plastic Tie 90 Elbow er Blue Plastic Tie A 8 Hose Sr A Nose K 46 Hose 90 Elbow Red Plastic Tie Orange Plastic Tie Red Plastic Tie C 12 Hose Suction Hose No Plastic Tie D 12 Hose Red Plastic Tie br am BL KE lace G 20 Hose Suction Hose No Plastic Tie mnt V A 8 Hose Red Plastic Tie H 12 Hose 90 Elbow Orange Plastic Tie ye rs L Hose Blue Plastic Tie D
19. 20 mm bolts Each 3 4 8 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 17 frame These hardened washers are important igure RH Rear Frame Mount Weldment P N 02982005 Figure 19 LH Front Frame Mount Weldment P N 02982014 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 5 8 LH Rear Frame Mount Weldment P N 02982006 RH Front Frame Mount Weldment P N 02982015 Center Frame Weldment P N 02981168 Frame Installation 3 Install Rear Frame Mount Rails Rear frame rails consist of a LH amp RH We have started with the Left Hand Rail The three point lift stabilizer brackets will need to be unbolted on both sides In the illustra tion 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 re moved 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 amp 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 unde
20. 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 amp 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 amp Removal Tool Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc 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 ona 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 amp 5 and will E need to be installed first make certain to put the rubber zil ee washer back on fastene
21. Asy Man 01 05 2004 Alamo Group Inc 11 20 Mounting Component ID Control Valve Fittings 2 Item Part No Qty Description 02981888 Valve amp Fittings Asy 6 Spool 1 02981370 1 Valve Asy w o Fittings 2 02090800 2 Adapter Hyd Elbow 12MB 12MJ 90 3 02972177 11 Adapter Hyd Straight 10MB 6MJ 4 03200284 1 Adapter Hyd Straight 6MB 4MJ 5 02981889 1 Adapter Hyd Straight 10MB 6MJ 6 02972208 1 Valve Solenoid Asy 7 02975438 1 Adapter Hyd Straight 8MB 8FJX 8 02981890 1 Adapter Hyd Straight 8MB 6MJ Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 21 Mounting Component ID Hydraulic Lock Valve X 2 Cy s 4 5 Item Part No Qty Description 02972208 Solenoid Valve Asy 1 02971425 1 Seal Kit f solenoid Valve 2 02975198 1 Coil 12V DC w Dual 8 32NF Studs 3 02975199 1 Cartridge Solenoid Valve 4 02975438 1 Adapter Hyd Straight 8MB 6FJX 5 02981890 1 Adapter Hyd Straight 5MB 6MJ Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 22 Mounting Component ID DIVERTER VALVE Door Swing Cylinder Diverter Valve Asy P N 02977622 The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two or more if valves are stacked funtions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pres
22. Blade Bar to Spindle BOIS sieheritedancarecedsntacesioaarostedencutevsesuteetale 400 ft Ibs AS BON EE E 400 ft Ibs OO pl ad LE EE See Set Up Instructions 11 TORQUE VALU ES BOLTS Recommended Torque Ft Ibs amp Nm IMPORTANT Listed below IS BOLT TORQUE and NOT APPLICATION TORQUE Component Application Torque will vary depending on what is bolted down and the type material Metal that is being bolted together Thread condition and lubrication will vary Torque settings ALWAYS CHECK MARKINGS ON TOP OF BOLT HEAD OR OTHER BOLT DESCRIPTIONS Inche Sizes Metric Sizes 2 B 9 D Plain Head 3 Dashes ft Ibs N M Not Used Not Used Not Used 35 47 55 79 75 102 875 1186 1200 1627 800 1084 1600 2169 900 1220 2100 2847 910 1234 1250 1695 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 1 7 NOTES Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 1 8 Section 2 Maverick Boom New Holland Tractor TS 100A 115A 125A 135A Tractor Preperations verick NH TS 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 2 1 General Information Installation Requirements FEE GENERAL INFORMATION The tools you will need at the assembly site are as follows Impact wrench or socket and ratchet set Rubber mallet Box end Allen and adjustable wrenches Alignment
23. Boom Lift Cylinder The boom lift cylinder will be connected to the boom at the rod end of the cylinder See Figure 2 amp 4 when it is shipped from factory The hoses will also be connected to the cylinder The retaining pin for the lift cylinder will be located in the turret assembly The Lift Cylinder will be fastened to boom with tie wire It will not be required to remove this tie wire before mounting boom on turret assembly Main Boom MountPin 4 Booms amp Lift Cylinder Mounting Pins The Boom and lift cylinder mounting pins are shipped installed in the turrert assembly Re See bed move both pins in preparation to mounting the 2 lt lt g A 1 boom See Figure 3 iat Lift Cyl Base Figure 3 nd Mount Pin Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 9 2 Boom Head Installation 9 Lower Boom onto Turret Assembly Us ing an over head hoist lift the boom by placing a lift strap at the boom hinge point See Figure 2 the boom assembly will be shipped with the two boom end tie wired together See Figure 3A The wire tie will need to be removed as it is tied through the boom hinge pin hole Lift the boom above the turret assembly and lower it back down onto the turret assembly aligning the boom with the mounting pin hole Install the Mount Pin through the turret and into the boom Make certain the pin is installed cor rectly as one side of the pin is self lo
24. Construction Multi Section Individual Spool with electro hydraulic solenoids Tie rod bolt together type Valve Controller Mechanical over Electric 3 axis multi function lever type joystick Valve Porting and Hose Connections Hoses connect to valve as shown by color code See Decal P N 02981986 below Electrical connections connect as shown Reference label on connector and corresponding solenoid Hose Connector Attachment Stripe to Cylinder Base Slelelele o Ji CTI Solid to Cylinder Red 02981986 8 Valve Spool Functions amp Spec s Boom Feature Main Relief at Inlet 3335 psi Valve Spool Functions amp Specs Band Spool Cyl Travel Port Work Port Pressure Color No Function Direction Relief Rating G W 1 Swing Forward B 3045 psi 2 0 G 1 Swing Back A 3045 psi 2 0 OR 2 Lift Down B 1160 psi 7 92 OR W 2 Lift Up A Plug 7 92 B W 3 Dipper Out B Plug 3 17 B 3 Dipper In A 1160 psi 3 17 Y W 4 Telescope Out B 2030 psi 3 17 Y 4 Telescope In A Plug 3 17 R W 5 Tilt Up A Plug 3 17 R 5 Tilt Down B 2030 psi 3 17 G 6 Swivel CW top A 2755 psi 6 60 G W 6 Swivel CCW top B 2755 psi 6 60 Valve Spool Functions amp Specs The Cylinder Cycle has adjustable settings slow medium and fast Time Cylinder cycle of unit Time indicates the time for the Cylinder to travel the full amount of its extension or retraction The lift times up and d
25. 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 l will be supplied to mount the new tank There is a Figure 10 front and a rear bracket See Figure 11 amp 12 Front Fuel Tank Rear Fuel Tank Bracket P N Bracket P N 02982206 02982207 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 5 4 Fuel Tank Replacement 4 Install Pick Up Tube amp 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 Pick Up Tube Unit tank to the tractor See Figure 13 The new tank will have a fuel capacity of 51 gallons 9 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 in Stalled correctly the front bracket will have 2 outer Tank holes same as the tank see Figure 11 amp 13 The P N 02982198 rear bracket
26. 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 atthe proper level or condition Never Start or run unit low or out of oil 9 DO NOT install add any oil unless you know it is the correct type and the container is clean Make certain the oil is not contaminated with dirt or any liquid Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 1 2 SPECIFICATIONS MAVERICK CUTTING CIRCUIT SPECIFICATIONS Hyd Pump Speed Front Aux PUMpP 1950 RPM Hyd Motor FN 1220 RPM Hyd Motor RAR cc 199 HP Hyd Motor Rotation as viewed f Top of the Deck CW Clockwise Relief Valve Setting At Motor 4000 PSI Relief Valve Setting At Pump 8 0 4500 PSI Hyd Pump Flow Front Pump 1950 RPM 25 3 GPM Hyd Oil Operating Temperature 100 F Ambient 155 165 F Hyd Oil Filtration Discharge f Charge Pump 10 Micron Ayd TankOapaCi te tn unes 17 1 2 Gal Hyd Motor Start Stop Time Approximate 6 Seconds Cutting Diameter Rotary Head 58 Inch SPE 4 5
27. I EL zj Service Port Connection A aie O GO Qi og ns K l 1 a QIO A IK X Return Connection EL 2 ON TT K ET Port Load Sense i T2 Signal PL A Port A Pump Pressure Connection P1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 31 Mounting Component ID Cyl Cnirl Valve Connections HYDRAULIC HOSE CODES Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some have a Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attachted to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose __ Always Check Hose Size Color Code amp Part Number Boom Cylinder Circuit Hoses connections from Control Valve Color Tie Green Green White Orange Orange White Blue Blue White Yellow Yellow White Red Red White Green Green White Yellow Yellow White Code G G W OR OR W B B W Y Y W R R W G G W Y Y W Hose Size SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 4 SAE 4 SAE 4 SAE 4 Valve Pressure Filter Switch Ma
28. Key Switch Connection Can 2 XS EG Mode Ground Connector X1 Control K3 Control Box Display Box Display Connection Connection G1 Connects to G2 Plug 7 of Exterior Wire Harness Code Connection Can 1 XS Module Can1 Connection 2 of 3 Connections Can2 XS Module Can 2 Connection 3 of 3 Connections CC1 Positive Key Switch Connection MUST Connect to key switch wire CC2 Negative Chasis Ground D XS Moudule C1 Connection 1 of 3 Connections G1 Exterior Harness G2 Plug coonnects Interior amp exterior Harness J1 Joystick Resister Harness 9 Pin Plug K3 Control Box Display Connection 1 of 2 Connections M1 E Stop Switch use A or B of Switch M2 E Stop Switch use A or B of Switch X1 Control Box Display Connection 2 of 2 Connections FIGURE 14 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 7 Joystick Electrical Mounting 8 Wire Exterior amp Interior Harness Schematic The wire harness schematics and instructions will need to be used together to install the wire harness The interior Harness and the exterior harness will connect together with one plug connection Figure 14 16 17 18 amp 19 pertain to the interior harness Plugs have codes on them to identify where they connect the connections will have codes on them to identify where the connection goes The code on the plug and the code on the connection may not be the same see the code connectio
29. Lift Sec n 02981875 1 K FJX L FJX Hose 16 16FJX 16FJX 94 Lg Red Tie Motor P Dipper Sec n 02981876 1 H FJX N FJX Hose 16 16FJX 16FJX 98 Lg Org Tie Motor R Dipper Sec n 02981877 1 B FJX E FJX Hose 12 12FJX 12FJX90 140 Lg Blu Tie Case Drain Lift Sec n 02981878 1 J FJX M FJX Hose 12 12FJX 12FJX 96 Lg Blu Tie Case Drain Dipper Sect n NOTE 1 Hose End 1 amp End 2 these are where the ends of that hose connect the letter shows location of that end and show type hose fitting at that end NOTE 2 The hoses have plastic ties on the to show which hose is which The colors are abreviated to YEL Yellow YEL W Yellow with Whiter stripe GRN Green GRN W Green with White Stripe RED Red RED W Red with White Stripe BLU Blue BLU W Blue with White Stripe ORG Orange ORG W Orange with White Stripe NOTE 3 Sect n Location where hose is located on boom Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 28 Mounting Component ID Motor amp Boom Pump Hose B 90 C A A 907 HJT p Fa i m m Item PartNo Qty Description A 02981427 1 Hose 8FJX 8FJX 90 24 Lg w Red Tie Charge Filter to Pump B 02981428 1 Hose 8FJX 8FJX 90 21 Lg w Blu Tie Case Drain to Tank C 02981429 1 Hose 12FJX 12FJX 23 Lg Pump to Suction Filter hose under pump and cannot be seen in drawing D 02981430 1 Hose 12FJX 12FJX 3
30. 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 Sys tem and the Cylinder Hydraulic System 4 Avoid hydraulic contamination by filtering the hy draulic oil while filling the hydraulic tank Filter buggies or carts are commercially available for Pre cleaning oil before it is installed or hydraulic system cleanup These consist of a high efficiency high capacity filter a circu lating pump a drive motor and hoses for connecting to oil supply See Figure 2 amp 3 When adding hydraulic oil use only new oil from a sealed barrel Used oil or oil from an open barrel may contain high levels of contamination Transfer the new oil into the hydraulic tank by using a hydraulic filter pump unit equipped with a properly operating micron filter to achive rquired cleanleness level is a must This will insure that the oil being added is safe to use Do not just pour the oil directly into the hydraulic tank sin
31. STD LOCKNUT TOPLOCK 3 8 LOCKNUT 3 4 NC LOCKNUT TOPLOCK 1 2 NC PLB BOLT HEX HEAD 1 2 13NC X 1 1 4 PL GRB DECAL WATCH YOUR STEP BOLT HEX HEAD 3 4 NC X 5 1 2 PL GR8 GAS CAP WLDMT STEP BOLT HEX HEAD 3 8 NC X 1 1 4 PL GR5 BOLT SOCKET HEAD 10 24 X 1 LOCKWASHER 10 STD PL FLATWASHER 3 16 PL STD WLDMT FUEL TANK WLDMT FRONT BRACKET WLDMT REAR BRACKET Replacement Fuel Tank Kit P N 02980938 is in Mount Kit P N 02982343 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 9 Mounting Component ID 24 ft Cab amp 2wd 02980888 Lexan Door kit RH Door Consist of the following Item No em NOOO BR O D F Part No 02980803 02980889 00021900 00750940 02766400 02981016 02981035 Qty 1 1 2 4 2 1 1 Description LEXAN DOOR NEW HOLLAND TS A TRIM PUSH ON WEATHER SEAL 199 BOLT HEX HEAD 5 16 NC X 1 3 4 PL GR5 LOCKNUT TOPLOCK 5 16 NC PLB BOLI HEX HEAD 5 16 NC X 1 1 2 CARTON NH TS A LEXAN DOOR INSERT LEXAN DOOR INSTALLATION Lexan Door Kit P N 02980888 is in Mount Kit P N 02982343 02980916 Exhaust Relocation Kit Consist of the following Item No em O OI BOND F Part No 02980917 02980728 701513C 00754566 02980933 02959132 Qty 1 3 3 3 1 2 Description PIPE EXHAUST NH TS115A BOLT HEX HEAD M12 P1 75 X 30mm PL GR10 9 M12 FLATWASHER LOCKWASHER 12MM WLDMT EXHAUST BRACKET CLAMP 3 1 2HD MUFFLER CL
32. X 2 PL GR5 LOCKWASHER 5 16 PL STD BOLT HEX HEAD M10 P1 5 X 30mm PL GR8 8 LOCKWASHER M10 SPRING Bolt Bag P N 02982345 is in Component Box P N 02982344 which is in Mount Kit P N 02982343 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 8 Mounting Component ID 24 ft Cab 2wd 02971789 Wheel Weight Kit Consist of the following Item No em O OI R ON F Part No 02970758 02971569 02971791 02979603 00012200 00012300 Qty 1 3 1 3 3 3 Description WHEEL WEIGHT 1400 LBS WASHER WHEEL WEIGHT DRAWING WHEEL WEIGHT INSTALLATION BOLT HEX HEAD 7 8 NC X 16 PL GR 8 4 OF THREAD LOCKWASHER 7 8 PL STD NUT HEX 7 8 NC Wheel Weight Kit P N 02971789 is in Mount Kit P N 02982343 02976671 Auxillary Wheel Weight Kit Consist of the following Item No Part No 00012200 00012300 00760266 02976644 Qty 2 2 2 3 Description LOCKWASHER 7 8 PL STD NUT HEX 7 8 NC BOLT HEAX HEAD 7 8 NC X 5 1 2 GR8 PLATE WHEEL WELDMENT Auxilary Wheel Weight Kit P N 02976671 is in Mount Kit P N 02982343 02980938 Fuel Tank Consist of the following Item No D 3 O 0 NO O R ON F Part No 00011100 00015800 00037200 00001800 02776600 03200285 00752405 108693 02976633 00753642 02980996 63121800 31001000 02982198 02982206 02982207 QD lt 0 OD DU ND BRAD OW Description FLAT WASHER 7 8 PL
33. as they are very heavy Figure 27 Boom Rest Support Weldment P N 02982022 Boom Rest f 24 ft or 30 ft boom Weldment P N 02982314 Bolts to f 24 ft boom boom rest amp P N 02982025 f 30 ft boom Bolts to top of Figure 28 tractor axle Figure 29 Boom Rest Support rN i LH side of tractor Upper Axle Strap axle stra nl OE holder VW NE i Noe Boom Rest Maverick NH TS 100A 115A 125A 35A Asy Man 01 05 2005 Alamo Group Inc Section 5 11 Frame Installation Counter Weight Installation 24 amp 30 Foot Boom 1 Counter Weight CWT Installation The Counter weight See Figure 1 mounts on the LH side Under Frame Weldment ts 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 amp 34 2 Additional Counter Weight CWT Installation The 30 foot boom model has an additional bolt on weight at the
34. com viewable and print able with ADOBE ACROBAT READER If you do MDM Master Display Mini not have Adobe Acrobat Reader it can be ob Be Distt aa A tained at www adobe com Freq Inputs E Gas Make certain to view the MDM section as this Op 109 is the type used on the maverick boom there are listings at the web site that will not apply to the FIGURE 8 maverick boom New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 6 CONTROL VALVE ELECTRONIC NETWORK Maverick Electronic Network continued The XP2 The XP2 is a controller module that is mounted at the front of the tractor next to the maverick control valve The function of this compo nent is to provide a gateway for incoming and outgo ing information Information is sent via the network to this module in order to provide control of the sole noids for valve operation See Figure 9 REFER ENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANU FACTURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com The XT2 The X12 is also a controller mod ule that Is mounted at the front of the tractor on the side of the tank The function of this component is to provide a gateway for incoming and outgoing infor mation This module receives input from instrumen tation then provides that infor
