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Versa Mower/NH TS-100110115125135A - Assembly Manual

1. Not used Not used Not used 1250 1695 2060 2793 NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 2 4 General Information IMPORTANT Change the return filter in tank and suction filters after the first 200 hours of operation Change the filters again at 700 hours then change the oil and filters at 1600 hours After that continue to change the filter every 800 hours and the oil every 1600 hours Hydraulic oil to be used is Universal Tractor Hydraulic Use the above procedures as part of a good filter maintenance program Between filter changes monitor condition of filter by reading Pressure Gauge mounted on filter on top of the Tank If pressure reads 15 psi or greater at 1800 RPM engine speed and normal operating temperature 140 deg F or greater filter element should be changed Pressure gauges are color coded to help indicate when to change element WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result CAUTION To prevent personal injury alway
2. bracket to the front of the stabilizer tack weld it P N 02980750 to the versa frame See Figure 7 DO NOT Flat Axle Remove Versa frame yet the Hydraulic Tank Mount Bracket must be fitted to the Versa frame and the P N 02879100 mounting tabs welded on to the versa frame See Step 8 8 Figure 8 NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 3 4 Versa Frame 8 Pre Fit Hydraulic Tank Make certain that the Versa Frame has been tack welded to the mounting plate on the LH side of Versa Frame See Figure 6 The Hydraulic Tank will need to be pre fit to the Versa Frame Using an over head hoist align the outside Tank Mounting holes in tank with the holes in the Versa Frame Snug the two bolts of tank for the two outer holes These holes are slotted so the tank can be moved forward or back to give Hydraulic tank and tractor components Fuel Tank clearance See Figure 8 amp 9 When you have sufficient clearance with the tractor components and hy draulic tank install the inner two tank mounting lugs to the Tank with the two bolts supplied The Tank Mounting lugs will sit on the Versa Frame on the inside of the tank Tack weld the lugs to the versa frame Remove the Tank from the versa frame and set it aside for now See Figure 9 10 amp 11 The Tank Mounting Lugs can be welded now or wait until the versa frame is unbolted and removed Mounting 9 Install the Versa Frame Step The Ve
3. pd Page 5 5 Wiring Schematic 16 Yellow ON Off Push Pull Switch EN po dh Switch Plug q 12 Brn Fuse Holder E a with Fuse Starter Solenoid Wire Starter Solenoid Wire Switched Power Supply Ground 16 Black Solenoid Connector Ring Connector to Ground Connecters Shipped Loose in Separate Plastic Bag 16 Black 16 Red to Switched Power Supply 16 Yellow On l Solenoid Connector gt 12 Brown Line at Cutter Valve wy Connector to Figure 14 Starter Solenoid NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 5 6 Wiring Harness Wire Harness Connections 1 Disconnect Battery Cable Discon nectthe battery cables before attempting any of the electrical connections this is to protect the tractor electrical system as wellas the mower electrical connections Electrical connections should never be attempted with the battery connected Use Ohm Meters to testelectrical connections 2 Wire Harness Schematic The wiring har ness schematic list the plug wire type wire F color and where the wires connect The wire harness will be shipped complete The wire harness will need to be connected correctly or it will not function properly DO NOT operate any unit that is not functioning correctly See Figure 14 Cutter Solenoid amp Wire Harness Connection 3 Connect Starter Solenoid Wires The starter solenoid wire are the two brown wires The t
4. Hoses item 1 and 2 from the Control Valve See Figure 25 to the Swing Cylinder See Figure 26 Use the recommended hose end torque values in general E KSE amp ig D V gt NV peu SS ART j A gt A o Se M CS WARNING When working with or on the machine take care and stay alert Always Y be careful Always be alert for hazards Watch out for others NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 12 Optional Heads Available ATTACHMENT OF HYDRAULIC HOSES ON VERSA BOOM contin ued 11 Attach the 1 4 hoses item 1 and 2 from the Control Valve See Figure 27 r outed around Solenoid Valve See Figure 28 to the Lift Cylinder See Figure 29 Use recommended Aue a an an amaro aforra LAN artian Se Figure 2 WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 13 Optional Heads Available ATTACHMENT OF HYDRAULIC HOSES ON VERSA BOOM contin ued Attach the Dipper Cylin
5. O ring fittings Use the pipe thread sealant liquid only Do not substitute with some other type of sealant such as teflon tape paint shellac etc Hoses supplied have two types of fittings solid or swivel Some hoses have solid fittings on both ends others have a solid fitting and a swivel fitting Hoses with two solid fittings will fit into either a internal solid thread or a swivel adapter union When installing either type hose solid fittings must be installed first then install the swivel end of the hose or fitting The Versa hydraulic system incorporates three basic types of hydraulic fittings A Standard pipe NPT or NPTF thread fittings This type reguires a small amount of evenly applied sealant B Swivel fittings This type does not require any sealant on the swivel end because it seals against an internal flare C O Ring fittings This type does not require any sealant on the O Ring end of the fitting It is extremely important to avoid getting pipe thread sealant inside the fittings or hoses KEEP THE INTE RIOR OF ALL HYDRAULIC COMPONENTS CLEAN Inspect the inside diameter of each hose before as sembly Make certain that no obstruction is present Dirt sand dust etc are abrasive and once in the system can cause immediate or early failure When assembling the fittings and hoses be careful not to introduce any dust or contaminants into the system Keep all fittings hoses and hydraulic components