35. crane The crane should have arated capacity to lift the heaviest component or assembly A 5 ton crane is recommended for the assembly work If a smaller crane is used be sure not to exceed the rated capacity of the crane Always follow all OSHA crane operating and inspection rules regulations inspection requirements and recommended practices when using the crane 63 Never work under any component that is lifted by the crane Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 2 4 General Information Installation Requirements WARNING Wear personal protective equipment when assembling the mower As a minimum that should include Safety Glasses Safety Shoes Gloves Hard Hat Hearing Protection Welding Helmet WARNING Before attempting to assemble ensure that the tractor engine is off and the tractor transmission is in the park position with the parking brake engaged O Remove the engine key and keep it in your pocket to prevent inadvertent starting or movement of the tractor O Place wheel blocks in front and behind the tractor wheels to prevent the tractor from moving Never attempt to start the tractor unless properly seated in the tractor seat with the seat belt fastened around you O Never attempt to operate the tractor and mower controls unless seated In the tractor seat with the seat belt fastened around you WARNING Securely block up and support t
36. 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 2005 Alamo Group Inc Section 2 6 General Information Installation Requirements Lay Out Components in Display It is helpful to lay out the component in as neat a display as possible Lay out the Bolts according to size and length Lay out the Nuts and washer by size This will allow you to see how many of each part as you use them and help to identify any missing parts See figure 6 See Mount Kit Specification and Component Identification Section to help ID Components All the component that are received should be check and sorted as to what they are Shown below is a general example of the components laid out this is not a lay out of the components in
37. in Cab in Operator view Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 3 Common Box Component List IMPORTANT NOTICE These are parts that are shipped with every unit these parts will remain the same no matter which size boom is used or which model tractor is used DO NOT order any of these parts unless you are certain that that is what you want most theses a are complete assemblies and may contain more prts than are wanted to perform repairs If ordering parts that are listed here it is recommended that you look the parts in a regular parts manual under the specific assembly number 02981781 Common box Consist of the Following Items ITEM PART NO 00037200 02981381 02959924 10058000 02981441 00024100 00992000 00001000 02981377 00015800 00011100 02981383 02981384 02090800 02962181 02977622 02981803 02981373 02981704 03200762 02962181 00015800 00011100 00753642 02964135 02090800 02981371 00001800 02981436 02981463 02981468 00002700 00001300 02892000 02968923 63042700 03200587 02981372 02822700 QTY 7 1 1 1 D WOOP CO 1 mr D AAN BR NAN ON DN DD ND 00 2 0 NO DESCRITION LOCKNUT TOPLOCK 3 4 NC PUMP COVER ASSEMBLY LOGKNUT TOPLOCK 1 4 NC PLB BOLT HEX HEAD 1 4 NC X 1 PL GR5 KNOB CR30 X 1 1 2 STUD FLATWASHER 1 4 PL STD CABLE 1 4 AIRCRAFT 7X19 CABLE CLAMP OIL COOLER ASY W FAN
38. of the exterior harness See figure 11 12 13 8 14 Secure wires under arm rest A FIGURE 11 Joystick P N 02981347 with Resister Harness FIGURE 12 P3 T 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 amp 14 The Connections Three Separate Pugs Can 1 Can 2 amp D will be inside the side panel after it is reinstalled and will not be visible unless you remove the side panel See Figure 14 16 17 amp 18 The XS Module does not have amount bracket it will need to be mounted by the assembly technician inside panel where it will be out of the way notinterfere with any tractor components and be secured It can be tied in or bolted The Only Plugs protruding from behind RH Interior panel shoud be the plugs for the display control box See Figure 14 16 17 amp 18 FIGURE 13 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 6 Wi i i mm N o bo c Oos mmm e SE 0 Emmett il 9 5 m mh m oy m XS Module P N 02981533 MF Interior Wire Harness Schematic P N 02981375B Remove console cover tie strap J1 Joystick Connection 9 Pin XS Module P N 02981538 inside wee S console D XS Module P1 Joystick Connection 6 Pin Connector Can 1 XS Y Module Connector CC1 Pos
39. 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 2005 Alamo Group Inc Section 10 5 CONTROL VALVE ELECTRONIC NETWORK Maverick Mower Head Circuit continued from Previous page MDM Master Display Mini Analog Inputs Prop Outputs Digital Inputs Digital Outputs 1 Freq Inputs E Gas r Item A Maverick Electronic Network Figure 8 Electronic Network The electronic network is the control and communication network that receives and transmits data to certain components in the boom control system Its purpose is to manage the incoming and outgoing information There are five main components The MDM is an operator Display that is located in the cab The purpose of the display is to house the programming software for the system control and provide an interface between the operator and the Maverick Boom The interface is utilized through a multi screen function that allows the operator to set individual parameters for customized control functions The display also provides tools such as an on board measurement device useful for determin ing short circuits component loss and or power supply issues REFERENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAIL ABLE FROM THE MANUFACTURER ON THE INTERNET AT www iqan
40. the two plugs on the interior harness plug KS 7 8 X1 See Figure 21 8 22 EA The display control box cannot be tested until the interior and exterior wiring harness installation has been com Cab RH Rear pleted and all the other installations of unit have been mE Corner Post amp done DO NOT reconnect battery cables at this time the A electrical wiring is NOT done FIGURE 22 Display Control Box Bend Upward 60 Here P N 02982324 Mount Plate Igan Display Control Box Mount Ls FIGURE 23 FIGURE 24 g s Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 10 Exterior Wire Harness Schematic P N 02981375A 13 Exterior Wire Harness The exterior wire harness will run from the cab of the tractor to the front It will include the wiring for the sensors at the pump The connections for the valve actuator assemblies The electronic modules that are mounted to the right side of the tank and the module on the front of the valve The plugs have codes labeled on them there is a matching code on them where the plugs are connected Some plugs have instructions and or color codes Read the next pages of this manual to become familiar with the wire harness connections There are two electronic modules bolt on the tank assembly inthe front of the tractor The XT2 module bolted on the right hand side of the tank and the XP2 bolt on the LH side in front of the 6 spool valve See Fi
41. 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 MODULES AND DISPLAY COMPONENTS MUST BE UNPLUGGED Check the Tractors Opertion Repair Service or any other manual from the tractor manufac turer of the tractor to find any special electronic or special proedures about the tractor electronics Taking a few minutes to check could save you from a major damage to the electronics Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 2 7 NOTES Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 2 8 Section 3 MAVERICK New Holland Tractor TS 100A 115A 125A amp 135A Pump amp Driveshaft Installation 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
42. 02971569 02971791 02979603 00012200 00012300 Qty 1 3 1 3 3 3 Description WHEEL WEIGHT 1400 LBS WASHER WHEEL WEIGHT DRAWING WHEEL WEIGHT INSTALLATION BOLT HEX HEAD 7 8 NC X 16 PL GR 8 4 OF THREAD LOCKWASHER 7 8 PL STD NUT HEX 7 8 NC Wheel Weight Kit P N 02971789 is in Mount Kit P N 02982341 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 1 13 Mounting Component ID 24 ft Cab amp 4wd 02980938 Fuel Tank Consist of the following Item No D 3 O 0 NO O R ON F Part No 00011100 00015800 00037200 00001800 02776600 03200285 00752405 108693 02976633 00753642 02980996 63121800 31001000 02982198 02982206 02982207 lt nm 40 O O WU ND 1 PB PR D O Description FLAT WASHER 7 8 PL STD LOCKNUT TOPLOCK 3 8 LOCKNUT 3 4 NC LOCKNUT TOPLOCK 1 2 NC PLB BOLT HEX HEAD 1 2 13NC X 1 1 4 PL GRB DECAL WATCH YOUR STEP BOLT HEX HEAD 3 4 NC X 5 1 2 PL GR8 GAS CAP WLDMT STEP BOLT HEX HEAD 3 8 NC X 1 1 4 PL GR5 BOLT SOCKET HEAD 10 24 X 1 LOCKWASHER 10 STD PL FLATWASHER 3 16 PL STD WLDMT FUEL TANK WLDMT FRONT BRACKET WLDMT REAR BRACKET Replacement Fuel Tank Kit P N 02980938 is in Mount Kit P N 02982341 02980888 Lexan Door kit RH Door Consist of the following Item No em NOOO BR O D F Part No 02980803 02980889 00021900 00750940 02766400 02981016 02981035
43. 1 Lg w Red Tie Pressure Filter to Supply E 02981431 1 Hose 4FJX 4FJX 90 35 Lg w Red Tie Pump Load Sense to Valve PX F 02981432 1 Hose 4FJX 4FJX 90 20 Lg w Blu Tie Pump Regulator to Tank F noo 1 Hose 4 Hose f Base end of Stabilizer Cyl to Tank port Via a Tee fitting G 02981433 1 Hose 20FJX 12FJX 24 Lg Pump to Suction Filter H 02981462 1 Hose 12FJX 12FJX 90 20 Lg w Org Tie Valve Return to Tank NOTE Hoses are not shown in drawing above this is for clarity The hose routing is for the hoses which connect from one point to the other Use the instructions and hose description listed to follow hose routing Example Hose A connects to one end marked A and the other end of hose connects to the other item marked A This is done with the other letters as well the hose must connect to the same letter markings on each end as in drawing Some hose will be marked with a colored plastic tie Some hose will have a straight fitting or a 90 fitting This is to allow hoses to be routed to where they clear other items when connecting hose put the end on that has the correct fitting as noted in drawing with 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
44. 1 05 2004 Alamo Group Inc 11 34 Component Identification P N 02980933 Exhaust Relocation Bracket P N 02981415 Arm Rest Controller Mount Weldment RH Side Shown LH TT Tractor End Bent opposite way P N 02981725 Battery Relocation P N 02981404 Tank Rail Mount RH Bracket Weldment amp P N 02981405 Tank Rail Mount LH P N 02982005 Rail Weldment PIN 02982006 Rail Weldment RH Rear LH Rear Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 35 Component Identification P N 02982022 Boom Rest Stabilizer Widmnt P N 02982014 Rail P N 02982015 Rail Weldment RH Front Weldment LH Front P N 02982198 Fuel Tank Weldment 51 Gals 02982206 Fuel Tank Brkt Weldment Front Bend Upward 60 Here P N 02982324 Mount Plate Igan Display Mount 02982207 Fuel Tank Brkt Weldment Rear Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 36 Component Identification P N 02983143 Front Axle Stabilizer Top Bracket Weldment Included in Front Axle Stabilizer Kit Only for 4 WD Tractors U 9 P N 02982314 for 24ft Boom Rest Weldment amp P N 02982025 for 30ft P N 02983144 Front Axle Stabilizer Boom Rest Weldment Bottom Bracket Weldment Included in Front Axle Stabilizer Kit Only for 4 WD Tractos V 12 P N 02981316 Cylinder Asembly Included in Front Axle Stabilizer Kit Only P N 02982320 Cyl Suppo
45. 11 Mounting Specification Component Identification VIO WIT IRIE ES RS a ainai 11 2 to 11 37 Component Parts Identification Descriptions 11 2 to 11 37 Section 12 Pre Delivery Inspection Check List CRIS nee o eo nee 12 2 to 12 3 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Index 3 NOTES Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Index 4 Section 1 Model Specifications Maverick Boom 24 amp 30 Section 1 1 SPECIFICATIONS MAVERICK READ THIS BEFORE BEGINNING ASSEMBLY REPAIRS OR TESTING The Maverick has computerized electronics The electronic components can be damaged if care is not taken when performing repairs testing and or during assembly DO NOT DO NOT short any wires across or allow them to be shorted out 2 DO NOT attempt to jump across any wires or supply them with alternate power source 3 DO NOT install higher rated fuses than are recommended by manufacturer 4 DO NOT do any welding on unit unless the computer modules are unplugged first this is to prevent a power surge going into modules THIS IS VERY IMPORTANT This could also apply to the tractor components Check Tractors repair guide for specific instruction about tractor model and type 5 DO NOT attempt to repair or adjust a component that is not intended to be repaired example sealed components as there are no serviceable components inside 6
46. 1832 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Red Tie Tilt Lift Sectn 02981833 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Red Wht Tie Tilt Litt Sectn 02981834 x Z C SE EES Se ee ee ee ee ee ee ee ee O FJX Hose 6 6MJ 6FJX 96 Lg Blu Tie Dipper Dipper Sec n 1 1 1 1 1 1 1 1 1 02981835 1 Y MJ P FJX Hose 6 6M J 6FJX 96 Lg Blu Wht Tie Dipper Dipper Sect n 02981836 1 Z FJX Hose 6 6MJ 6FJX 88 Lg Yel Tie Ext n Dipper Sectn 02981837 1 Z MJ Q FJX Hose 6 6MJ 6FJX 88 Lg Yel Wht Tie Ext n Dipper Sectn 02981838 1 Z MJ V FJX Hose 4 4MJ 4FJX 176 Lg Yel Tie Door Dipper Sec n 02981839 1 Z MJ U FJX Hose 4 4MJ 4FJX 176 Lg Yel Wht Tie Door Dipper Sect n 02981840 1 Z MJ X FJX Hose 4 4MJ 4FJX 176 Lg Grn Tie Swivel Dipper Sec n 02981841 1 ZW W FJX Hose 4 4MJ 4FJX 176 Lg Grn Wht Tie Swivel Dipper Sectn 02981842 1 ZW T FJX Hose 6 6MJ 6FJX 176 Lg Red Tie Tilt Dipper Sectn 02981843 1 ZW S FJX Hose 6 6MJ 6FJX 176 Lg Red Wht Tie Tilt Dipper Sect n 02981846 1 C FJX F FJX Hose 416 16FJX 16FJX90 102 Lg Red Tie Motor P Lift Sec n 02981847 1 A FJX D FJX Hose 16 16FJX 16FJX90 102 Lg Org Tie Motor R Lift Sec n 02981848 1 K FJX L FJX Hose 16 16FJX 16FJX 54 Lg Red Tie Motor P Dipper Sect n 02981849 1 H FJX N FJX Hose 16 16FJX 16FJX 58 Lg
47. 2982198 02982206 02982207 lt mm 40 O O WU N 1 PB PR D O Description FLAT WASHER 7 8 PL STD LOCKNUT TOPLOCK 3 8 LOCKNUT 3 4 NC LOCKNUT TOPLOCK 1 2 NC PLB BOLT HEX HEAD 1 2 13NC X 1 1 4 PL GRB DECAL WATCH YOUR STEP BOLT HEX HEAD 3 4 NC X 5 1 2 PL GR8 GAS CAP WLDMT STEP BOLT HEX HEAD 3 8 NC X 1 1 4 PL GR5 BOLT SOCKET HEAD 10 24 X 1 LOCKWASHER 10 STD PL FLATWASHER 3 16 PLSTD WLDMT FUEL TANK WLDMT FRONT BRACKET WLDMT REAR BRACKET Replacement Fuel Tank Kit P N 02980938 is in Mount Kit P N 02981892 02980888 Lexan Door kit RH Door Consist of the following Item No em 1 2 3 4 5 6 7 L Part No 02980803 02980889 00021900 00750940 02766400 02981016 02981035 Qty 1 1 2 4 2 1 1 Description LEXAN DOOR NEW HOLLAND TS A TRIM PUSH ON WEATHER SEAL 199 BOLT HEX HEAD 5 16 NC X 1 3 4 PL GR5 LOCKNUT TOPLOCK 5 16 NC PLB BOLT HEX HEAD 5 16 NC X 1 1 2 CARTON NH TS A LEXAN DOOR INSERT LEXAN DOOR INSTALLATION exan Door Kit P N 02980888 is in Mount Kit P N 02981892 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 19 Mounting Component ID 30 ft Cab amp 4wd 02980916 Exhaust Relocation Kit Consist of the following Item No tem 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
48. 340 02981517 02976531 02981953 02981787 02981988 02981992A 02918600 00011400 QTY DESCRITION ADAPTER HYD STRAIGHT 16MB 8MJ ADAPTER HYD 10MB 10 FJX90 ST ADAPTER HYD ELBOW 16MB 16MJ45 PUMP LS VARIABLE DISP PUMP MED DUTY HYDROSTAT TANK ASY HYDRAULIC HOSE 8 8FJX 8FJX90 24 LG HOSE 8 8FJX 8FJX90 21 LG HOSE 12 12FJX 12FJX 23 LG HOSE 12 12FJX 12FJX 31 LG HOSE 4 4FJX 4FJX90 35 LG HOSE 4 4FJX 4FJX90 20 LG HOSE 20 20FJX 20FJX 24 LG HOSE 12 12FJX 12FJX90 20 LG DECAL HOSE amp ELEC CONNECTION DECAL AW ISO VG 100 DECAL WARNING PRESSURIZED TANK DECAL WARNING HOSE BURST DECAL ALAMO IND YELLOW ASY VALVE amp FITTINGS PLASTIC TIE ORANGE 11LG PLASTIC TIE RED 11LG DECAL ALAMO IND YELLOW ADAPTER HYD 16MB 10MJ STRAIGHT ADAPTER HYD ELBOW 16MB 8MJIC 90 ELECTRONIC KIT includes the following 9 items CONTROLLER 3 AXIS 5 BUTTON HARNESS WIRE CONTROLS HOUSING DISPLAY amp SWITCH MODULE XP2 EXPANSION MODULE XT2 EXPANSION MODULE XS EXPANSION SWITCH PUSH PULL DWG INST MAVERICK HARNESS ASY MDM MODULE amp PROGRAM BOLT EYE TURNED 1 4 NC20 X 1 ADAPTER HYD ELBOW 6FJX 6FJX45 HOSE HANGER FORMED BOLT HEX HEAD 3 4 NC X 1 1 2 PL GR8 amp DECAL JOYSTICK OPERATION OPERATORS MANUAL amp PARTS MANUAL ASSEMBLY BOLT HEX HEAD 3 4 10NC X 2 PL GR8 BOLT HEX HEAD 3 8 NC X 1
49. 4LG 15 02982324 1 PLATE IQAN MOUNT 16 02981894 1 BOLT BAG NH TS115A C 4MV 17 02981895 1 TS AFRONT AXLE STABILIZER KIT 18 02982279 1 INSTALLATION MANUAL TS115A 125A 135A MAVERICK Component Box P N 02981893 is in Mount Kit P N 02981892 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 17 Mounting Component ID 30 ft Cab amp 4wd 02981894 Bolt Bag Consist of the following Item No D 3 CO 0 NO OI R V LV F 20 Part No 02980967 00754566 02976344 00022200 02975692 02971158 00059500 02032200 02980723 02970066 02959587 00037200 02960521 5312316 02963646 00748547 02981985 02966556 02972088 02980721 02918600 00759457 00011700 00762398 00755954 Qty 4 4 4 4 14 D O O gt PMOPOA KO O NB NN BR ND ND RB Description BOLT HEX HEAD M12 P1 75 X 60mm PL GR10 9 LOCKWASHER 12MM BOLT HEX HEAD 7 16 NC X 1 1 4 PL GR8 LOCKWASHER 7 16 PL BOLT HEX HEAD M20 P2 5 X 50MM PL GR10 9 LOCKWASHER 20MM NUT HEX 1 NC PL LOCKWASHER STD 1 BOLT HEX HEAD M18 P1 5 X 80 PLGR10 9 LOCKWASHER 18MM BOLT HEX HEAD 3 4 10NG X 6 PL GRB LOCKNUT 3 4 NC BOLT HEX HEAD 3 4 NC X 2 3 4 PL GR8 WASHER 3 4 20 MM HARDENED BOLT HEX HEAD 3 4 NC X 2 1 2 PL GR8 FLATWASHER 1 1 32 X 2 3 16 X 22 HARDENED WASHER 18MM HARDENED BOLT HEX HEAD 1 NC X 11 PL GR8 amp BOLT HEX HEAD 3 4 NC X 3 1 2 PL GR8 BOLT
50. AMP Exhaust Reloctaion Kit P N 02980916 is in Component Box P N 02982344 which is in Mount Kit P N 02982343 02981750 Battery Relocation Kit Consist of the following Item No em RON F Part No 02980917 02981725 00011400 00012101 00013901 Qty 1 1 3 3 3 Description PIPE EXHAUST NH TS115A WLDMT BATTERY BRACKET BOLT HEX HEAD 3 8 NC X 1 LOCKWASHER 3 8 PL NUT HEX 3 8 NC PL Battery Reloctaion Kit P N 02981750 is in Component Box P N 02982344 which is in Mount Kit P N 02982343 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc eae Mounting Component ID 24 ft Cab amp 4wd New Holland TS 100A 115A 1 25A 135A Cab amp 4wd Page 1 8 thru 1 11 24 foot Maverick 4wd Mount KiT Only Mount Kit P N 02982341 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 11 Mounting Component ID 24 ft Cab amp 4wd New Holland TS 100A 115A 125A 135A Cab 4wd IMPORTANT NOTICE The following Part Assembly Numbers are for reference and should not be ordered as replacement parts unless all the components in that assembly are wanted These will break down to bills of material of the components Some of numbers listed are NOT individual Parts but complete assemblies and or box of assemblies Check before ordering 24 foot Maverick 4wd Mount Kit 02982341 Maverick Mount Kit NH TS 100A 115A 125A 135A Cab 4wd Consist of the Follow
51. Cyl Rod End Port Y Tie Valve A Port to Diverter valve P2 Port Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05 2005 Alamo Group Inc Section 4 7 Oil Cooler Fan Assembly Connecting Oil Cooler And Fan As sembly 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 ip i turned on amp off automatically It setto run ona Diverter Valve program that will run the fan in the cooling rotation for a designated time 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 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 nu a R Swivel l Rod Nia Ed C4 Port G Tie From en A 2 me L EP Port to P1 Diverter amg ER Port G WTi i 79 1 pes Cyl in T Ba r X Mr a 7 A Sn Oe SP alv v A POI l ag za Alej Fo m k NE A EF ae Joor Cyl Rod End H Port Y Tie FIGURE 7 Exterior wire harness con fia Tr A j A p U 1 z k nection marked R1 connects jel WE M here DE m FIGURE 8 FIGURE 9 LS Ki Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo G
52. End Head Tilt Down Base End Swivel CW Rod Enq Swivel CCW Base End Door Open Rod End Door Closed Base End Hyd Function Pressure Flow to Motor Return Flow From Motor Case Flow From Motor to Boom Case Flow at Boom to Tank 6 HYDRAULIC CYLINDER PRESSURE RATES Oylinder Typ sus saa ce Cylinder Working Pressure Hydraulic Cylnder Repair Specs Welded Cylinders 3000 PSI Cylinder Cylinder Piston Nut Gland Seal Kit Part No Function Torque ft Ibs Torque ft Ibs Part No 02981275 Swing 400 500 80 120 Head 02982066 02981278 Lift 30 ft 400 500 80 120 Head 02982069 02981279 Lift 24 ft 400 500 80 120 Head 02982070 02981277 Dipper 400 500 80 120 Head 02982068 02981280 Tilt 400 500 80 120 Head 02982071 02961480A Door Rotary 150 250 80 120 Head 02975528 02970710A Door Flail Axe 40 60 80 120 Head 02975532 02971423 Slide Timber Cat 400 500 50 60 Tie Rod 02973505 02811000A Door Ditcher 150 250 80 120 Head 02975528 02981316 Stabilizer 40 60 80 120 Head 02982073 02981315 Swivel Rotary 300 400 80 120 Head 02982072 02981276 Extension 300 400 80 120 Head 02982067 2005 Alamo Group Inc 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
53. Figure 21 The front cover plate will be installed using the original hardware 3 Install Pump Mount Driveshaft Cover The Pump Mount has a bolt on cover on top of it See Figure 17821 The cover and bolts are furnished with kit In figure 21 is shown without pump in Stalled 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 speci fication Bolt Toque Chart and hoses are se cured so as not to interfere with another compo nent Air Conditioner amp Oil Cooler Hoses Pump Mount Cover Bolts Here Air Conditioner amp Oil GoBler Hoses a Front Cover Figure 20 VAE Figure 21 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 3 8 Section 4 MAVERICK New Holland Tractor TS 100A 115A 125A 135A Hydraulic Tank amp Control Valve Installation Hydraulic Tank amp Control Valve Installation Hydraulic Tank and Control Valve installation This Section covers the installation of the Hydraulic Tank and Control Valve Assembly The Tank and valve are shipped as an assembly 1 Locate Tank and Valve Asy this will need to be lifted with a hoist the front bumper widmnt 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 hose
54. Grn Wht Tie Swivel Lift Sec n 02981857 1 Y MJ Z FJX Hose 6 6Md 6FJX 115 Lg Yel Tie Ex n Lift Sec n 02981858 1 Y MJ Z FJX Hose 6 6Md 6FJX 115 Lg Yel Wht Tie Ex n Lift Sect n 02981859 1 Y MJ Z FJX Hose 6 6MJ 6FJX 115 Lg Red Tie Tilt Lift Sectn 02981860 1 Y MJ Z FJX Hose 6 6Md 6FJX 115 Lg Red Wht Tie Tilt Lift Sec n 02981861 1 Y MJ O FJX Hose 6 6MJ 6FJX 135 Lg Blu Tie Dipper Dipper Sect n 02981862 1 Y MJ P FJX Hose 6 6MJ 6FJX 135 Lg Blu Wht Tie Dipper Dipper Sect n 02981863 1 Z MJ R FJX Hose 6 6MJ 6FJX 125 Lg Yel Tie Ext n Dipper Sect n 02981864 1 Z MJ Q FJX Hose 6 6Md 6FJX 125 Lg Yel Wht Tie Ex n Dipper Sectn 02981865 1 Z MJ V FJX Hose 4 4MJ 4FJX 214 Lg Yel Tie Door Dipper Sec n 02981866 1 Z MJ U FJX Hose 4 4MJ 4FJX 214 Lg Yel Wht Tie Door Dipper Sect n 02981867 1 ZW X FJX Hose 4 4MJ 4FJX 214 Lg Grn Tie Swivel Dipper Sec n 02981868 1 Z MJ W FJX Hose 4 4MJ 4FJX 214 Lg Grn Wht Tie Swivel Dipper Sectn 02981869 1 Z MJ T FJX Hose 6 6MJ 6FJX 214 Lg Red Tie Tilt Dipper Sectn 02981870 1 ZW S FJX Hose 6 6MJ 6FJX 214 Lg Red Wht Tie Tilt Dipper Sect n 02981873 1 C FJX F FJX Hose 416 16FJX 16FJX90 140 Lg Red Tie Motor P Lift Sec n 02981874 1 A FJX D FJX Hose 416 16FJX 16FJX90 140 Lg Org Tie Motor R
55. HEX HEAD 1 8UNC X 10 1 2 PL GR8 amp BOLT HEX HEAD 3 4 10UNC X 2 PL GRB BOLT LAG 5 16 X 2 PL GR5 LOCKWASHER 5 16 PL STD BOLT HEX HEAD M10 P1 5 X 30mm PL GR8 8 LOCKWASHER M10 SPRING Bolt Bag P N 02981894 is in Component Box P N 02981893 which is in Mount Kit P N 02981892 02971789 Wheel Weight Kit Consist of the following Item No em O OI R O D F Part No 02970758 02971569 02971791 02979603 00012200 00012300 Qty 1 3 1 3 3 3 Description WHEEL WEIGHT 1400 LBS WASHER WHEEL WEIGHT DRAWING WHEEL WEIGHT INSTALLATION BOLT HEX HEAD 7 8 NC X 16 PL GR 8 4 OF THREAD LOCKWASHER 7 8 PL STD NUT HEX 7 8 NC Wheel Weight Kit P N 02971789 is in Mount Kit P N 02981892 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc le Mounting Component ID 30 ft Cab amp 4wd 02976671 Auxillary Wheel Weight Kit Consist of the following Item No Item 1 2 3 4 Part No 00012200 00012300 00760266 02976644 Qty 2 2 2 3 Description LOCKWASHER 7 8 PL STD NUT HEX 7 8 NC BOLT HEAX HEAD 7 8 NC X 5 1 2 GR8 PLATE WHEEL WELDMENT Auxilary Wheel Weight Kit P N 02976671 is in Mount Kit P N 02981892 02980938 Fuel Tank Consist of the following Item No D 3 CO 0 NO O R O IL F Part No 00011100 00015800 00037200 00001800 02776600 03200285 00752405 108693 02976633 00753642 02980996 63121800 31001000 0
56. 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 Air After Cooler the Oil Cooler and Air Conditioning condenser rE these hoses need to be tied up in such away that they will notrub on driveshaft after it has is installed Installing Pump Drive Components barnas 1 With Front Bolster as shown See Figure 1 Remove any plastic plugs that are located in the Mh LE threaded holes in the front a
57. IE elescope Cy l gt 4 I g D O 6 Hose O Ji D S Red White TE o O L a eee Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 9 6 Boom Head Installation 11 Routing Cylinder Hoses from Boom to Valve The Hose from the boom to the valve will be split the four hoses to the door cylinder and swivel cylinder will run together through a section of 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 amp 17 The other cylinder hoses from the boom will be inserted into sleeving material and also be routed under the tractor to the LH side See Figure 14 They will continue up the LH side to the front of the tractor where they will connect to the valves ports The hoses will be held to the frame with metal hose hold ers bolted to the tractor frame See Figure 15 NOTE the hoses must be run through the sleeving material O
58. Inch Head with Fure 5 I L Swivel Hitch Mount Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 9 4 Boom Head Installation Motor Case Drain 12 Hose Blue Tie Door Cyl 4 Hose lt Ba Yellow White Tie 844 Fg Cyl 4 Hose iota n d Green White Tie ss hey Cyl 4 Hose Green Tie 50 Inch Heag VY e Swivel Hitch Mount 16 Hose Orange Tie Pressure 16 Hose Red Tie EE me RESE er a F urene ar Fa op er eee a Lg tee 11 Li m eh 7 rd 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 2005 Alamo Group Inc Section 9 5 Boom Valve Hydraulic Schematic ees Into Lift B Port 5 Hose No Plastic Tie O Figure 11 _ 4 Hose DO alo g F cl a 8 TD 6 Spool Control Valve O 513 ao Returns to same port on S _ _ tan as Oil cooler Hose ANA O IB QUE g E wan Tank Return B Ports F 9 Orange Tie QU A Ports V 3 U Pressure Supply Red Tie a No Colored Ties only H i o Lolore les only HOSE z Bands P N 02981825 si E 9 Diverter Valve 6 Hose M P1 Jed C1 H Swing Cyl i nn amt PT f O Boom Lift Cyl f 4 Dipper Cyl f i O 6 ST Io 2 6 Hose yellow Winite g r f 3 e _ 2 yar 183 Telescope Og gi
59. L to Enable Cutterhead MNA nha _ O Key F 1 to power motor This is best done when the engine RPM is at idle speed Doing this at high RPM will cause the system pressure to surge sending fluid over the relief and causing excess heat to be introduced into the system At any time the Cutter Head Motor E Stop emergency stop can be pushed to disable the motor circuit If this is done the Switch must be raised in the run position before the motor circuit can be reactivated New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 10 CONTROL VALVE INSTRUMENTATION Maverick Operator Interface continued Cutterhead is On Oil Temp 43 I F RS At this time the motor circuit is powered and the mower head motor is active This screen also shows the tank temperature in degrees Fahrenheit To turn off the motor at this time Key F 1 Tuer Ut doat ick key FL to Disable Jowstach GS i i The Joystick Master control switch must be off to prevent accidental movement of boom and cutting head when ever mower is not being operated such as when in transport Cylinder Supply Pump Pressure Adjust If Needed F as a Special Note If after setting the display a controls check to make certain that functions operate correctly If the Boom will not lift The Pump m aN A for the Cylinder supply may have to be adjusted Pressure Adjust This is a simpl
60. LOCKNUT TOPLOCK 8 8 NC FLATWASHER 3 8 STD COOLER MOUNT RH COOLER MOUNT LH ADAPTER HYD ELBOW 12MB 12MJ90 ADAPTER HYD STRAIGHT DIVERTER SOLENOID VALVE VALVE AND HYD TANK ASY Includes the Next 47 Items INDICATOR ELEC W PACKARD MOUNT MODULE ADAPTER HYD ELBOW 6MB 4MJ 90 ADAPTER HYD STRAIGHT LOCKNUT TOPLOCK 3 8 FLATWASHER 3 8 STD BOLT HEX HEAD 3 8 NC X 1 1 4 PLGR5 ADAPTER HYD STRAIGHT ADAPTER HYD ELBOW 12MB 12MJ90 FILTER MEDIUM PRESSURE LOCKNUT TOPLOCK 1 2 NC PLB KIT FLANGE 20 CODE 61 ADAPTER FLANGE 1 1 4 X 20MJ 45 BRACKET SHIPPING ONLY FLATWASHER 1 2 PL STD LOCKWASHER 1 2 BOLT HEX HEAD 1 2 13 NC X 1 1 2 PL GR8 amp FILTER ASY PRES ELEMENT ADAPTER HYD STRAIGHT PLUG HEX HEAD 8MB FILTER HEAD W IND PORT ADAPTER HYD ELBOW Continued Next Page Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 4 Common Box Component List 02981781 Common box Consist of the Following Items Contiuned from previous page PART NO ITEM 18 19 20 21 22 23 24 25 26 02968167 02981435 02043600 02981369 02978986 02981388 02981427 02981428 02981429 02981430 02981431 02981432 02981433 02981462 02981986 02979473 02971123 02965262 02971943 02981888 02968896 02968894 02971943 02982347 02972064 02981805 02981374 02981375 02981376 02981531 02981532 02981533 02964028A 02982252 02982
61. NOT be used es A 7 lt pr g i in reassembly Snug the item 3 nut but DO NOT i gt b tighten 1 ing 10 Lifting the Latch and turning to the correct TROY angle slide the latch actuated rod through the hole on the latch Turn and lower latch in place Using the Nut original Bolts Washers and nuts bolt on the latch to PT ee j A Soe F P il pipe brace See Figure 7 These can be tightenedat lt this time Figure 1 11 Prepare the Door Hinges which are still on tractor See Figure 8 by making certain the round El 1000 Large Rubber rubber washers are in place the ID of washer will MERE Ji Washers a 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 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 Figure 8 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 carefull
62. Org Tie Motor R Dipper Sec n 02981850 1 B FJX E FJX Hose 12 12FJX 12FJX90 102 Lg Blu Tie Case Drain Lift Sec n 02981851 1 J FJX M FJX Hose 12 12FJX 12FJX 56 Lg Blu Tie Case Drain Dipper Sect n NOTE 1 Hose End 1 amp End 2 these are where the ends of that hose connect the letter shows location of that end and show type hose fitting at that end NOTE 2 The hoses have plastic ties on the to show which hose is which The colors are abreviated to YEL Yellow YEL W Yellow with Whiter stripe GRN Green GRN W Green with White Stripe RED Red RED W Red with White Stripe BLU Blue BLU W Blue with White Stripe ORG Orange ORG W Orange with White Stripe NOTE 3 Sect n Location where hose is located on boom Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 26 Mounting Component ID Hyd Hose Connections 30 FT Boom Z Hole in Side Y Hole in top of Lift Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 27 Mounting Component ID Hyd Hose Connections 30 FT Boom Part No Qty End 1 End 2 Description 02981879 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg Yel Tie Door Lift Sec n 02981880 1 Y MJ Z FJX Hose 4 4Md 4FJX 115 Lg Yel Wht Tie Door Lift Sec n 02981855 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg Grn Tie Swivel Lift Sec n 02981856 1 Y MJ Z FJX Hose 4 4MJ 4FJX 115 Lg
63. RAIL RH TSA MOUNT TANK RAIL LH TSA WLDMT BOOM REST STABILIZER WELDMENT ARMREST CONTROLLER INST MANUAL NH TS A MAVERICK ASY MOUNT PUMP COVER TSA HOSE 12 12FJUX 12FJUX 24LG PLATE IQAN MOUNT BOLT BAG NH TS115A C 2 MV24 Component Box P N 02982344 is in Mount Kit P N 02982343 02982345 Bolt Bag Consist of the following Item No D 3 CO 0 NO OI R O DL F 20 Part No 02980967 00754566 02976344 00022200 02975692 02971158 00059500 02032200 02980723 02970066 02959587 00037200 02960521 5312316 02963646 00748547 02981985 02966556 02972088 02980721 02918600 00759457 00011700 00762398 00755954 Qty 4 4 4 4 18 O0 O O PMOPMPOA KO V O NB NN BR V V 0 O R FA Description BOLT HEX HEAD M12 P1 75 X 60mm PL GR10 9 LOCKWASHER 12MM BOLT HEX HEAD 7 16 NC X 1 1 4 PL GR8 LOCKWASHER 7 16 PL BOLT HEX HEAD M20 P2 5 X 50MM PL GR10 9 LOCKWASHER 20MM NUT HEX 1 NC PL LOCKWASHER STD 1 BOLI HEX HEAD M18 P1 5 X 80 PL GR10 9 LOCKWASHER 18MM BOLT HEX HEAD 3 4 10NC X 6 PL GRB LOCKNUT 3 4 NC BOLT HEX HEAD 3 4 NC X 2 3 4 PL GR8 WASHER 3 4 20 MM HARDENED BOLT HEX HEAD 3 4 NC X 2 1 2 PL GR8 FLATWASHER 1 1 32 X 2 3 16 X 22 HARDENED WASHER 18MM HARDENED BOLT HEX HEAD 1 NC X 11 PL GR8 amp BOLT HEX HEAD 3 4 NC X 3 1 2 PL GR8 BOLT HEX HEAD 1 8UNC X 10 1 2 PL GR8 BOLT HEX HEAD 3 4 10UNC X 2 PL GR8 BOLT LAG 5 16
64. TE When bolting the center frame up to the front and rear frame mounting rails the bolts on the RH turret side must have the bolts installed from the bottom with the bolt heads on bottom under center under frame and the nuts on top See Figure 27 showing nuts on top The reason the nuts must be on top is so the bolts will not hit the swing cylinders when the turret assembly has been mounted The Bolts that are used to mount center frame are not the same lentgh The 8 bolts for the rear fame bracts bolts that face the rear of the tractor will be 3 4 X 3 1 2 long The other twelve bolts will be 3 4 X 2 1 4 long All 20 Bolts that at are used to mount center frame MUST have hardened flat washers install on both sides one under Bolt Head and one under Nut See Figure 26 amp 27 Using floor jacks or Fork lift position the center frame weldment up under the tractor See Figure 27 The center frame weldment will bolt to the front and rear mounting rails on both sides Make Certain to use hardened 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 RH Side Q Rear Top Mounting Holes use 3 4 X 2 1 3 4 bolts in these 4 places Front Mounting N Holes use 3 4 X 3 Rear of 2 1 4 bolts in SO Tractor these 8 places i Install with these openings to front of tractor LH Side of Front of Tractor Tractor R