6. and gloves A hard hat should be worn by anyone working under the crane hoist or block and tackle Hydraulic Filter Pump Cart 13 Torque Wrench 3 4 and 1 2 drive type Remember to follow each step closely and cautiously Be aware of all support personnel at alltimes Keep the assembly area as clean as possible clean up all spills when they occur A safe assembly area and a crew that is sensitive to the dangers involved in putting this implement together will help protect lives Keep all unauthorized personnel from the area Do not assemble the Versa in an area where children play 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 helping with the assembly NHTS 100A 115A 125A 1 35A Asy Man 07 04 2004 Alamo Group Inc Page 2 3 General Information RECOMMENDED TORQUE VALUES CHART RECOMMENDED HOSE END TORQUE VALUES FOR 37 DEGREE ANGLE STEEL HOSE END FITTINGS NOMINAL TORQUE VALUE SIZE IN FT LBS 1 4 3 8 1 2 5 8 3 4 1 1200 1 1 4 1600 1 1 2 2000 2 2800 Straight threads do not always seal better when higher torques are used Too much torque causes distortion and may lead to leakage RECOMMENDED TORQUE VALUES CHART RECOMMENDED TORQUE IN FT LBS Nm COARSE AND FINE THREADS 2 B 5 D 8 F Plain Three Six Head Dashes Dashes
7. 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 4 10 Section 5 VERSA MOWER Cylinder Control Cables New Holland Tractor TS 100A 115A 125A 8 135A 4 Page 5 1 Cylinder Control Cables Cylinder Control Valve Cables To Valve Spools The Remote Control Cables Connection to the valve and the Control Handle assembly See Figure 1 for listing of items 1 thru 8 listed in assembly steps 1 Remove the phillps head screws that are in the valve body next to the spool end 8 There are bolts in kit that will be used to replace these screws when needed See Figure 2 Slide the Bolt flange 8 Thread 750 16 NF jam nut entire length of threaded hub and onto the cable 7 Place flange on sleeve and thread flange sleeve assembly entire length of threaded hub and onto cable 2 amp 6 Thread 250 28 NF jam nut onto cable threaded rod until it bottoms 3 Place connector onto threaded rod and against jam nut Align connector so it will mate with spool terminal and secure jam nut against connector 4 Slide the connector onto spool and align the holes Insert pin through connector and spool holes 5 The control cables will need to inserted through the floor of the tractor cab and the Control Levers will need to be assembled to the cables before continuing with the next assembly steps With cable attached to the valve and control levers turn the flange sleeve assembly onto the threaded hub until it is flush with the valve face W
8. 800 hours and the oil every 1600 hours Hydraulic oil to be used is Uni versal Tractor Hydraulic Use the above procedures aspart of a good filter mainte nance program 8 Monitor Oil Condition Between filter changes monitor condition of filter by reading Pressure Gauge mounted on filter on top of the Tank See Figure 7 If pressure reads 15 psior greater at 1800 RPM engine speed and normal operating temperature 140 deg F or greater filter element should be changed Pressure gauges are color coded to help in dicate when to change element Figure 9 NH TS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 7 4 Initial Start Up Procedure INITIAL START UP PROCEDURE 1 Check all nuts and hex head bolts to ensure all are tight and all lock washers are fully compressed flattened Check all hoses and hydraulic connections Make certain they are securely tightened Refer to hose fitting tightening specification in the general information section Inspect all moving parts and make certain that no wires or hoses will be caught or pinched when the tractor or the mower is in operation Tie down loose wires and hoses Thoroughly grease all the lubrication points and install a lubricap on each grease fitting Refer the Operation and Maintenance Section of the operators Manual for grease fitting locations Jack front of tractor up enough to allow axle to pivot through its full range While turning wheels
9. Head continued 4 Attach Hydraulic Hoses as illustrated See Figure 3 Refer to your Operator s Manual and Parts Listing for part numbers and Hydraulic Schematic Tighten any leaking Hydraulic Fittings If fluid still leaks loosen the fitting apply a thread compound to the threads and tighten Care must be taken when tightening Hydraulic Fittings Too much tightening can cause the fittings to crack and require replacement fittings Please use recommended hose end torque values See Charts in General Information section or operators manual WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result NH TS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 6 5 Optional Heads Available PREPARATION FOR INSTALLATION OF VERSA BOOM 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 tir
10. half aside for now Make certain that the four retaining bolts for the Pulley adapter to the crankshaft pulley have been tightened From the side of the tractor RH side slide the Shaft Half of driveline shaft end first Se down into the opening below the radiator REN Drive Shaft from engine side insert it through the Assembly existing hole and or cut hole combination i until the shaft is pointed toward the frontofthe tractor andthe flange yoke is over far enough to align with the four threaded pulley adapter holes 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 atthis time These four bolts can be tightened by using a long socket extension run through along side the driveline shaft 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 Installing Pump Mounting Weldment 1 Install Pump Mounting Weldment The Pump Mount Weldment P N 02980666 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 02980666 with the opening for the driveline cover up Tighten the four mounting bolts now See F
11. on the hydraulic motor 2004 Alamo Group Inc Page 6 17 NHTS 100A 115A 125A 135A Asy Man 07 04 Optional Heads Available WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result ATTACHMENT OPTIONAL TIMBER CAT HEAD ON VERSA BOOM 1 Attach the Timber Cat Head to the boom using the pins included with the head Be careful not to damage the pivot bushings in the boom when inserting the pins Attach the 90 elbow Item 1 to the front port of the boom and position it so that it faces down Attach the 90 end of the return hose P N 02973125 to the fitting and attach the straight end to the 90 fitting Item 2 on the flow divider if it is not already connected Attach the pressure hose P N 02973124 to the rear port of the boom and attach the other end to the 90 elbow Item 3 on the flow divider if it is not already attached See Figure 39 Be sure the hoses are routed as shown in the figure and securly tighten all connections Start tractor and move the head tilt through its motions and check for
12. sealed until installed Do not allow any components to lie open and exposed to dust or contamination Do not lay parts down on the dirt or sand and then assemble them as this will introduce contaminants into the system CAUTION To avoid Hydraulic Contamination al ways keep all hoses and hydraulic fit tings capped until they are ready to be installed See Figure 1 amp 2 Figure 2 NH TS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 7 2 Filling Hydraulic System Fill Hydraulic System With Oil 1 Remove the Filler Cap Weldment It will be easier to unscrew the filler neck weldment to fill the hydraulic tank See Figure 3 2 Avoid Hydraulic Gontamination is Im portant Avoid hydraulic contamination by filter ing the hydraulic oil while filling the hydraulic tank Filter buggies or carts are commercially available for hydraulic system clean up These consist of a high efficiency high ca pacity filter a circulating pump a drive motor and hoses for connecting to the overhauled machine s hydraulic system See Figure 4 8 5 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 oil into the hydrau lic tank by using a hydraulic filter pump unit equipped with a properly operating 10 micron filter This will insure that the oil being added is clean Do not just pour the oil directly into the hyd
13. should not start if mower switch is on Is swing cylinder pinned in correct hole On rear swing type machine cylinder should be pinned to outside hole On front swing type machine cylinder should be pinned in inside hole Is machine equipped w proper operator protection Must have cage or cage panels Does mower operate when on off switch is operated Is head rotation correct On rotary heads looking from the top of the deck rotation should be clockwise so that debris will be thrown away from the tractor On flails rotation can be forward or reverse but forward rotation is standard If operating a square head are spindle housing bolts tight Is spindle assembly tight Are bolts that hold blade bar to spindle tight Does head operate smoothly at normal operating speed Head should not vibrate excessively All the above items should be checked off before delivery of mower unit to customer amp operator NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 7 7 NOTES NHTS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 7 8 Section 8 VERSA MOWER Mounting Specifications New Holland TS 100A 115A 125A 8 135A Tractor 07 04 Page 8 1 New Holland TS100A 115A 125A 135A Cab 2wd As of Date 07 04 Max front tire 10 00 16 F 2 Max rear tire 18 4 34 R 1 TS100A 4 cylinder engine Only Versa Mount Kit 02980734 Versa Mount Kit Single Stage Pump Tractor Hyd eee 0298
14. that align with the bracket to mount it to the door post See Figure 7 5 Control Stick Assembly Remove the Cross Screw from the bottom of the Control Stick Assembly DO NOT remove the screws that fasten the two housings halves together See Figure 8 6 Threaded Plunger Rod While holding the housing fully shift the Handle in the Control Stick Assembly to expose the female threaded end of the Plunger Rod See Figure 9 Cab gt Post Ride Coniro 7 Threaded Cable End While holding the Handle Mounting Handle to expose the Plunger Rod thread the Bracket Threaded Bead of the Cable into the end of the Plunger Rod and tighten securely Release the Handle allowing the Cable to pull into the Control we A Stick Assembly See Figure 10 I 8 Attach Cable To Plunger Once Cable is x attached to Plunger Rod slide the silver Conduit Sleeve into the bottom of the Control Stick As sembly and align the groove inthe Conduit Sleeve with the Cross Screw Hole See Figure 11 9 Reinstall Cross Screw Install the Cross Screw and tighten securely Work the Handle to make certain the cable is moving freely and not binding See Figure 12 Control Stick 10 Connect Control Stick to Cab Mount The Assembly control Sticks will be mounted to the cab mount s A ing bracket with three bolts These same three bolts will also mount the motor cut off switch mounting bracket First insert the three bo