65. UBU AU BU B gt Exterior Wire Harness Schematic P N 02981375A AA1 Swivel Cylinder CCW Connection Markings on Exterior Wire Harness AA2 Swivel Cylinder CW AA3 Tilt Cylinder Down AA4 Tilt Cylinder Up BB nt 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 Z1 _ E Connector XT2 Module F Connector XP2 Module AA 12 G2 Exterior Harness to G1 Interior Harness Hi Lock Valve Connection AA11 H2 Lock Valve Connection R1 Cooler Fan Connection AA10 S1 Temperature Connection Sensor AA9 TI Pump Solenoid 1 Connection AA3 V1 Pump Solenoid 2 Only on Timbercat Head MAT 2 W1 Charge Filter connection XI Return Filter Connection AA 6 G Y1 Common Connect to White Wire at Filter AAb Y2 Signal Connect to Black Wire at Filter AA4 ZI Negative Chasis Ground AA3 AA2 G2 AA1 Vi TT F r Y W 1 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 12 R1 FET Dt Delshelelelel E 1 DAGO DE H O GO 0 ae d do d ldldovdon4 Exterior Wire Harness Schematic P N 02981375A Six Spool Control Valve External Wire Connec tions for valve are marked A and B on Valve amp AA1 thru AA12 on wire
66. als Operators Manuals Assembly Manual or Service Manual many ofthese are available via the Alamo Industrial Internet site www Alamo Industrial Com Attempt to diagnose or repair problem before calling 2 Ifa callto Alamo Industrial is needed Certain Information should be available and ready forthe Alamo Industrial Service Staff Such information as Machine Model Serial Number Your Dealer Name Your Account Number and Any other information that will be useful This information is vital for the development of a prompt and correct solution to the problem This will also help to develop a database of problems and related solutions which will expedite a solution to future problems of a similar nature 3 The technician may be asked to provide detailed information about the problem including the results of any required trouble shooting techniques If the information Is not available The technician may be asked to get the information and call back Most recommendations for repairs will be based on the procedures listed in the Service Manual Trouble Shooting Guide and Information provided by customer CONTACT ALAMO INDUSTRIAL Alamo Industrial 1502 E Walnut St Seguin TX 78155 Technical Service Dept PH 830 379 1480 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Index 1 INDEX ASSEMBLY INSTRUCTION Page Introduction MIN Index 1 Section 1 Model Specifications DO NOT DO LIST IMPORTANT
67. at 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 amp grinder to chamfer the cut end and clean the splines DO NOT cut shaft with a Torch as this will change the hardness of the shaft 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 J 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 Rues Splined Glamp Yoke i Hol 4 Non Threaded Ho
68. battery tray using 02981725 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 instal lation Replace the battery cover See Figure 1 for now this will protect battery and cover CALE i Figure 3 a j Figure 4 SN Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc 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 MEG Factory hardware replacement exhaust pipe from turbo to Exhaust pipe t 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 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 th
69. by 9 Heat Treated Alloy Blade Bar DE o zalo oi kosa niui Stacked 3 Leaf Blade Bar Size 1 1 4 Thick X 5 Wide Ea Leaf Blade Bar Material SSSR ads ae us T1 Steel bottom amp HRFB Steel top amp Middle DJ 6 ge EE Rinnai 360 Deg Swing PRE High Carbon Alloy Steel Cutter Weight Approximate w Rotary Head 950 Ibs Cutter Deck Opening amp Closing Hyd Operated Door Recommended Hydraulic Oil ISO AW Hyd Oil See decal below Fluid Cleanliness level nr ISO 16 14 11 10F 20F 30 40 60 70F 90 10F HABER ez I nu AW ISO VG ee nn aux AW ISO VG 100 The correct hydraulic fluid is dependent upon ambient temperature Refer to chart when selecting proper grade 02982828 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 1 3 SPECIFICATIONS MAVERICK 2 BOOM SPECIFICATIONS Boom Reach 24 Foot Boom iii Out 24 Boom Reach 30 Foot Boom iii Out 30 LANE a oo en Manufactured Box Sections go RE ate ee a ev teers Chrome Plated Alloy ESS AE EE A E Greasable Weight 24 BOOM 1250 Ibs Weight SO gt 010 1 EEE 1450 Ibs PN Tractor Axle Mounted Bor MN SL ne ROPS or CAB Tractor Optional 3 FILTRATION Control Valve Functions Control functions include All Hydraulic Cylinders used to manipulate the Maverick Boom The boom and frame cylinders are powered by a self contained hydraulic system The pump is loctated on the front of th
70. case drain return hose for a total of 3 Note Motor Case Drain hose will be run through the Oil Cooler and then return to tank First is the 20 hose with the red plastic tie the lower connection at Boom See Figure 17 this is the pressure supply from the pump lower connection at pump See Figure 20 to the motor connection at the boom second is the 20 hose with the orange plas tic tie the upper connection at boom See Figure 17 This is the Return hose from the motor upper connec tion at pump See Figure 20 Third is the 16 Hose with the blue plastic tie the middle connection at the boom See Figure 17 which is the case drain from the motor This hose connects to the Oil Cooler Fan Assembly which is mounted under tractor bolster behind hydraulic tank See Figure 19 There is a short 16 hose See Red Tie 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 Figure 17 13 Pump Hose Routing at Tank The hose routing at tank is shown as reference to the Pump hose Sfeeving Material routing which most of will already be connected when fay Hoses the tank and pump assembly is shipped from the ds factory All hoses that you must disconnect and re ESRI connect during pump and or tank assembly refer to Bracket u Ge this figure for the correct location of hose See Figure Su 5 s a 21 DO NOT start tractor befo
71. ce most oils even from a sealed barrel have contaminants that should be removed before operating the hydraulic sys tem See Figure 2 amp 3 4 Important Change the return filter in tank and Figure 3 suction filters at recommended hours of operation See Operators Manual for maintenace schedule The only hydraulic oil to be used is the AW ISOAW Tractor Hydraulic Oil See Figure 4 for oil Grade with a cleanliness level of IS016 14 11 Always use a good Filter Maintenance program and Oil cleaning system before adding any oil to system New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 2 ATTENTION 10 F a F308 40F 60F 70 90 F 110 AMENER Re aner AW VG 46 r SER VG SE ng FW er VG 100 The correct hydraulic fluid is dependent upon ambient temperature Refer to chart when selecting proper grade 02982828 Prime Hydraulic Pump 1 The Hydraulic Pump MUST be Primed The hy draulic pump is primed by putting oil directly in to the pump Looking at the pump out near the end of the pump there is a Allen plug See Figure 5 Remove this plug and install only approved hydraulic oil See Step 1 through 3 of hydraulic tank filling Fill the cavity completely full up to plug threads IMPOR TANT This must be done before the unit is ever started Make cer tain that the O Ring Seal is on plug and reinstall it after cavity is full of oil now the pump is primed
72. cking in design Tighten the pin retaining nut and install cotter pin See Figure 3C Lift Cylinder j 6 Connect lower end of Lift Cylinder The Base end lower end of lift cylinder will mount S 4 into the turret under the boom mount The Cyl Vi inder will have to be extended to connect If cylinder has to be extended the best way is to unplug the ends of the lift cylinder hoses where they come out of the boom these 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 extended or collapsed After installing the cylinder lower mounting pin re plug the hoses that were in the drain pan until ready to connect hoses T Connect Head to Boom The mounting pins to install the head onto the boom will be shipped installed in the mount weldment Re move the mounting pins Use the hoist to lower boom down over head to connect head Align the upper head mount pin The lower mount pin is the connect the lift link See Figure 4 amp 5 The Door Cylinder and the Swivel Cylinder are shipped installed on the head with the hoses connected to the cylinder A AR ry T Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 9 3 Boom Head Installation 8 Heads Are received from the Factory with the Cylinder an
73. color with a stripe The Plugs should not fit but one way and that is by matching the codes on the plugs New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 12 Install Front Pump amp Tank Cover Install Front Pump amp Tank Cover 1 Install The Front Pump Tank Cover The front cover and tank cover are a bolt on part The hinges are made onto the cover and the other half of the hinges are made on the tank mount bracket There are two bolts one each hinge that bolt the two hinge halves together The is a safety cable that will bolt to the cover and the tank mount bracket this is to prevent the cover from opening to far forward and hitting the ground There are retaining latches that will bolt to the tank mount bracket and the cover The holes for the fasteners will have to drilled by the installation technician in the tank mount brackets and the front cover See Figure 19 20 21 amp 22 an LL FIGURE 19 Ez FIGURE 21 New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 13 Adjust Boom Swing Stop Boom Swing Adjustment 1 Boom Swing Stop Location The boom Stop adjust Turret ment cannot be seen from the top of the turret assembly See Assembly Figure 23 If the bottom cover plate See Item 24 is not already removed it will need to be it is bolted on from the under side of the turr
74. counter weight This additional weight bolts to the weight weldment on the 30 foot model only See Figure 32 Weight Attaching Pin LH Counter Weight 24 or Short Pin Rear side 30 Foot Boom Weight Mount Attaching Pin Long Pin Center Section Under Frame Weldment Additional bolt on Weight Used on Weight Attaching Pin Figure 32 AA j Short Pin front side en Dooni modei A only 3 Wheel Counter Weight CWT Installation The Wheel counter weight is in addition to the frame mounted counter weight they both must be usedtogether 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 Leftreartire 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 2005 Alamo Group Inc Section 5 12 Frame Installation 7 4 Figure 33 Mi Turret Assembly Installation 24 amp 30 Turret Assembly Theturret assembly is ea Secon shipped assembled with the hydraulic swing cyl Turret Mount inders hoses pivot bearing assembly boom 6 Attaching Pin Under Frame mount weldment and mounting pins installed Long Pin Weldment See Figure 35 amp 36 11 Foot Boom 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 p
75. d Head hoses Attached to Head The head will be received with the door cylinder l swivel cylinder and Motor attached to the head P The Hoses for the cylinders and the motor will oO nenne 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 8 10 Swivel Hitch Mount 9 Two Head Options There are two heads available 60 See Figure 4 5 amp 6 which has the head Swivel attachment on it The 50 Head which will not have the swivel attachement See Figure 9 amp 10 If using the 50 head leave the ports for swivel cylinder on boom capped See Figure 8 m 60 Inch Head with dil Swivel Hitch Mount 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
76. d of this section for Joystick control operation after start up procedure is completed Executing Set Up The following representations will outline the steps necessary to execute set up Key Escape or back at anytime to revert to the previous Alamo Industrial Boom Meru Key FL For Setup Key F 1 to access the set up menu Select Boon Operatina Speed Low Mer HU provided for customizable operation Key the corresponding F key to establish the desired boom speed This parameter is New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 9 CONTROL VALVE INSTRUMENTATION Maverick Operator Interface continued Choose Lutterhead tor Set Up FL ALL Others FRE F2 Tinbercat Sicklebar 1771 RES ET BET siti Key the corresponding F key for the head attachment that will be used This is an important step because this parameter chooses which direction the fluid will enter the motor The Timbercat Sicklebar mower is the only head attachment that currently requires the operator to send reverse flow for all others chose F 1 key for standard directional flow set le Complete FL to Enable Joystick e RTS O Key F 1 to activate Joystick the Boom will not move until the joystick is activated The Boom function Set up is now complete the boom speed the head attachment has been chosen and the joystick has been activated Motor Power Condition F
77. e 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 M 1 Wheel Weight Slot gt Bolt is shown extra long in drawing for illustration only Item Part No Qty Description 1 02979603 3 Hex Head Bolt 7 8 NC X 16 2 02971569 3 Wheel Weight Washer Special 3 02970758 1 Wheel Weight Casting 1400 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 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 7 2 Rear Wheel Counter Weight Installing Wheel Weight 1 This Wheel Weightis 1400 los Always use caution when working with it 2 Locate the three Holes in LH Rear Wheel Make sure these holes are 15 16 dia if not they must be reamed out 3 Lift Left Rear Tractor Wheel till it just clears the ground This will allow the Wheel to be rotated when aligning mounting holes for Weight 4 Using a forklift lift Wheel Weight into Wheel When Wheel Weight is centered in Wheel Se cure Forkliftand Set Parking Brake on Forklift Insert one of the three i
78. e When the function to raise the Head is activated there is no electric signal from Joystick The pressure against the valve when head is being raised will force Valve open like a relief Valve allowing Oil to pass through it If this valve will not open it could stop head from lifting or dropping The valve is plumbed into the Hydraulic Circuitry of the Head Tilt Function and is located near the Control Valve 3 Hydraulic Lock Valve 2 Item Part No Qty Description C2 y p 02972208 Solenoid Valve Asy 1 02971425 1 Seal Kit f solenoid Valve 2 02975198 1 Coil 12V DC w Dual m 8 32NF Studs 3 02975199 1 Cartridge Solenoid Valve I 4 02975438 1 Adapter Hyd Straight 8MB 6FJUX 5 02981890 1 Adapter Hyd Straight 5MB 6MJ Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05 2005 Alamo Group Inc 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 __ Always Check Hose Size Color Code amp Part Number See Figure 5 Boom Cylinder Circuit Hoses Color Tie Code Hose Size Port Diverter Hyd Funct
79. e 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 caus ing it to break When Removing Bolts from hinges make a note of the large rubber washer and the large 4 5 steel washer and there location as they willbe reused in the same location and order they are in See pr Figure 1 MA 4 Lay Removed door on a soft protected Figure 2 surface for the disassembly of the latch and brace components See Figure 2 Item 1 This isthe plastic cover for the latch and will snap off Item 2 This is the Latch and retaining bolts nuts amp 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
80. e an assistant or overhead hoistto help you align the drivelines halves as they are slid together the Driveline must be timed universal joints aligned the same as shown inthe pump amp driveline schematic on See Figure 10thru 17 Slide Driveline half and pump together until the shoulder on the pump slide inthe hole onthe 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 thatthe 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 Mounting Bolts P N 02980666 Pump Mount Weldment Bolts To Figure 10 Tractor Bolster Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 3 5 Pump Drive Assembly Instructions A LA F Driveshaft amp Pump Pump Shipped w Hyd Tank Valve M Mount Weldment is bolted to Tank installed Ps g 8 to 1 4 gap biwee B yoke amp pum as Push Pump into Pump U a D Install Pump Mount until flush hi Mounting Bolts Figure 16 i Maverick NH T 5 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 3 6 Pump Drive Assembly Instructions Installing Pump Driveline Cover 1 Install Pump Driveline Cover The Pump Driveline wi