15. they are mounted correctly The Front Mounting bracket will have a metal hose ring P N 02978281 that will need to be welded to them one for each side If Mounted correctly the front and rear LH 8 RH brackets will be the same width apart at the bottom where each has the three holes See Figure 3 4 Install Versa Mount Plate to Mounting Brackets The mounting Plates LH amp RH side will bolt to the mounting brackets using the six bolts on each side Bolt these plates to the out side of the mounting brackets Install all six bolts and snug them only as you will be removing tnem NHTS 100A 115A 125A 1 35A Asy Man 07 04 Removed Tractor Parts that will not be 3 used Front Mounting Bracket LH P N 02980737 8 RH P N 02980738 w Hose Ring P N 02978281 Welded on Rear Mounting Bracket P N 02980739 RH or LH 17 d M RAKO E Versa Mount Plate Figure 4 P N 02978816 later to completely weld them to the versa frame See Figure 4 2004 Alamo Group Inc Page 3 3 Versa Frame 5 Fitting The Versa Frame Using a floor jack insert the versa frame up under the tractor The Versa Frame will fit up against the versa mount plate See Figure 4 DO NOT do any welding of the versa frame until instructed to The Versa Frame will have to be aligned for distance Left to Right 6 Aligning Versa Frame with Mounting Brackets The Versa Frame must be aligned with the mounting frame to where it will extend out past mounting
16. 0831 TS1154 125A 135A 6 cylinder engine Only Versa Mount Kit 02980808 Options Lexan Window Kit 02980888 Side Screen Kit 02980642 Pump Guard Kit 02980652 Hydro 60 72 Mount Kit 02980830 Restrictions These mount kits were developed on borrowed TS100A 8 TS115A Cab 2wd tractors Every effort has been made to accurately position the frame and to size the hoses in order to maintain access to all service points and to provide proper transport clearance with the front tire Furthermore the TS125A amp 135A are reportedly equipped with Iveco engines Though the driveline should mate correctly to the crankshaft pulley we have no way of checking for proper driveline or service point access Until all four models have been mounted for inspection at our Seguin Tx facility the dealer customer will be held responsible for any necessary modifications to the mount kit design Effective January 12 2004 New Holland began providing loader brackets as standard equipment on TS A series tractors These brackets must be removed for proper Versa frame mounting Plan at least an extra hour or two to complete the removal The Versa frame must be positioned so that 1 3 8 exists between the hood and oil reservoir at it s closest point If it is closer the air filter may not be removable If further out the Versa flail head may contact the right front tire when in transport For the same reason the shorter Versa extension arm can not be utilized with th
17. 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 10 Optional Heads Available ATTACHMENT OF HYDRAULIC HOSES ON VERSA BOOM continued 7 Attach the 1 1 4 Pressure Hose item 1 and Return Hose item 2 from the Solenoid Cutter Valve See Figure 19 to the Hydraulic Tubes on the Versa Boom See Figure 20 Use the recommended hose end torque values in general information section Attach the 1 2 Return Hose item 1 from Cutter Valve See Figure 21 to the Control Valve See Figure 22 Use the recommended hose end torque values listed in general information section 1 PRESSURE 2 Return From WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connec tions before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 11 Optional Heads Available ATTACHMENT OF HYDRAULIC HOSES ON VERSA BOOM continued 9 Attach the 1 2 Pressure Hose from the Hydraulic Pump See Figure 23 to the Control Valve See Figure 24 Use the recommended hose end torque values on page 37 10 Attach the 1 4
18. 5 3 Cut Hole if Cab Floor For Cable A Wire Harness Insertion 5 3 Insert Wire Harness Through Cab Floor 5 3 to 5 4 Insert Cables Through Gab Flo r un u a ea 5 4 Install Control Handle Mounting Bracket 5 4 Connect Control Handles to Gables ue en ae 5 4 to 5 5 Connect Control Handles to Mounting Bracket 5 5 Mount Motor Cut Off Switch 8 Mount to Control Handles 5 5 Klee EE EE 5 6 to 5 7 SECTION 6 Versa Mower Optional Heads 6 1 to 6 19 Versa Flail EE P Ho 6 2 to 6 3 Versa Te E E 6 4 to 6 5 Versa Boom Install on Versa Mower Unit eee 6 6 to 6 19 SECTION 7 Filling Hydraulic Tank amp Initial Sage UE near 7 1 to 7 8 Check Hose Connections 8 Tobtmness AAA 7 2 Filling Tank With e Mee EE 7 3 Fill Pump Suction Hose With Hydraulic Ou 7 4 Initial Start Up Procedures 8 Cautions neon 7 5 to 7 6 Customer Pre Delivery Check ist 7 7 SECTION 8 Mounting amp Tractor Gpecifceaions ener 8 1 to 8 3 NHTS 100A 115A 125A 135A Asy Man 07 04 Page 0 3 NOTES NHTS 100A 115A 125A 135A Asy Man 07 04 Page 0 4 Section 1 VERSA MOWER Pre Delivery Check List New Holland Tractor TS 100A 115A 125A amp 135A Page 1 1 VERSA MOWER PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are properly assembled Saftey Equipment Operators Manu
19. Cutter Valve and Cylinder Control Valve The cutter valve and the cylinder control valve are mounted on the versa frame and should be already bolted on to it when it is shipped to you If they are not they will need to be bolted on The mounting plates for the valves are attached to the versa frame the valves will bolt on to them See Figure 24 amp 25 17 Connect Head to Extension Arm The Head has an option a rotary or a flail head they will both connect to the extension arm The head will be shipped assembled with the head attaching pin installed into the head See Figure 26 Remove the head attaching pin from the head See Figure 26 The Motor Hoses are attached to the head the motor hoses need to be put through the hose ring on the extension arm as head is moved toward the extension arm See Figure 27 As the head is moved closer to the extension arm the hoses slide further through the hose ring See Figure 27 Slide the head inward until the mounting lugs on the extension arm are aligned with the mounting tube on the head See Figure 28 Coat the retaining pin with anti seize and insert it into the extension arm lugs make certain to keep the retaining bolt hole in pin aligned with hole in head mounting tube When pin is in install the retaining bolt and locking nut See Figure 28 Insert Motor Hoses through hose ring NHTS 100A 115A 125A 1 35A Asy Man 07 04 Cylinder Control Valve te 2 g A Ed j i Cut
20. Tractor 3 3 Install Mounting Brackets 10 tractores 3 3 Fit Versa Frame to Mounting Brackets een 3 4 Install Rear Axle Stabilizer Bracket 3 4 Pre Fit Hydraulic Tank 8 Install Tank Mounting Lugs 3 5 Install Frame Step to Versa Frame nee 3 5 Welding mounts to Versa Frame an 3 6 Mountih Hydraulic Tank 3 7 Install Extension Arm Frame 3 8 Install Cutter Valve and Cylinder Control Vahye 3 9 Connect Mower Motor Hoses serrana 3 10 SECTION 4 Pump Driveshaft Cylinder Control Valve amp Cutter Valve Connections 4 1 to 4 9 Prepare Tractor FrantB lster u u esen0u an ea 4 2 Install Pulley Adapter Fiada iowstetnexaenemenensetanse 4 3 Install Pump Mount Weldment to Tractor o 4 3 Install Driveshaft Shaft half amp Tube Hal srta 4 3 to 4 4 Install Pump to Driveshaft and to Pump Mount Weldment 4 4 Install Pump Driveshaft Cover to Pump Mount Weldment 4 4 to 4 5 Pump Ara Driveshaft schemalie un ras 4 6 Install Pump HoSeS sseancmsacenas iavtostsiesdianca date nama Zai fa kennen 4 7 Hydraulic SCHEMAlG suspeitos sa na 4 8 to 4 9 Continued Next Page NHTS 100A 115A 125A 135A Asy Man 07 04 Page 0 1 INDEX VERSA MOWER ITEM PAGE NO SECTION 5 Cylinder Control Cables 8 Wire Harness ee 9 1 to 5 8 Connect Cable To Valve 3P00l u u u n u na 5 2 to
21. VERSA MOWER Assembly Instruction Manual M New Holland Cab or Rops Tractor Models TS 100A TS 110A TS 115A TS 125A 8 TS 135A VERSA MOWER Tractors equipped with additional options special equipment tractor manufacturer modi fications 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 Manual ALAMO INDUSTRIAL SE eg 1502 E Walnut EEE Seguin Texas 78155 JA ALAMO GROUP 21 0 379 1 480 ALWAYS ON THE CUTTING EDGE 2004 Alamo Group Inc INTRODUCTION ABOUT THIS MANUAL The intent of this publication to provide the competent technician with the information necessary to perform the CORRECT Assembly to the Alamo Industrial Product This will in turn provide for complete customer satisfaction Itis hoped that the information contained in this and other Manuals will provide enough detail to eliminate the need for contact of the Alamo Industrial 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 entir
22. a minimum of 11 1 4 of ground clearance on tractors eguipped with 18 4 30 rear tires The mount kit labeled for use with tractor hydraulics includes a single stage pump and hydraulic hoses fittings for coupling to the rear tractor remotes Note the tractor must be eguipped with at least a two spool hydraulic valve to utilize this mount kit The Lexan window kit option is comprised of a molded piece of General Electric brand 3 8 Lexan with a scratch resistant coating on both sides It has been designed as a replacement for the standard right hand tempered glass door that comes eguipped with the tractors First Cut w Long Extension Arm Short Ext Arm is Not Optional Rotary 56 HY60 OR 31 gt 5 Overlap HY72 OR 25 gt 5 Overlap Flail 57 3 4 SHD88 OR 20 5 gt 6 3 4 Overlap SHD96 OR 18 5 gt 8 3 4 Overlap NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 8 3 NOTES NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 8 4 PH RAMS Versa Mower Assembly Manual New Holland Tractor Model TS 100A 110A 115A 125A 8 135A 2004 Edition Manual P N 02981358 NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc
23. abase of problems and related solutions which willexpedite 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 NH TS 100A 115A 125A 135A Asy Man 07 04 Page 0 1 INDEX VERSA MOWER ITEM PAGE NO INDEX VERSA MOWER Introduction Index Section E 0 1 a s RR SR EPE MR Rn PO S MOP O Si RR E 0 2 to 0 3 SECTION 1 Pre Delivery Inspection Checklist eee eee eee 1 1 to 1 4 SECTION 2 General ere LE 2 1 to 2 6 Assembly Area Preparation erra 2 2 to 2 3 Tools Required and or Hecommended eee 2 3 Recommended Hose End Torque Specifications 2 4 Recommended Bolt Torque Specifications oooonororonnn nn 2 4 Warning Danger And Caution Information 2 5 SECTION 3 Mainframe Installation nn 3 1 to 3 10 Mainframe Component Identification noone 3 2 Remove Tractor Components from
24. al is with Unit The Safety Decals are installed as listed in the Assembly Manual Valve operation plate is installed Operators cage or Tractor Cab is in place Deflectors are installed on the Mower Head Tractor Rops or Cab with seatbels installed properly All Foot Guards and safety switch are installed and functional Frame Axle Plate Bolts are torqued Head Mounting Bolts tightened Frame attaching Bolts tightened Front Support Bolts are torqued Hydraulic Tank mounting Pins Bolts in place correctly All Welds inspected toinsure proper welds and locations Hydraulic System Oil Level in Hydraulic Tank is within the sight gauge Hose connections are tight Hoses do not have any kinks or twist in them Front Pump Shaft adapter bolts are tight Front Pump Shaft Coupler Drive Shaft is lubricated and has an anti seize compound on the Splines of Pump and Shafts The Pump Drive Shaft has correct alignment Suction Hose has no leaks or kinks Flail Mower Head Skid Shoe Bolts are torgued Motor Bolts are torqued Belt Alignment amp tension adjustment is correct Cutter shaft bearings are properly lubricated Roller bearings are properly lubricated Blades swing freely All Belt guards are installed correctly NHTS 100A 115A 125A 135A Asy Man 07 04 Page 1 2 VERSA MOWER PRE DELIVERY INSPECTION CHECKLIST Pre Operation Inspection Check the following items before operating the unit to assure that they are p