81. e 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 2005 Alamo Group Inc Section 5 6 Frame Installation Under Mount Frame Asy 24 amp 30 ft are the same except for the LH weight 30 ft model only LH Counter Weight Turret Asy Machined Turret Boom Mount Pin Weight Attaching Pin Long 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 2005 Alamo Group Inc Section 5 7 Frame Installation Frame Installation 1 Frame Components The frame will include the rear axle mounts a LH amp RH Frame rail Two front frame mounts a LH amp RH One center frame weldment See Figure 17 18 19 20 amp 21 2 Install Frame Components The Frame components will only fit one way The Frame com ponents are a Bolt together assembly no welding will be required The Frame components will bolt together and to the tractor using mostly 3 4 and or
82. e interior panel of cab will need to be loosened and or removed this allows mounting of the XS module See Figure 6 amp Next pages for wiring LEN schematics continued in step 6 FIGURE 7A Switch Switch Mounting Nut BLO Wire Fasteners 4 Depth Control Clip Knob 2 Switch Asy Complete N hr Knob Retaining GL Screw Knob Plug FIGURE 8 FIGURE 9 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 O 2005 Alamo Group Inc Section 8 5 Le sr A x a ae oy mm z l mi i 7 VY SME s 1 ji k a a i Ba Joystick Electrical Mounting 6 Interior Wire Harness continued The interior wire harness schematic See Figure 11 amp 12 shows the wire harness as it is run through the cab The XS Module will need to be mounted inside the cab the best place is behind the RH side panel See Figure 6 9 amp 12 The wire harness will need it be put under this panel also with the connectors in the appropriate place to connect with the interiorcomponents The harness to the joys stick will need to be run along the panel at the back ofthe cab CAUTION The Harness has two wires that run under the floor mat the positive wire MUST connect to the ignition key switch of the tractor for a power source DO NOT Connect the positive wire anywhere else See Step 9 amp Figure 14 wire CC1 The plug G1 willneedto run through the floor to the exterior of the cab it will connect to the plug G2
83. e process that will require a 7 16 se Control 7 16 Hex wrench for this adjustment and a 1 2 wrench for the nen locking nut Looking on the LH side of the pump there are two adjustments one has a 7 16 hex head and the other a ridged round head Only adjust the one with the hex head DO NOT adjust or change the round ridged adjustment as it is set from the factory Adjust the 7 16 hex one by turning it in till it seats completely Do not force adjustment after is seats Then back it back out 1 2 turn this will give you the 2800 psi required to operate the boom See Figure 16 amp 17 Hold the adjusting nut while turning the locking nut so the adjustment nut does not turn with it changing the setting Pressure Adjust Nut 7 16 Hex amp Locking Nut 1 2 Hex New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 11 CONTROL VALVE JOYSTICK JOYSTICK FUNCTIONS Figure 18 To operate a function the following series of events must work 1 The Joystick Controller is moved in the correct direction the required distance During its movement an electrical signal is sent to the electric Controller in the proper Valve Section of the Control Valve 2 The Electric Controller sends an electrical signal which causes the Proportional Control Valves to actuate the proper amount based on the signal from the Controller EXAMPLE Valves 1 amp 3 allow Pilot Pressure Oil to flow to the correspo
84. e 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 PMD TYD a a te Piston Type Pump Speed Front Engine Mounteg Run Engine to 540 PTO Speed Relief Setting at the Pump osnove 4500 PSI Pump Flow Front Engine Operating Speed 25 3 GPM Boom Cylinder Pump Circuit Spe c s FP CE serine Piston Type PUMO DOCO REE 1800 RPM Pump Flow Front Engine Operating Speed 15 6 GPM Low Pressure Standby 250 PSI Hi
85. e two factory u Bolts that were used on the original exhaust pipe See Figure 8 4 Reinstall the muffler to the exhaust pipe us ing the factory bolts and hardware Check all the El bolts and components to the exhaust for tightness P Factory Exhaust and fit L Mount Bracket Replacement gan j New Exhaust Pipe Figure 7 Exhaust Bracket Figure 8 P N 02980917 P N 02980933 Maverick NH TS 100A 115A 125A 35A Asy Man 01 05 2005 Alamo Group Inc Section 5 3 Fuel Tank Replacement E za ee aaa aaa 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 appropri ately 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 Pete RH Mounting Brackets The LH factory step will have to f Rear Tire amp be removed from the tractor before attempting to Wheel remove the fuel tank the step will not be reused te 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
86. ear Mounting Holes use 3 4 X P N 02981168 Center Section Under Mount Frame Wldmnt 3 1 2 bolts in these 8 places Figure 26 6 Install Boom Rest Weldment The boom rest weldment for the 24 foot boom and the 30 ft boom are not the same See Figure 29 The boom rest weldment bolts to the RH Side on the Rear Frame mount weldment behind the tractor axle weldment See Figure 30 It is recommended that this be installed using an overhead hoist and supported by the hoist until boom rest and support brace See Figure 28 amp 30 are completely installed The Boom Rest Support also serves as the top axle strap for the RH Axle mount See Figure 30 Rear View Onn SE Ps KE FEN EE Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 5 10 Frame Installation r Install LH Axle Strap The Axle Strap bolts down over the top of the Axle LH Side and bolts run SE A through the Rear Frame rails The RH Side the axle M FA I9 1 side of tractors 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 amp 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
87. ee d to the B port of valve for the lift bracket top 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 Back side tank Install the cylinder with the rod end toward the axle and the base end of cylinder up to the bracket item 3 P N 02983144 bolted to tractor frame Number 4 hose with a blue plastic New front axle tie at the front side of tank See Figure 41 through 48 bracket bottom The Brackets bolt to the tractor axle and form a clamp around front axle housing item 1 8 2 The Stabi RH Front lizer cylinder is charged only when the boom lift cylinder is Tire side activated and is controlled automatically with the boom lift controls Figure 41 The three axle brackets are as follows tem PartNo Qty Description P N 02982320 Cyl Sup port Weldment ln 1 02983143 1 Top Axle Bracket cluded in Front Axle Sta 2 02983144 1 Bottom Axle Bracket bilizer Kit Only 3 02982330 1 Stabilizer Support Bracket 4 02981316 1 Hydraulic Cylinder See Mount Kit amp 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
88. ents that will be hit and damaged by saw DO NOT use a torch to cut holes in cab floor 6 Access Panels of Tractor interior Panels in the cab will need to be loosened and or removed to gain access to connections and or mounting of components Do not remove any panels until instructed to do so Installing Seat Replacement Arm Rest i Replace RH Factory Arm Rest The fac tory seat RH arm rest will be replaced with a weldment designed to serve as the armrest and mount for the emergency stop switch and the joystick assembly See Figure 5 6 amp 7 Unbolt the Arm Rest Weldment factory arm rest and bolt on the replacement arm P N 02981415 rest The Arem rest is retained using the same type method as thr factory arm rest this is what allows the arm rest to be raised up and down See Figure 6 See the bottom of the welded replacement arm FIGURE 5 rest It may be required to use adie grinder in slotted hole th help with alignment of retaining bolt See Figure 6 Under Side of 2 Install Emergency Stop Switch The emer Welded Arm gency Stop E Stop Switch mounts into the arm Rest with rest in the smaller of the two holes The Knob and Slotted Hole mounting nut will need to be removed and the switch installed from the bottom of the arm rest Replace mounting nut and knob See Figure 5 7 amp 8 3 Locate Joystick Assembly The joystick assembly has a flange around the bottom it uses 4 screws to mount joystick to the arm rest Lower t
89. et assembly From the under side you will see the swing cylinders and cylinder pivot mounts See Figure 25 2 The Swing Stop Lug which is part of the Turret Cylinder Link Weldment See Figure 27 On the side toward the rear there will be a lug with a bolt and locking nut in it See Figure 27 Loosen the bolt and locking nut turn the bolt outward 3 Swinging Boom DO NOT Swing Boom until the UM boom has been run with it sticking out away from tractor and all electronic control adjustments have been done The gt boom must be working smoothly Slowly with low engin gt RPM with some one guiding you swing boom inward toward Bottom cab until the boom rest lug is aligned with the boom rest pin Turret See Figure 26 Set boom securely down over pin Bus Cover 4 Final Swing Stop Adjustment Unscrew the stop bolt gt See Figure 27 until the head is against the swing stop lug of M the turret cylinder link weldment See Figure 27 Hold the bolt so it won t turn tighten the locking nut down against the T turret stop swing lug Recheck to make certain the boom will not hit the cab of the tractor It will stop at the turret SP lug when properly Swing IE 4 adjusted This Cvlind vlinde may have to be Nl adjusted more than once NEVER allow unit to be run if Boom will hit the cab this will damage cab Figura 25 Z New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo G
90. gh Pressure OOM Din 2 to hus ii chi nia 3000 PSI Horse Power at 1850 RPM Engine Speed 28 5 HP 5 HYDRAULIC HOSE CODES Hydraulic Hose Band Mark Color Codes Hose s and or fittings are marked with a Color Coded Plastic Band around it Some Bands are a solid Color and some have a Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attachted to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose __ Always Check Hose Size Color Code amp Part Number Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 1 4 SPECIFICATIONS MAVERICK Boom Cylinder Circuit Hoses Color Tie Code Green G Green White G W Orange OR Orange White OR W Blue B Blue White B W Yellow Y Yellow White Y W Red R Red White R W Green G Green White G W Yellow Y Yellow White Y W Motor Circuit Hoses Color Tie Code Red R Orange OR Blue B Blue B Hose Size SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 4 SAE 4 SAE 4 SAE 4 Hose Size SAE 16 SAE 16 SAE 8 SAE 12 Hyd Function Swing Back Rod End Swing Forward Base End Lift Down Rod End Lift Up Base End Dipper In Rod End Dipper Out Base End Telescope In Rod End Telescope Out Base End Head Tilt Up Rod
91. gure 25 27 amp 28 The exterior wiring harness should be laid out and connections need to be start at the first connection coming from the tractor cab connection this allows the harness to be moved around and under components as needed NOTE V1 Pump Solenoid 2 is only used when the Timbercat Head is installed and will be installed into plug next to Pump solenoid 1 which is used with all heads Note Unless the timbercat head is used only Solenid 1 will be installed which is Plug V1 leave plug T1 tie to othrer plug out of the way H1 amp H2 Lock Valve Connection BB Diverter Valve Y1 Connect to White Wire 8 Y2 Connect Pump Solenoid A AA See to Black Wire Valve Filter T1 Sol 2 A V1 Sol1 Below W1 Charge Filter L G2 Plug to Interior Wire Harness R1 Cooler Fan 91 Temp Sensor E XT2 Module FIGURE 25 F XP2 Module Plug Valve Valve Decal Below shows the Hose location and Plastic tie color on hose Label Function Label Also the markings for the wire harness plugs on valve A or B AA1 Swivel B See Figure 18 8 18A AA2 Swivel AA3 Tilt AA4 Tilt AAS Telescope AA6 Telescope AA7 Dipper AA8 Dipper AA9 Lift AA10 Lift AA11 Swing Door AA12 Swing Door FIGURE 26 NOTE Decal Stripes to Base and Solid to Rod end refers to the plastic ties on hoses only amp not electricl connections Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 11 U gt
92. he wiring of joystick down through hole in arm rest Make certain the three plugs are in the hole and not FIGURE 6 being pinched See Figure 9 amp 12 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 3 Joystick Electrical Mounting Resistor Harness P N 02981990 Is attached to the Joystick when it is recieved Wire Harness Side el IY M PIa IU M ATE ng R w W Pin Numbers x z 4 Locations A A 2 i PCB Assembly PE Pin Numbers amp Locations Joystick Side FIGURE 7 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 4 Joystick Electrical Mounting 4 Resister Harness to Joystick The Joystick will be shipped with the resister Harness connected to it as an assembly See Figure 7 amp 8 The Interior wire harness plug has 2 connectors on it A 9 Pin Connector labeled J1 and a 6 Pin Connector labeled P1 These two connections will plug into the interior wire harness with the same code gt ime when the interior harness is installed See Figure 7 amp ee ea ey 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 sid
93. he 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 O 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 Use an overhead crane forklift or other coworkers to lift heavy items Ensure lifted components are securely supported O Never walk or work under a lifted component Use extreme care when moving handling or adjusting the tractor tires The tires are extremely heavy and could fall and crush you gt D Z Use an overhead crane or forklift to move the tires O Properly fasten the tires to the material handling equipment to prevent the tire from falling WARNING The hydraulic oil is under high pressure and a hydrauli leak can cause oil to be injected under the skin gt Before starting the tractor ensure all hydraulic connections have bee tightened Never check for leaks with your hands Use a piece of wood or cardboard to check for the leak making sure your hands and face are kept away from the leak area Repair any leaks before operating the equipments Clean up all oil that has leaked according to the requirements of the oil supplier Oil
94. he 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 amp 4 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 2 Joystick Electrical Mounting Locating Joystick and electrical components 1 Joystick Assembly with Resister Harness The joystick has the resister wire harness attached to it when you received the joystick 2 Emergency Stop Switch The emergency Stop E Stop Switch will be sent with the knob and mounting nuts installed onto it These will need to be removed when mounting switch 3 Replacement Seat Arm Rest The Tractor seats Rh arm rest will be replaced with a fabricated one to mount E Stop Switch and Joystick 4 Wire Harness The Wire harness is in two piece The interior harness inside the cab and the exterior harness connecting to the interior harness and running outside the cab to the pump and tank area at the front of the tractor ST Wire Harness through Floor of Tractor Cab Some tractors may have a hole all ready through the floor of the cab on the RH side Lift Floor mat and check if no hole possible with rubber plug in it a hole will need to be cut with a hole saw If cutting holes in floor of cab always check under side of floor to make certain there are no compon
95. hose connections and all mounting bolts for the axle stabilizer kit P N 02981316 Cylinder Assembly ___ Upper Cy Included in Front Axle Stabilizer Kit Only C Mount Bolt Lower Cyl Mount Bolt Pressure Hose End Upper Clamp Mount Bolt Support Bracket End Maverick NH TS 100A 115A 125A 35A Asy Man 01 05 2005 Alamo Group Inc Section 5 15 NOTES Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 5 16 Section 6 MAVERICK New Holland Tractor TS 100A 115A 125A 135A Optional RH Lexan Door Installation Optional Lexan RH Door Kit Installation New Holland TS Series Optional Door Kit No 02980888 RH Lexan Door Kit Option P N 02980888 Remove amp Dis Assembly of Factory Stock Glass Door 1 To remove the factory door make certain 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 amp 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 Se
96. hts and Reflectors are clearly visible Follow local traffic codes f Never operate with Flail Mower or Folding Section raised if passersby bystanders or traffic are in the area to reduce possibility of injury or death form objects thrown by Blades under Shields or implement structure 8 Before dismounting secure flail mower in transport position or lower to ground Put tractor in park or set brake disengage PTO stop engine remove key and wait until noise of rotation has ceased to prevent entanglement in rotating parts which may cause injury or death Never mount or dismount a moving vehicle Crushing from runover may cause injury or death 5 TRANSPORT SAFELY 6 USE SMV LIGHTS amp 1 DO NOT OPERATE WITH 8 DO NOT MOUNT OR LOCK UP REFLECTORS MOWER OR WING RAISED DISMOUNT WHILE MOVING 002369 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 prov
97. hts equal 1800 Ibs This will not include the amount of weight to the tire from the installed liquid which will vary with the size of the tire and the liquid that is added Auxiliary Wheel Weight Kit No 02976671 Qty Part No Description 2 00012200 Lockwasher 7 8 2 00012300 Nut 7 8 NC 2 00760266 Bolt 7 8 NC X 5 1 2 GR8 3 02976644 Auxiliary Wheel Weight Plate 136 lbs Each 2 Install Auxiliary Wheel Weights The Auxiliary Wheel Weight bolt to the larger 1400 Ib wheel weight There are two slots in the large weight that the 7 8 bolt heads will slide into It is recommended that the tractor wheel is in position so these two slots has one facing front and one to the rear Slide the two 7 8 bolts into the slots the slots will prevent the heads of the bolts from turning The Bolts in the large wheel weight will have to be aligned to the proper distance apart to match the distance of the holes in the auxiliary weights Slide the auxiliary weight over the two bolts do this with all three weight for this kit Install the lockwashers and hex nuts Tighten the bolts to required tightness See bolt torque charts in tractor preparation section Wheel Weight P N 02970758 Ln Auxillary Weight Figure 4 Attaching Stots Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 7 4 Section 8 MAVERICK New Holland Tractor TS 100A 115A 125A amp 135A Joystick Wire Harness amp Valve Instal
98. ide for complete customer satisfaction tis 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 neces sary CONTACTING MANUFACTURER Please help us Help You Before You Call Alamo Industrial Service Staff Members are dedicated to helping you solve your problem or your customer s service problem as quickly and efficiently as possible Unfortunately we receive entirely to many calls with only a minimum amount of information In some cases the correspondent has never gone 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 Hydraulic or Mechanical Trouble Shooting Request for Technical Information or Specifications Mounting or Fitting Problem Special Service Problem Equipment Application Problems Tractor Problem Inquiries oF ta a HOW YOU CAN HELP Make sure the callis 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 Manu
99. ie 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 Go 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 2005 Alamo Group Inc Section 9 8 Hydraulic Hose Connections O O Six Spool Control Valve S gt U lt gt External Wire Connec tionsforvalve are marked gt A and B on Valve amp a AA1 thru AA12 on wire OD harness connections 90 O IE Pressure Supply Port P Diverter Valve C1 Port to Swivel Cyl Base End Port G W Tie Valve B Port to Diverter valve P1 Port G W Tie Diverter Valve C4 Port to Swivel Cyl Rod End Port G Tie 4 Through holes are mounting holes N Diverter Valve C3 Port Valve A Port to to Door Cyl Rod End Diverter valve P2 Port Port Y Tie Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 Diverter Valve C2 Port to Door Cyl Base End Port Y W Tie 2005 Alamo Group Inc 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
100. in and the front and back short mounting pins See Figure 36 amp 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 ontop 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 Turret Attach ing Pin Short Pin one Front side and one rear side Maverick NH TS 100A 115A 125A 35A Asy Man 01 05 2005 Alamo Group Inc Section 5 13 Frame Installation Cn SOS 3 Turret Assembly Installation Theturret assembly mounts on the RH side onto the center section under frame See Figure 36 amp 37 Using a hoist or other lifting device lower the turret assembly until itis 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 amp 38 4 AL LE Figure hts 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 aro
101. ing Items tem od zad RO ONE a A Part No 02980888 02971789 02980938 02982005 02982006 02982014 02982015 02982314 02981893 Gty o Description LEXAN REPLACEMENT DOOR KIT RH SIDE WHEEL WEIGHT KIT 1400 LBS REPLACEMENT FUEL TANK KIT RAIL WELDMENT RH REAR RAIL WELDMENT LH REAR RAIL WELDMENT RH FRONT RAIL WELDMENT LH FRONT BOOM REST WELDMENT COMPONENT BOX 02981893 Component Box Consist of the following Item No Part No 02980699 02980719 02980694 02980916 02981750 02982000 02982157 02981404 02981405 02982022 02981415 02982279 02981464 02982292 02982324 02981894 02981895 02982279 2 lt ee ee ee a dt th ht dl a td td td td a Description PULLEY ADAPTER NHTS A ASSY TS A PUMP MOUNT W COVER PLATE BOOM REST STABILIZER KIT EXHAUST RELOCATION TS115A KIT BATTERY RELOCATION DRIVELINE MODIFIED 02975257A HOSE BUNDLE 6 CYL MAVERICK MOUNT TANK RAIL RH TSA MOUNT TANK RAIL LH TSA WLDMT BOOM REST STABILIZER WELDMENT ARMREST CONTROLLER INST MANUAL NH TS A MAVERICK ASY MOUNT PUMP COVER TSA HOSE 12 12FJUX 12FJUX 24LG PLATE IQAN MOUNT BOLT BAG NH TS115A C 4MV TS A FRONT AXLE STABILIZER KIT INSTALLATION MANUAL TS115A 125A 135A MAVERICK Component Box P N 02981893 is in Mount Kit P N 02982341 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc Hei Mounting Component ID 24 ft Cab amp 4wd 02981894 Bolt Bag Co
102. ion Green G SAE 6 A Swing Back Rod End Green White G W SAE 6 B Swing Forward Base End Orange OR SAE 6 A Lift Down Rod End Orange White OR W SAE 6 B Lift Up Base End Blue B SAE 6 A Dipper In Rod End Blue White B W SAE 6 B Dipper Out Base End Yellow Y SAE 6 A Telescope In Rod End Yellow White Y W SAE 6 B Telescope Out Base End Red R SAE 6 B Head Tilt Up Rod End Red White R W SAE 6 A Head Tilt Down Base End Green G SAE 4 A P2 Control Valve tor Diverter valve Green White G W SAE 4 B P1 Control Valve to Diverter Valve Green G SAE 4 C4 Swivel CW Rod End Green White G W SAE 4 C1 Swivel CCW Base End Yellow Y SAE 4 C3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Motor Circuit Hoses to Boom Connections Listed as reference Color Tie Code Hose Size Hyd Function Red R SAE 16 Pressure Flow to Motor Orange OR SAE 16 Return Flow From Motor Blue B SAE 8 Case Flow From Motor to Boom Blue B SAE 12 Case Flow at Boom to Tank Diverter Valve The Diverter Valve bolts onto the front frame mount bracket on the LH side of the tractor the holes are in the bracket See Figure 5 6 amp 7 The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two o
103. ires 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 an other power supply as it could cause interference with the electronic components due to a power surge 10 Tractor RH Side Panel reinstalled When the tractor side panel is reinstalled the plugs 2 Plugs K3 amp X1 forthe Display control box will be sticking up out from be hind the panel See Figure 21 Runthe wiring harness in from behind panel use caution to not let wire harness interfere with or be in a position to damage or be damaged by other tractor components behind panel 11 Install Display Control Box Mount Bracket The display mount control box mount to the Rh rear cab post See Figure 22 amp 23 There are two plastic plugs in the plastic cover over cab post Remove these two plug to expose two 10 mm bolt holes in cab post Position the mounting bracket with the bent end at the post and using the 10 mm bolts furnished bolt the bracket to the post P N 02982324 Mount Plate Igan Display 12 Install Display Control Box The display control Control Box Mount box will bolt to the mount plate P N 02982324 that is mounted to the RH Rear Cab corner post See Figure 22 23 amp 24 There is a wire setion on disply control box that a will pug into
104. kits are made for selected tractors with standard configurations Only the noted options and tire sizes listed in the Mounting Specifications will work with these mount kits Other options front axles or different tire sizes may prevent the mount kit from fitting your nonstandard tractor Alamo Group cannot take responsibility for these problems or any modifications made to the unit Throughout these instructions references are made to right or left directions Right and left are determined by sitting on the tractor seat and facing the direction of travel forward always DANGER A signal word DANGER WARNING or CAUTION is used with the Safety Alert 1 symbol DANGER identifies the most serious hazards Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 2 2 This is the Safety Alert symbol When you see this symbol on your machine or in these instructions be alert to the potential for personal injury Follow recommended precautions and safe operating practices General Information Installation Requirements WARNING Safety signs with signal word WARNING are typically used to point out more serious hazards CAUTION General precautions are listed on CAUTION safety sign CAUTION also calls attention to safety messages in these instructions CRUSHING AND PINCH POINTS MD MOVING MACHINERY PARTS CAN PINCH OR CRUSH OR FALL WHICH MAY CAUSE INJURY OR DEATH 02962765
105. lation Joystick Electrical Mounting Installing Wiring Harness and Joystick 1 Preparing Tractor Floor Mat First thing to do is remove the Battery Cables from Battery Do Not perform any work on Tractor or Boom Electronics unless this has been done Raise the Floor Mat up on the RH Side by the RH Door You will need to fold it back approx 12 to 14 inches See Figure 1 amp 2 DO NOT Tear or Cut any Holes in Rubber Floor Mat as it will NOT be required You may find a rubber plug or you may have to cut a hole with a hole saw this will have to be decided during installation If you need to cut a hole check the under side of cab for any obstruction or any component that might be damaged before you cut the hole The hole is going to have to be oblong in order for the plug to go through it Measure Wire Harness plug Coded G1 to determine the size hole In Figure 2 below the tractor had two holes from the tractor manufacturer 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 amp 2 Floor mat can be reinstalled by over wire harness with out cutting any holes in floor mat Pull Floor Mak loose here Cu Hole in flor lg i cab if not one 4 already in it Eu FIGURE 2 fl 2 Remove Tractor RH Side Panel Remove the side panel on the RH side of the cab so t
106. les ES Tube End Flange Yoke Shan Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc 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 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 RH Tank Rail LH Tank Rail 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 amp 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
107. ll have acover 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 0001 7000 install and tighten these now See Figure 6 Tractor Engine Pulley Time Universal Joints Pulley Adpater w Mounting Pump End Bolts amp Washers 4 bolts Clamp Yoke Driveline Asy mA f f i HO P N 02980398 ie n 4 Driveline Mounting Bolts Driveline Cover RS SS SS Driveline Cover Mounting Bolts on Flatwashers amp Lockwashers 4 LO O O P N 02980666 Pump Hr __ Mount Weldment Bolts To Tractor Bolster Bolts Pump Reference Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 3 7 Pump Drive Assembly Instructions Install Tractor Guards amp Covers LH Side Engine Guards Removed From Tractor 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
108. mation to the network for further utilization See Figure 10 REFER ENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANU FACTURER ON THE INTERNET AT www iqan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com The XS The XS is expansion module that provides extra input and output capabilities in order to gain more flexibility on the network See Figure 11 The XS is responsible for receiving the signals from the joystick and other in cab inputs and making them available on the network REFERENCE PRODUCT MANUAL FOR MDM DISPLAY THIS MANUAL IS AVAILABLE FROM THE MANUFAC TURER ON THE INTERNET AT www igan com viewable and printable with ADOBE ACROBAT READER If you do not have Adobe Acrobat Reader it can be obtained at www adobe com XP2 Expansion Power Analog inputs 4 Prop Output 4x Digital Inputs 4 Digital Outputs 4 Freg Inputs 2 E Gas Op 110 XT2 Expansion Transmission Analog Inputs 10 Prop Outputs 2x J1909 CAN hub 4 Digital Outputs 6 Freq Inputs 3 E Gas 1 Op 111 FIGURE 10 XS expansion signal New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 7 CONTROL VALVE INSTRUMENTATION Maverick Instrumentation Instrumentation The Maverick Boom uti lizes instrumentation for certain decision making activities Listed below are the sensors Incl
109. must be equipped with heavy duty eight bolt front wheel hubs amp spindles 02982343 Maverick Mount Kit NH TS 100A 115A 125A 135A Cab 2 wd Consist of the Following Items tem dd ee nl ei 0 Part No 02980888 02971789 02976671 02980938 02982005 02982006 02982014 02982015 02982314 02982344 Qty gt o Description LEXAN REPLACEMENT DOOR KIT RH SIDE WHEEL WEIGHT KIT 1400 LBS AUXILLARY WHEEL WEIGHT KIT 408LBS REPLACEMENT FUEL TANK KIT RAIL WELDMENT RH REAR RAIL WELDMENT LH REAR RAIL WELDMENT RH FRONT RAIL WELDMENT LH FRONT BOOM REST WELDMENT COMPONENT BOX 02982344 Component Box Consist of the following Item No Item NOOR D gt Part No 02980699 02980719 02980694 02980916 02981750 02982000 02982157 Qty Se Ne Description PULLEY ADAPTER NH TS A ASSY TS A PUMP MOUNT W COVER PLATE BOOM REST STABILIZER KIT EXHAUST RELOCATION TS115A KIT BATTERY RELOCATION DRIVELINE MODIFIED 02975257A HOSE BUNDLE 6 CYL MAVERICK Continued next page Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 1 Mounting Component ID 24 ft Cab amp 2wd 02982344 Component Box Consist of the following Item No Continued from previous page Item 8 9 10 11 12 13 14 15 16 Part No 02981404 02981405 02982022 02981415 02982279 02981464 02982292 02982324 02982345 2 lt 51 ee hd Description MOUNT TANK
110. n drawing D 02981430 1 Hose 12FJX 12FJX 31 Lg w Red Tie Pressure Filter to Supply E 02981431 1 Hose 4FJX 4FJX 90 35 Lg w Red Tie Pump Load Sense to Valve PX Connects to top side of pump as shown F 02981432 1 Hose 4FJX 4FJX 90 20 Lg w Blu Tie Pump Regulator to Tank Connects to bottom side of pump not seen Fo 1 Hose 4 Connects here w Tee Fitting Connect to Base End Stabilizer Cyl G 02981433 1 Hose 20FJX 12FJX 24 Lg Pump to Suction Filter H 02981462 1 Hose 12FJX 12FJX 90 20 Lg w Org Tie Valve Return to Tank Jo 1 Hose 16 w Red Tie Pressure from Pump to Motor Bottom Port K lt 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 2005 Alamo Group Inc Section 9 12 Section 10 MAVERICK Fill Oil Tank Electronic Controls Setting New Holland Tractor TS 100A TS 115A TS 125A TS 135A Hydraulic Oil Installation 2 WD amp 4 WD Hydraulic Tank Filling 1 Filling With Recommended Hydraulic Oil The oil used MUST MEET the requirements as to type and cleanliness level THIS IS A MUST The oil must be type ISO Grade Hydraulic Oil w protection wear grade based on abient temperature See Decal Figure 4 The grade of oil will vary with the ambient twmperature The Fluid Cleanliness level
111. n 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 amp 19 When the small cover is replaced the plugs and wires need to be moved to the back of the panel near the RH rear cab post See Figure 17 amp 18 Cuta notch in the panel at the rear so the cover will fit down around the wire harness plugs See Figure 17 amp 18 Also the rear tractor panel will need a notch cut in it to allow the wire harness to be installed between the side and rear panel Cut this notch near the bottom of the rear panel See Figure 19 Cut Notch in Small cover panel to allow harness to fit through Display Control Box Connections FIGURE 19 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 8 Interior Wire Harness Schematic P N 02981375B CAN 1 XS S MODULE i SE CAN 2 TE XS MODULE o NOTE See Figure 11 for Jo listing of Code Locations K3 lt J 4 Mo M1 X1 7 CCI Must connect to Key switch wire CC2 G1 i ll Gi HT FIGURE 20 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 9 Interior XS Module amp Display Control Box 9 Connect Wires to Key Switch There are two wires on the interior Harness that connects to the key switch W
112. n the LH side there is a hole in the center frame weldment the hoses can be run through it if wanted Connect the hoses to the valve as shown See Figure 11 amp 17 t 17 Figure 13 Hose Support Bracket 4 SleevifigMaterial T ea Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc 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 Color Coded Plastic Band around it Some Bands are a solid Color and some are Colored with a Stripe The purpose of the colored bands are to provide a quick reference for hose and port connection A metal band is also attached to the hose on that band is an Alamo Industrial Part Number for reference if needing a replacement hose __ Always Check Hose Size Color Code amp Part Number See Figure 4 Boom Cylinder Circuit Hoses Color Tie Code Hose Size P Diverter Hyd Function Green G SAE 6 A Swing Back Rod End Green White G W SAE 6 B Swing Forward Base End Orange OR SAE 6 A Lift Down Rod End Orange White OR W SAE 6 B Lift Up Base End Blue B SAE 6 A Dipper In Rod End Blue White B W SAE 6 B Dipper Out Base End Yellow Y SAE 6 A Telescope In Rod End Yellow White Y W SAE 6 B Telescope Out Base End Red R SAE 6 B Head Tilt Up Rod End Red White R W SAE 6 A Head Til