25. ar with this type injury or gangrene may result ATTACHMENT OPTIONAL FLAIL MOWER ON VERSA BOOM 1 With a forklift or hoist lower the Boom Weldment down on the Flail Mower Head Align the Boom Weldment with the Mower Head Hitch Post Insert special bolts Item 1 P N 02956972 and Item 2 P N 00752405 into Boom Weldment and Hitch Post Attach nut Item 3 P N 02030300 and Item 4 P N 00037200 to bolt and tighten securely NOTE Additional support may be needed at the end of the Boom to aid in installation See Figure 37 Attach Hydraulic Hoses as illustrated See Figure 37 Fully extend and retract cylinder to make certainhoses do not bind or kink Then secure fittings Tighten andy leaking Hydraulic Fittings If fluid still leaks loosen the fitting apply a pipe thread compound to the threads and tighten Care must be taken when tightening Hydraulic Fittings Too much tightening can cause the fittings to crack and require replacement fittings Use recommended hose end torque values charts found in general information section NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 16 Optional Heads Available NOTE Hoses should not interfere with flail opera tion such as being pinched kinked or enter ing the cutter housing Hoses may be twisted slightly too hold them up or inward Tighten fitting once proper location is found ARNING Escaping fluid under pressure 7 can penetrate the skin causing serious inj
26. cations are based on the bolt torque chart NHTS 100A 115A 125A 135A Asy Man 07 04 Page 1 3 NOTES NH TS 100A 115A 125A 135A Asy Man 07 04 Page 1 4 Section 2 VERSA MOWER General Information New Holland Tractor TS 100A 115A 125A amp 135A 4 Page 2 1 General Information To help you assemble your new Versa and mount it to your tractor we provide you with drawings instructions and general information When needed you can get information or clarification from Alamo Group Customer Service or from engineering departments over the phone This publication provides general information not specifically for your case or tractor but in connection with the drawings this publication offers you some valuable assistance please read it thoroughly These mount kits are made for selected tractors with standard configurations Only the noted options and tire sizes listed on the installation drawings will work with these mount kits Other options front axles or different tire sizes may prevent the mount kit from fitting your non standard tractor Alamo Group cannot take responsibility for these problems or any modifications made to the unit These instructions have been prepared to assist you in the correct procedure for mounting an Alamo Group A Boom on your tractor Throughout these instructions references are made to right or left directions Right and left are determined by sitting on the tractor seat and facing t
27. ctor seat so the suction hose will connect to it The dual port side will be to the right side of tractor as sitting in tractor seat The top port on the right side is for the pressure feed to the motor on the cutting head The bottom port on the right side is the pressure supply for the cylinder control valve See Figure 6 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 DO NOT Start Tractor after pump has been installed until all hydraulic connections have been made and filling will oil procedure has been completed If tractor is started with pump dry it and the hydraulic system will be damaged Installing Pump Driveline Cover 1 Install Pump Driveline Cover The Pump Driveline willhave a cover P N 02980398 which retained by four 1 4 X 3 4 bolts P N 00021400 four 1 4 flatwashers P N 00024100 and four 1 4 lockwashers P N 00017000 install and tighten these now See Figure 6 NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 4 4 Pump amp Driveshaft Install Pump Driveline cover here Mounting Bolts P N 02980666 Pump Mount Weldment Bolts To Tractor Bolster Suction H ai Pump Pressure Ports large portto motor small portto cyl control valve supply Pulley Adapter a Suction of Driveshaft Hose a Pressure Hose to Cutter Valve e 4 Pressure Hose to Cylinder F
28. d into place See Figure 5 Cut an X shaped cut in rubber mat above the 2 hole you cutin the floor Install the wire harness through the cut hole in floor and through the cutin the rubber floor mat The Cut Off Switch and fuse are connected to the wire harness on the inside of cab See Figure 5 Insert Control Cables Through Hole in Floor of Tractor Cab The cables and wire harness will run up through the floor of the cab Insertthem from the under side of the floor and up through the floor and floor mat If the Cable cover boot is used make certain that the four retaining screw do not screw into any thing under the floor mat or cab that will cause damage Make certain to inspect before at tempting to install the boot See Figure 6 NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 5 3 Cylinder Control Cables 4 Install Cable Control Mount Bracket Make certain that you mark the cables as to which is which on the control valve this is important to make certain that the location will match the operating instruction decal The Control Stick assembly can not be installed until the cables are run up through the cab floor The cable control mounting bracket will mount to the cab door post on the right hand front side There are four threaded holes in this cab door post Hold the bracket up against the door post and determine the height that you want the control handles Use the two holes
29. d still leaks loosen the fitting apply a thread compound to the threads and tighten Care must be taken when tightening Hydraulic Fittings Too much tightening can cause the fittings to crack and require replacement fittings Use recommended hose end torque values found in chart on page 37 NOTE Hoses should not interfere with mower operation such as being pinched kinked or entering the cutter housing The hoses may be twisted slightly to hold them up and or inward tighten the fitting once the proper location is found NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 15 Optional Heads Available Hose P N Hose P N 02961059 02961059 Hose P N Female JX 02961058 Attach 45 Deg Elbow in an 90 Deg End upward position as shown o O 45 Deg Elbow Female JX 90 Deg P N end on Hose 02960411 P N 02961058 i o O Position Motor Elbow Fitting As Figure 36 apo WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor famili