113. nd discard them they Tractor MIA O will not be needed The Casting will have two Bolster ING 2 N Existing Holes Driveline Hole in it See Figure 1 UNE vane iy Installing Pulley Adapter as SU 1 Install Pulley Adapter The Pulley adapter Figure 1 P N 02980699 is a round plate with 4 threaded holes and four non threaded holes init Notice this pulley adapter will not have a center hole in it See Figure 3 The four non threaded holes are used pias ENON 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 amp 3A Guards Removed From Tractor Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc 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 th
114. nding end of the Spool Thus causing it to move Valves 2 amp 4 allow the Oil from the opposite end of the Spool to return to the Tank NOTE Lift Swing and Dipper functions are Proportional Door and Tilt functions are ON or Off Only See later section for explanation of Proportional 3 The Spool position Transducer sends an electrical signal to the Electronic Controller which indicates the position of the Spool 4 The Electronic Controller will continue to adjust the Valves 1 4 in order to maintain an equilibrium between the Joystick signal and the feedback signal 5 Reaction time from the time the Joystick is moved until the Spool moves is approximately 300 milliseconds Trigger Dipper Telescope u Trigger Swivel Door Joystick Functions Push Buttons Only i co Top Left Swivel CW Trigger Bl Top Right Swivel CCW Bottom Left TitUp Lift Dipper Tele Botom Right Tilt Down Down Up Out Push Button amp Trigger Switch Top Left Door Open Lift Dipper Tele 4 i Top Right Door Close Down In Handle Movement Push Front Lift Down Pull Back Lift Up Push Right Dipper Up Push Left Dipper Down Rotate Right Swing Back Rotate Left Swing Forward Trigger amp Handle Movement Push Right Telescope Out FIGURE 18 Push Left Telescope ln The Joystick is P N 02981374 The Plug in connections are marked with numbers on the plastic plug The wires are solid color or a
115. nsist of the following Item No D 3 CMD 0 NO OI R VZ VL F 20 Part No 02980967 00754566 02976344 00022200 02975692 02971158 00059500 02032200 02980723 02970066 02959587 00037200 02960521 5312316 02963646 00748547 02981985 02966556 02972088 02980721 02918600 00759457 00011700 00762398 00755954 Qty 4 4 4 4 14 D O O D D BR KO O NB OR V V R RAR Description BOLT HEX HEAD M12 P1 75 X 60mm PL GR10 9 LOCKWASHER 12MM BOLT HEX HEAD 7 16 NC X 1 1 4 PL GR8 LOCKWASHER 7 16 PL BOLT HEX HEAD M20 P2 5 X 50MM PL GR10 9 LOCKWASHER 20MM NUT HEX 1 NC PL LOCKWASHER STD 1 BOLT HEX HEAD M18 P 1 5 X 80 PLGR10 9 LOCKWASHER 18MM BOLT HEX HEAD 3 4 10NG X 6 PL GRB LOCKNUT 3 4 NC BOLT HEX HEAD 3 4 NC X 2 3 4 PL GR8 WASHER 3 4 20 MM HARDENED BOLI HEX HEAD 3 4 NC X 2 1 2 PL GR8 amp FLATWASHER 1 1 32 X 2 3 16 X 22 HARDENED WASHER 18MM HARDENED BOLT HEX HEAD 1 NC X 11 PL GR8 BOLT HEX HEAD 3 4 NC X 3 1 2 PL GR8 amp BOLT HEX HEAD 1 8UNC X 10 1 2 PL GR8 amp BOLT HEX HEAD 3 4 10UNC X 2 PL GRB BOLT LAG 5 16 X 2 PL GR5 LOCKWASHER 5 16 PL STD BOLT HEX HEAD M10 P1 5 X 30mm PL GR8 8 LOCKWASHER M10 SPRING Bolt Bag P N 02981894 is in Component Box P N 02981893 which is in Mount Kit P N 02982341 02971789 Wheel Weight Kit Consist of the following Item No em OonRWN F Part No 02970758
116. nter 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 th
117. nts 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 XS expansion signal ltem A ltem B FIGURE 6 Maverick Mower Head Circuit 1 The Motor Circuit The motor circuit for the cutting head operation is operated through display Figure 6 Item A By selecting the activation parameter the coil will shift the servo piston at the hydrostatic pump Figure 7 item B stroking the pump into the On position Flow will then be supplied to the hydraulic motor at the cutter head Figure 6 ltem C Activate the motor circuit while the engine RPM is at idle Once activated the engine RPM can be raised to the 540 PTO required speed if the 540 PTO engine speed is not noted onthe tractors RPM gauge consulttractor owners manual to find what the required speed is At any time
118. 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 2005 Alamo Group Inc Section 10 4 CONTROL VALVE BOOM CONTROL Maverick Boom Control System 1 Operating the Boom Control functions is done so by means of a load sensing electronic over hydraulic system There are three main areas of that system the electronic network instrumentation and hydraulic components 2 system compone
119. onl model only LH Counter Weight Turret Asy Machined Turret Boom Mount Pin Fe Weight Attaching Pin Long Pin Boom Mount Attaching Pin Long Pin Turret Cylinder Link Center Section Frame Weldment Boom Mount Attaching Pin Medium Pin Boom Mount Machined Boom Mount Attaching Pin Short Pin Swing Cylinders Swing Cylinder Pivot Bushings Swing Cylinder Trunnion Mount Weldment Swing Cylinder Cover Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 24 Mounting Component ID Hyd Hose Connections 24 FT Boom Z Hole In Side of Lift NG s Ls Nin if Z ANNY SR s a HADH AA K h Do ar SUITE MS Lol ar I A Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 25 Mounting Component ID Hyd Hose Connections 24 FT Boom Part No Qty End 1 End 2 Description 02981823 Y MJ Z FJX Hose 4 4MJ 4FJX 76 Lg Yel Tie Door Lift Sect n 02981824 Y MJ Z FJX Hose 4 4MJ 4FJX 76 Lg Yel Wht Tie Door Lift Sec n 02981828 Y MJ Z FJX Hose 4 4MJ 4FJX 76 Lg Grn Tie Swivel Lift Sec n 02981829 Y MJ Z FJX Hose 4 4MJ 4FJX 76 Lg Grn Wht Tie Swivel Lift Sec n 02981830 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Yel Tie Ext n Lift Sec n 02981831 Y MJ Z FJX Hose 6 6MJ 6FJX 76 Lg Yel Wht Tie Ex n Lift Sect n 0298
120. or bolts torque to 120 ft Ibs All Welds inspected toinsure proper welds and locations Hydraulic System zas Oil Level in Hydraulic Tank is within the sight gauge Hose connections are tight Hoses do not have any kinks or twist in them Front Pump Shaft adapter bolts are tight Front Pump Shaft Coupler Drive Shaft is lubricated and has an anti seize compound on the Splines of Pump and Shafts The Pump Drive Shaft has correct alignment Suction Hose has no leaks or kinks Rotary Mower Head Skid Shoe Bolts are torqued to 120 ft Ibs Spindle Housing Bolts are torqued to 400 ft Ibs The Spindle Housing is properly lubricated Motor Bolts are torqued to 120 ft Ibs Blade Carrier Bar Bolts torque to 400 ft Ibs Blade Bolts are torqued and the retainings Pins are in place Blades Swing freely Boom Boom Telesoping Bearings Adjusted completely inward All Hoses tightened and no leaks All hoses secured to where they will not rub get pinched or hanging down where they may catch on something All Decals installed Pump Primed and Pressure adjusted if needed only applys to Pump for Cylinder control Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05 2005 Alamo Group Inc Section 12 2 MAVERICK PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before opera
121. own 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 2005 Alamo Group Inc Section 1 6 SPECIFICATIONS MAVERICK 9 HOSE END FITTING TORQUE SPECS Hose End Type 37 Degree Angle End Steel Hose End Fittings Dash Nominal Cyl Torque Torque Size Size in in Ibs ft Ibs 4 1 4 140 12 6 3 8 230 19 8 1 2 450 38 10 5 8 650 54 12 3 4 900 75 16 1 1200 100 20 1 1 4 1600 133 24 1 1 2 2000 167 32 2 2800 233 Straight Threads do not always seal better when higher torques are used Too much torque causes distortion and may lead to leakage DO NOT over torque fittings and DO NOT allow any contaminants to enter system through fittings when installing them 10 Special Torque Specifications Rotary Heads Mor NN 100 ft lbs IIIS ORDER emcee eaaeene 425 ft lbs Spindle to Adjusting Nut Bearing Preload 25 in lbs Rolling Torque Blade Bar Leaf Bolts 1 1 4 Bolts 2000 ft Ibs
122. pins Forklift or hydraulic floor jacks with rolling back boards Small chain hoist or block and tackle Multidirectional Levels Hydraulic Filter Buggy or Cart Safety shoes safety glasses and gloves A hard hat should be worn by anyone working under any raised component D OP LP ORNE 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
123. ple 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 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 9 11 MOTOR amp BOOM PUMP HOSE ROUTING Listed Below are the location part number hose size type and function of the hoses at the tank this list is to be used with figure 21 as a reference Item PartNo Qty Description A 02981427 1 Hose 8FJX 8FJX 90 24 Lg w Red Tie Charge Filter to Pump B 02981428 1 Hose 8FJX 8FJX 90 21 Lg w Blu Tie Case Drain to Tank C 02981429 1 Hose 12FJX 12FJX 23 Lg Pump to Suction Filter hose under pump and cannot be seen i
124. ponents Some of numbers listed are NOT individual Parts but complete assemblies and or box of assemblies Check before ordering 30 foot Maverick 4wd Mount Kit 30 Maverick booms must be mounted on 4wd tractors only due to front axle spindle loading 02981892 Maverick Mount Kit NH TS 100A 115A 125A 135A Cab 4wd 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 T 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 PULLEY ADAPTER NHTS 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 6 02982000 1 DRIVELINE MODIFIED 02975257A 7 02982157 1 HOSE BUNDLE 6 CYL MAVERICK 8 02981404 1 MOUNT TANK RAIL RH TSA 9 02981405 1 MOUNT TANK RAIL LH TSA 10 02982022 1 WLDMT BOOM REST STABILIZER 11 02981415 1 WELDMENT ARMREST CONTROLLER 12 02982279 1 INST MANUAL NH TS A MAVERICK 13 02981464 1 ASY MOUNT PUMP COVER TSA 14 02982292 1 HOSE 12 12FJX 12FJUX 2
125. r install the fastener untill the The W0 Ene shoulder of the fastener is into the hole in the door DO NOT Tighten Fastener at this time T Install Outer Door Handle and fasteners Item 9 This is the outer door handle before itcan 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 amp 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 meet here Inner Latch eee Actuater Rod Figure 5 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc 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 spaceris 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 dis flat washer here The flat washer WILL
126. r Figure 22 frame rail See Figure 18 amp 23 The RH Rail looks different at the rear because the boom rest will bolt here later LE Rear Frame Mount Weldment P N 02982006 VETA T RH Rear Erame Mount Weldment 4 Install Front Frame Mount Rails The Front Albi Frame mount rails will consist of a RH amp LH See M INGE Preda Va Figure 19 20 24 amp 25 These will only fit one way as i 1 VER 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 L TOA the tractor See Figure 24 Make certain that all 3 4 ET l and 20 mm bolts have hardened flatwashers on fh 2 A TE em Figure 23 b 1 a T s FM ai sage gt LH Front Frame RH Front Frame i Mount Weldment Mount Weldment X PIN 02982012 P N 029820157 Kv l Figure 241 1 Maverick NH TS 100A 115A 125A 35A Asy Man 01 05 2005 Alamo Group Inc Section 5 9 Frame Installation 5 Install Center Frame Weldment The Center Frame Weldment has a front and a back side LH amp RH side The Center frame must be installed with the two openings See Figure 26 toward the front of the tractor These openings are to allow for the movement of the swing cylinders when moving the boom to the boom rest position IMPORTANT NO
127. r fora filter element change WARNING This filter does not have a by pass The element must be changed at the appropriate time to avoid element danmage and system contamination gt New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 8 CONTROL VALVE INSTRUMENTATION Maverick Instrumentation continued The Return Filter Switch The return filter switch is located at the return filter mounted on to the tank top The fluid returning from the cylinder control valve is filtered before returning to tank at this loca tion See Figure 15 The sensor monitors back pressure created by the filter assembly while cylin der circuit is in operation When the back pressure reaches 25 psi the switch will trigger and prompt the operator for a filter element change WARNING This filter does not have a by pass The element must be changed at the appropriate time to avoid element damage and system contamination Maverick Operator Interface FIGURE 15 The Operator Interface The operator selects parameters provided by a menu system in the MDM display control box The parameters are used to establish how the boom unit functions The menu system is comprised of two sections The first section is setup the second section powers up the boom control circuit and cutter head circuit The following steps outline how to successfully page through the menu system to execute operation See the en
128. r more if valves are stacked functions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pressure The Port openings on this diverter valve are marked with letter number codes which show which port is connected to which hose and where that hose connect on other end See Figure 5 4 amp 7 Port Function amp Connection 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 2005 Alamo Group Inc Section 4 6 Hydraulic Hose Connections O OD Six Spool Control Valve 8 gt 40 External Wire Connec tionsforvalve are marked gt A and B on Valve amp D AA1 thru AA12 on wire OD harness connections a Do O TE Pressure Supply Port P Diverter Valve C1 Port to Swivel Cyl Base End Port G W Tie Valve B Port to Diverter valve P1 Port G W Tie Diverter Valve C4 Port to Swivel Cyl Rod End Port G Tie 4 Through holes are mounting holes Diverter Valve C2 Port to Door Cyl Base End Port Y W Tie Diverter Valve C3 Port to Door
129. ra Maverick Installation Manual see 02982279 Standard Features Modified exhaust pipe for boom transport clearance Replacement arm rest with joystick console Neapco style driveline with double U joints 1400 wheel weight plus 408 auxiliary weight kit Right hand replacement Lexan door 3 8 Lexan replacement door right side only See Figure 4 51 gallon replacement fuel tank oe EE sl A 10 of ground clearance with the min tire size shown Restriction Notes 1 Exhaust must be modified for clearance See Figure 1 Battery box must be relocated by installing battery relocation brackets See Figure 3 2 3 Factory Seat Arm rest RH Side will be replaced by metal arm rest joystick mount See Figure 2 4 Electronic components and display modules will have to be mounted in cab See Figure 5 these must be mounted inside Cab to keep them protected from weather 5 Display must be set to correct operating parameters before unit will function See Figure 6 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 2 Mounting Specifications Figure 1 Replacement Exhaust Pipe Figure 2 Seat Mounted Joystick Elbow amp Bracket Figure 3 Battery Box Clearance gt dr M la MG TL em 1 LL yun T Z pytt gl a tg 1 L L 1 1 Figure 5 Electronic Module mounted amp Figure 6 Electronic Display Screen unseen behind cab panel mounted
130. ractor stays on the ground when the boom is fully extended horizontally with 200 lbs placed on the outside of the mower head Post Operation Inspection Check that the oil in the hydraulic tank has not turned milky in color or has foam on top Check that there are no loose fasteners or hardware Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05 2005 Alamo Group Inc Section12 3 NOTES Maverick NH TS 100A 115A 125A 135A Asy Manl 01 05 2005 Alamo Group Inc Section 12 4 INDUSTRIAL Maverick Assembly Manual New Holland TS 100A 115A 125A 135A 2005 Edition P N 02982279 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc
131. re all steps of the m installation is completed if tractor is started damage to the hydraulic system will occur Orange Tie Top Fitting 2 1 HoseFrom Oil Cooler to Lank return No Plasttc Pines 20 i Cooler m s T ni Maverick NA TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 9 10 Hydraulic Tank Hose Routing J 16 Hose B 8 Hose Red Plastic Tie 90 Elbow NES Blue Plastic Tie A 8 Hose E Aa ROSE K 46 Hose 90 Elbow Red Plastic Tie Orange Plastic Tie Red Plastic Tie LE p LA mt C 12 Hose sa Suction Hose V No Plastic Tie D 12 Hose Red Plastic Tie fe n AA mms ee G 20 Hose Suction Hose No Plastic Tie mnt rt Cd p AC Cl aj LI A her VE 1 7 Te A 8 Hose Red Plastic Tie L Hose Sg Blue Plastic Tie H 12 Hose 90 Elbow Orange Plastic Tie D 12 Hose Red Plastic Tie B 8 Hose G 20 Hose Blue Plastic Tie Suction Hose No Plastic Tie 4 Hose 8 Tee Tank Return Blue Plastic Tie H 12 Hose Orange Plastic Tie NOTE Hoses are not shown in drawing above this is for clarity The hose routing is for the hoses which connect from one point to the other Use the instructions and hose description listed to follow hose routing Exam
132. re 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 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 41 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 8 17 NOTES Maverick NH TS 100A 115A 125A 135A Asy Man 01 05