30. der Hoses item 1 and 2 See Figure 30 to the Control Valve See Figure 31 Use the recommended hose end torque values See Torque Charts in General Information section Attach the Tilt Cylinder Hoses item 1 and 2 See Figure 32 to the Control Valve See Figure 33 Use the recommended hose end torque values See Torque Charts in General Information section NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 14 Optional Heads Available ATTACHMENT OF HYDRAULIC HOSES ON VERSA BOOM continued 8 Attach the 1 1 4 Hose with the spiral steel band from the Articulating Arm See Figure 34 to the Hydraulic Motor on the Versa Boom Head See Figure 35 Use the recommended hose end torgue values See Torgue Charts in General Information section ATTACHMENT FLAIL AXE MOWER HEAD ON VERSA BOOM 1 With a forklift or hoist lower the Boom Weldment down on the Flail Axe Head Align the Boom Weldment with the Flail Axe Hitch Post Insert special bolts Item 1 P N 02956972 and Item 2 P N 00752405 into Boom Weldment and Hitch Post Attach nuts litem 3 P N 02030300 and Item 4 P N 000037200 to bolt and tighten securely NOTE Additional support may be needed at the end of the Boom to aid in installation See Figure 36 Attach Hydraulic Hoses as illustrated in FIGURE 85 Fully extend and retract tilt cylinder and make certain hoses do not bind or kink then secure fittings Tighten any leaking Hydraulic Fittings If flui
31. ely 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 DA E I HOW YOU CAN HELP Make sure the call is necessary Most of the calls received may not be necessary if the Dealer Service Technician would do the following 1 Check the Service Information at your Dealership provided by Alamo Industrial This would include Service Bulletins Information Bulletins Parts Manuals Operators Manuals Assembly Manualor Service Manual many of these are available via the Alamo Industrial Internet site www Alamo Industrial Com Attempt to diagnose or repair problem before calling 2 Ifa callto Alamo Industrialis 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 dat
32. ersa Flail to the same height as the Extension Arm and move into position Fasten Versa Flail and Extension Arm together using Pin Item 1 P N 02959438 Bolt Item 2 P N 10318000 and Nut Item 3 P N 00001800 Attach the Linkage Arm Weldment to the Versa Mower with Shackle and Screw Pin Item 4 P N 02880200 CAUTION To prevent personal injury always wear SAFETY SHOES SAFETY GLASSES and GLOVES A HARD HAT should be worn by anyone working under a Crane Hoist or Block and Tackle NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 2 Optional Heads Available Versa Flail Mower Attachment Optional Head Continued 4 Attach Hydraulic Hoses as illustrated See Figure 2 NOTE These hoses are to be routed through Top Pig Tail Bracket on Linkage Arm Refer to your Operator s Manual and Paris Listing for part numbers and Hydraulic Schematic Tighten any leaking Hydraulic Fittings If fluid still leaks loosen the fitting apply a thread compound to the threads and tighten Care must be taken when tightening Hydraulic Fittings Too much tightening can cause the fittings to crack and require replacement fittings Use recommended hose end torque values See charts in general information section Cutter Valve Cutter Valve has M Block i fe gt 8 M2 stamped into M1 Pressure Hose z P R it at these fittings Upper Fitting e jih ef M1 Pressure Hose Front side of Motor Q Motor M2 Return Hose Lower MO M2 R
33. es Refer to your tractor s Operator s Manual for instructions on Rear Wheel Adjustment for your particular tire See Figure 5 Hydraflate rear left tire as much as needed for stability but stay in factory recommend limit Extend front wheels as needed to provide clearance between tire and mounting brackets tank amp etc See Figure 6 Install00749117 Safety Decal on left fender or elsewhere clearly in operator s view WARNING A Never operate the tractor with a loose wheel rim or disc Always tighten nuts to the specified torque and at the recommended intervals NH TS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 6 6 Optional Heads Available PREPARATION FOR INSTALLATION OF VERSA BOOM continued NOTE If Versa Boom is being installed on a Versa Mower that is already in use Extension Arm as well as Mower Head must be removed With a forklift or hoist raise Boom Mount Weldment and slide into Basic Tractor Mount Weldment Insert pin into Boom Mount Weldment and Basic Tractor Mount Weldment To prevent pin from backing out attach bolt and nutin pin Bolttop flanges of Boom Mount Weldment to vertical cylinder mount using hardware provided Refer to your Installation Manual provided in your mount kit for part numbers and quantities See Figure 7 Fasten counterweight to Basic Tractor Mount Weldment with fasteners called out on the Installation Manual See Figure 8 When i
34. eturn Hose Fitting OW Back Side of Motor WARNING Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 3 Optional Heads Available Versa Ditcher Head Attachment Optional Head 1 With a Hydraulic Jack raise the Extension Arm Assembly to a level position 2 Using a Forklift raise Versa Ditcher to the same height as the Extension Arm and move into position 3 Fasten Versa Ditcher and Extension Arm together using Pin Item 1 P N 02880700 Bolt Item 2 P N 10318000 and Nut Item 3 P N 00001800 Attach the Linkage Arm Weldment to the Versa Ditcher with Shackle and Screw Pin Item 4 P N 02880200 See Figure 3 CAUTION To prevent personal injury always wear SAFETY SHOES SAFETY GLASSES and GLOVES A HARD HAT should be worn by anyone A working under a Crane Hoist or Block and Tackle NH TS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 6 4 Optional Heads Available Versa Ditcher Head Attachment Optional