133. residue on the ground can result in unjury from slipping or falling Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 2 5 General Information Installation Requirements TRACTOR PREPARATION FIGURE 1 amp 2 1 Temporally remove ROPS and fenders from tractor axle Move left rear tire out so that it is 50 inches from the outside of left rear tire to the center of tractor Then move the right rear tire out so that it is 96 inches between the outside of the left and right rear tires Refer to your tractor s Operator s Manual for instructions on Rear Wheel Adjustment for your particular tire FIGURE 1 Hydraflate rear left tire as much as needed for stability but feared in factory COMME uimit FIGURE 1 96 WARNING Never operate the tractor with a loose wheel rim or disc Always tighten nuts to the specified torque and at the recommended intervals 2 Extend front wheels out so that it is 55 inches between the inside of the tires This will allow no interference between tire ane kot mount bracket FIGURE 2 SE Syren FIGURE 2 55 TL ICILI i iil i LILI IC IL an SNE 4 H Ml o z A ME J OL GN Sa sr ker FEES gt Taels MA lelli 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
134. roup Inc Section 10 14 Adjust Boom Swing Stop Turret Assembly as seen from the bottom Swing Stop Lug Turret Swing Stop Lug with Built onto the Adjusting Bolt amp Locking Nut Turret Cylinder Link Weldment Swing Cylinders New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 15 NOTES New Holland NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 10 16 Gection 11 Maverick New Holland Tractor TS 100A 115A 125A 135A Mounting Specifications S E Mounting Specifications New Holland TS 100A 115A 125A 135A Cab 2 amp 4wd As of 01 05 05 10 00 16SL F 2 Min 11 00 16SL F 2M Max 2wd Front Tire 12 4 24 R 1 Min 14 9 24 R 1W Max 4wd Front Tire 18 4 30 R 1 Min 18 4 34 R 1W Max Rear Tire Mount Kits 24 Maverick 2wd Mount Kit oooooooooooooce 02982343 Page 11 7 thru 11 10 24 Maverick 4wd Mount Kit ooooooooooosoooce 02982341 Page 11 11 thru 11 14 30 Maverick 4wd Mount Kit ss 02981892 Page 11 15 thru 11 18 Common pParts Box Common Parts BOX iii 02981781 Page 11 4 thru 11 6 Common Parts Box shipped with all models no matter which boom or tractor model 2wd tractors must be equipped with heavy duty eight bolt front wheel hubs amp spindles 30 Maverick booms must be mounted on 4wd tractors only due to front axle spindle loading Options Ext
135. roup Inc Section 4 8 Section 5 Maverick Boom New Holland Tractor TS 100A 115A 125A amp 135A Battery Modification Exhaust Modification Fuel Tank Modification Main Frame Installation verick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 5 1 Battery Holder Relocation EE 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 Battery 3 Install Replacement Battery Tray Bracket Relocation Install the replacement battery tray bracket See Bracket Figure 2 using the same bolts and holes as the P N original bracket This Bracket is designed to move battery further back Install original
136. rt Weldment Included in Front Axle Stabilizer Kit Only Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 37 Component Identification Two Wires in plug amp 1 Blue Wire Connection 1 Black Wire Connection Connecte to R1 Connec tion of Exterior Wire Harness T J Oil Cooler Fan Assembly P N 02981377 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 38 Section 12 MAVERICK New Holland Tractor TS 100A 115A 125A 135A PRE DELIVERY INSPECTION CHECKLIST MAVERICK PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled See following page 1 4 for component location Saftey Equipment Operators Manual is with Unit The Safety Decals are installed as listed in the Assembly Manual Valve operation plate is installed Operators cage or Tractor Cab is in place Deflectors are installed on the Mower Head Tractor Rops or Cab with seatbels installed properly Frame and Boom NH TS 100A 115A 125A amp 135A Axle Plate Bolts are torqued to 280 ft Ibs Boom Rest Axle Plate Bolts are torqued to 280 ft Ibs Front Rail Bolts are torqued to 425 ft Ibs Front Support Bolts at tractor are torqued to 355 ft Ibs Rear Rail Bolts torque to 425 ft Ibs Rotat
137. s 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 amp 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 amp RH Tank rails Do notremove from hoist until tank has been bolted on and bolts tightened 3 Rotate Fittings to make better access to Valve and tank connections The fittings in the pump and valve may have to be rotated to make Figure 1 it more accessable whenconnecting the hoses Hose Connections To Pump And Hyd Tank See Figure 2 tem PartNo Qty Description A 02981427 1 Hose 8FJX 8FJX 90 24 Lg w Red Tie Charge Filter to Pump B 02981428 1 Hose 8FJX 8FJX 90 21 Lg w Blu Tie Case Drain to Tank C 02981429 1 Hose 12FJX 12FJX 23 Lg Pump to Suction Filter hose under pump and cannot be seen in drawing D 02981430
138. sure The Port openings on this diverter valve are marked with letter number codes which show wich port is connected to which hose and where that hose connect on other end See Figure 18 Port Function amp Connection P1 Hose Hydraulic Pressure from Door Swivel B Port on Control Valve P2 Hose Hydraulic Return to Door Swivel A Port on Control Valve C1 Hose to Head Swivel Cylinder Base End C2 Hose to Door Cylinder Base End C3 Hose to Door Cylinder Rod End C4 Hose to Head Swivel Cylinder Rod End Electric solenoid retaing Electric Solenoid Ti These 2 threaded holes on back C1 Port this side for mounting diverter valve side Not to frame Not Seen Seen to head swivel cyl base Q N end P1 Port Pressure from Control Valve door swivel port of control C4 Port this valve v side Not Seen to head swivel These 4 holes are through holes U cyl rod end that would be used if this were a stacking valve to stack two or I L CJ 3 46 L SA cd more valves together These holes are not used in this application Q C2 Port to door cyl base end P2 Port Return to control valve door swivel port of control valve C3 Port to door cyl Rod end Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 23 Mounting Component ID Under Mnt Frame Asy 24 30 Under Mount Frame Asy 24 amp 30 ft are the same except for the LH weight 30 ft model
139. t Down Base End Green G SAE 4 A P2 Control Valve tor Diverter valve Green White G W SAE 4 B P1 Control Valve to Diverter Valve Green G SAE 4 C4 Swivel CW Rod End Green White G W SAE 4 C1 Swivel CCW Base End Yellow Y SAE 4 C3 Door Open Rod End Yellow White Y W SAE 4 C2 Door Closed Base End Orange OR SAE 12 T Valve Return To Tank Red R SAE 12 P Pressure to Valve Motor Circuit Hoses to Boom Connections Listed as reference Color Tie Code Hose Size Hyd Function Red R SAE 16 Pressure Flow to Motor Orange OR SAE 16 Return Flow From Motor Blue B SAE 8 Case Flow From Motor to Boom Blue B SAE 12 Case Flow at Boom to Tank Diverter Valve The Diverter Valve bolts onto the front frame mount bracket on the LH side of the tractor the holes are in the bracket See Figure 5 amp 6 The Diverter valve is a electrical operated valve that allows the hydraulic pressure to be shared to operate two or more if valves are stacked functions with a single pressure supply This valve is strictly a diverter valve and is designed to direct the pressure not regulate the flow or pressure The Port openings on this diverter valve are marked with letter number codes which show which port is connected to which hose and where that hose connect on other end See Figure 4 5 amp 6 Port Function amp Connection P1 Hose Hydraulic Pressure from Door Swivel B Port on Control Valve G W T
140. tand Operator s Manuals Safety Signs and Instructional Decals for tractor amp flail mower to prevent misuse abuse amp accidents Practice before operating mower in a confined area or near passersby Learn how to stop engine suddenly in an emergency Be alert for passersby and especially children 2 Allow no children on or near implement or tractor Allow no riders on tractor or implement Falling off can cause serious injury or death from being runover by tractor or mower or contact with Flail Mower Blades 3 Operate only with tractor having Roll Over Protective Structure ROPS and with seatbelt fastened securely and Snugly to prevent injury and possible death from falling off or tractor overturn Personal Protective Equipment such as Hard Hat Safety Glasses Safety Shoes and Ear Plugs are recommended 4 Block up or support raised machine and all lifted components securely before putting hands or feet under or working underneath any lifted component to prevent crushing injury or death from sudden dropping or inadvertent operation of controls Make certain that area is clear before lowering or folding 5 Before transporting put Lift Lever in detent or full lift position Install Transport Safety Devices securely on folding implements Slow down when turning and on hillsides Install Restrictor in folding circuit to slow down lowering and unfolding if action is faster than is desirable 6 Make certain that SMV sign Warning Lig
141. the hoses away from driveshaft N 3 Remove Pump Shipping Bracket The pump Pump Shoa is shipped using a bracket that bolts to the pum and Ba Bracket the tank assembly Before pump can be installed it OI 0 m will have to be unbolted from pump and tank The Figure 8 LS i See sed 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 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 3 4 Pump Drive Assembly Instructions Installing Driveline Half to Pump 1 Install Driveline Half to Pump Installthe 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 atthis time See Figure 9 amp 14 Driveline Tube Half with Figure 9 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 us
142. ting the unit to assure that they are properly assembled Flail Mower Head Skid Shoe Bolts are torqued to 120 ft lbs Motor Bolts are torqued to 120 ft lbs Belt Alignment amp tension adjustment is correct Cutter shaft bearings are properly lubricated Roller bearings are properly lubricated Blades swing freely Tractor Mower Operation Inspection Using all Safety precautions operate the Tractor and Mower unit for 30 minutes and while the unit is running check the following items Note Only make adjustments after the mower has been turned off and all motion has stopped and all hydraulic pressure has been relieved Check for Hydraulic oil leaks at the hose connections Operate the boom and mower head throughout its full range of motion and check for hose s rubbing pinching or kinking Make sure the Return Filter Gauge is reading in the Green after Oil is warm Check the function of the Mower Head On Off Valve and switch for proper function Make sure that the tractor will not start with the mower on off switch in the on position Check the Blade Rotation for the Rotary Mower Head to make sure it is turning Clockwise looking from the top of the mower deck Make sure the control valve boom movements agree with the valve operation decal Make Sure Boom Movement operates as expected and is smooth and under control no air in the control system Look for any unusual or excessive noise or vibrations Make sure the left rear wheel of the t
143. uded on this unit Tank Temperature Sensor Charge Pres sure Filter Switch Valve Pressure Filter Switch and Return Filter Switch Tank Temperature Sensor The tank tem perature sensor monitors the fluid temperature in the area of the pump suction screens the tempera ture is real time and is used on the network to accomplish certain objectives The first is to display on the interface while the cutter circuit is operating The 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 12 The Charge Pressure Filter Switch The charge pressure filter switch is located at the filter in the charge loop on the hydrostatic pump See Figure 13 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operator for a filter element change of filter element The Valve Pressure Filter Switch The Valve pressure filter switch is located at the pres sure filter in the valve pressure circuit between the closed center load sense pump and the control valve See Figure 14 The sensor monitors the back pressure created by the filter element when in use When the back pressure reaches a setting of 50 psi the switch will trigger and prompt the operato
144. uit 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 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 zA WARNING This filter does not have a by Sr pass The element must be changed at the appropri IGU RE 3 ate time to avoid element damage and system contamination Maverick NH TS 100A 115A 125A 135A Asy Man 01
145. und because of the large diameter of the bearing This bearing must be greased before unit is put into service It is easier to get to grease fittings now than after boom has been installed On the under side of the turret assembly are the grease fittings for the swing cylinder pivot mounts these need to be greased before operating the unit Also there is a bolt on cover on the under side of turret that will be installed See Figure 40 atalatertime Greasing the cylinder pivots will need to be done before the cover is installed See Figure 39 and the boom swing stop will need to be adjusted but this cannot be done until a later time making it best to leave this cover of until then After greasing components at assembly of unit operator should consult the operators manual for maintenance requirements Figure 39 39 I Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc 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 P N 02983143 the boom the upper pressure supply hose 4 hose with New front axle blue plastic tie is t
146. verick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc Port U BU B gt U BE gt UU 5 gt U U gt 11 32 Hyd Function Swing Back Rod End Swing Forward Base End Lift Down Rod End Lift Up Base End Dipper In Rod End Dipper Out Base End Telescope In Rod End Telescope Out Base End Head Tilt Up Rod End Head Tilt Down Base End Swivel CW Rod End Swivel CCW Base End Door Open Rod End Door Closed Base End Component Identification XP2 Expansion Power ur Analog inputs 4 Prop Output 4x2 Digital Inputs 4 Digital Outputs 4 Op 0193 Freq Inputs 2 E Gas Igan Display Unit XP2 Expansion Power XT2 Expansion Transmission Analog Inputs 10 Prop Outputs 2x 11303 CAN hub 41 Digital Outputs 6 Freq Inputs 3 E Gas 1 XS expansion signal XT2 Expansion Transmission XS Expansion Signal Tank Temperature Sensor Charge Pressure Filter Switch Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 33 Component Identification RH Side Install with these openings to front of tractor Front of a Side of Tractor ractor Rear View OR a O HO o o o o SO o O k Jlo o OJ I mm me P N 02981168 Center Section Under Mount Frame WIdmnt P N 02976633 LH Side Step Wldmnt P N 02980694 LH Rear Top Axle strap Maverick NH TS 100A 115A 125A 135A Asy Man 0
147. will have 1 hole in the outer end same Mounting as the tank See Figure 12 amp 13 Tabs 6 Install The new Fuel tank onto Tractor The Figure 13 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 T 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 Rear Bracket 1 Bit N Front Figure 15 M FE 2 Bolts ga Maverick NH TS 100A 115A 125A 35A Asy Man 01 05 2005 Alamo Group Inc Section 5 5 Frame Installation Ce hs 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 Ce
148. will have the same color tie but the size length or fittings will be different Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 29 Mounting Component ID Swing Cyl Hose 24 30 NOTE Male JIC Hose End To Extend Up Thru Holes Item PartNo Qty Description A1 02981825 Hose 46 6FJX 6FJX 28 Lg Bi 02981825 Hose 46 6FJX 6FJX 28 Lg C1 02981826 Hose 6 6FJX 6MJ 16 Lg Geen Tie C2 02981827 Hose 46 6FJX 6MJ 16 Lg Green White Tie 34 02968832 Plastic Tie Green 35 02968833 Plastic Tie Green White dr hr L NOTE Hose are not shown in drawing this is for clarity The hose routing is for hoses which connect from one point to the other Use the instructions and hose descriptions listed to follow hose routing Example Hose A1 connects to one end marked A1 and the other end connects to the other connection marked A1 This is done with the other letters as well the hose must connect to the same letter mark on each end Some hose have a plastic colored tie on it to ID hose and location To ID hoses always check hose size length and colored plastic tie Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2004 Alamo Group Inc 11 30 Mounting Component ID Cyl Cnirl Valve Connections Service Connection Port B Port B 100G 8AIMS peeH JL PESH LE zop O 1 en 25 A A O NOOO Zo o O 7 F TRE ni pe ll a t
149. y 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 Maverick NH TS 100A 115A 125A 135A Asy Man 01 05 2005 Alamo Group Inc Section 6 4 Section MAVERICK Standard Wheel Weight amp Auxiliary Wheel Weight Installation New Holland Tractor TS 115A 125A amp 135A 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 80 Calcium Chloride and 70 Water this mixture will add weight at about 10 5 Ibs per gallon Follow the Mixture procedures furnished by the Manufactured of the Brand of Calcium Chloride that 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 Sid

Maverick/NH TS-100A,115A,125A,135A

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