35. excessive twisting and bending It may reguire many attempts to obtain the optimum hose connection position Once Hose position is achie ved start the tractor and po sition the head in a safe area for operation if necessary baracade the head to prevent Pressure any contact while it is being Hose operated This unit is dan gerous STAY AWAY any time the tractor is in opera tion Turn on the head and bring the tractor engine up to normal operating speed 540 PTO RPM Tighten any leak ing hydraulic fittings Caution too much tightening can cause the fittings to crack and require replacement Use recommended hose end torque valves found in the Maintenance Section NHTS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 6 18 Optional Heads Available BUZZBAR HEAD SHEAVE INSTALLATION Make sure the bushing and bore of the sheave are free of dirt paint metal chips etc 10 ft lb Max DO not use lubri cants to install bushings use of lubricants dur ing installation may cause sheave break age Insert cap screws and lockwashers en gaging only 2 or 3 threads See Figure 40 With the key in the keyway slide the loosely assemblied unit on to the shaft and position for good belt allignment Shimming under the pulley may make it easier to position Carefully tighten cap screws alternately OTE There will and progressively until tapers are seated ES KI be a gap be About 5ft Ib t
36. h a fork lift but can be done with a floor jack or over head hoist Slide the Extension Arm under the base of the Versa Frame until the mounting pin holes align See Figure 22 Coat the mounting pin with Anti Seize compound before installing it into the versa frame It should not require an excessive amount of force to install the pin Moving the extension arm will help align it with the versa Figure 21 frame and make it easier to install the retaining pin See Figure 23 The retaining pin will have z to be aligned when it is installed so the retaining Install Exten bolt can be installed The Pin retaining bolt will sion Arm under go through the frame and pin then be locked Versa frame with a locknut The pin can be rotated by insert ing a drift pin or punch into the pin hole to align the holes Install the retaining bolt into the hole of the versa frame and put tighten the locknut 15 Connect the Extension Arm Lift Cylin d der The Lift cylinder connects to the versa frame Install the cylinder pin in the center hole mi of versa frame The lower hole would be used if the tractor was a tall tractor and the extension Figure 22 arm needed to be lower See Figure 24 amp 25 Install Exten sion Arng Connect Retaining Pin Extension Arm Lift Cylinder to Versa frame M pour 24 NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 3 8 Versa Frame 16
37. he Tank Valve Pump and Cylinders Connect the hoses to the cylin ders valves and pump using the hydraulic sche matic See Figure 14 DO NOT unplug any hoses or fittings until you are ready to connect them this will help to keep contamination out of Tm Suction Hose system When the Suction hose is connected to from Tank to the tank DO NOT tighten the clamp as the hose V Pump LH will have to be removed when the tank is filled Side of See Figure 10 through 19 tractor Figure 11 S ax t gt WwW Pressure Hose to G R i Hose fro Cutter Valve Large p to Cutter are VA l BAT argew Host A 4 I ressure Hosefrom W x ump toCylindeb gs ontrol Valve G f lt ose A s M Pressure Hose to Cylinder Figure 12 Control Valve Small Hose Figure 13 NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 4 7 Pump 8 Driveshaft Tilt Cylinder Lift Cylinder Mower Fold Extension Arm Motor Cutter Valve Front Of Mower Hydraulic Schematic E 1e S Figure 14 Pump RH View NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 4 8 Pump amp Driveshaft Cylinder Control Valve Cutter Control Valve Return Filter Figure 18 sto Tilt Cylinder Lift Cylinder Extension Arm Figure 19 Assembly NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 4 9 NOTES NHTS 100A 115A 125A
38. he direction of travel 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 for safe assembly and operating practices DANGER A signal word DANGER WARNING or CAUTION is used with the Safety Alert symbol identifies the most serious hazards 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 NOTE 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 pack aged 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 prop erly clean please adhere to the following procedure 1 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 Un package the mower unit carefully so that the seals on the hydraulic components are not broken or pulled off Lay out parts to make location easy Figure 1 Inspect and clea
39. hen turning the flange sleeve assembly make certain that the control levers remains in the neutral position Tighten the 750 16 NF jam nut against the sleeve to lock in position 6 Bring flange into position and bolt assembly to valve housing Tighten screws sufficiently to flatten lockwashers secure flange 8 Caution overtightening flange bolts will distort flange 7 Return Nut 5 Align Holes Insert Pin 4 Screw Connector onto Rod er ees SOG LZ wer DUU LDA J O27 B 2 Screw Flange Sleeve Back 1 Screw Nut Back 3 Screw Nut d 6 Screw Flange Sleeve in Flush With Face Of Valve a BoltFlange To Valve Body Figure 1 NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 5 2 Cylinder Control Cables Install Cable Controls in Tractor Cab 1 Cut Hole in Floor of Tractor Cab The cables and wire harness will run up through the floor of the cab Cut a 2 hole using a 2 hole saw See Figure 4 Where you cut the hole is to be determine by the technician installing the unit Cut the hole where it is out of the way and will not interfere with any of the tractor or operator functions Check under side of cab floor to make certain saw will not cut through any thing it should not The Cabs rubber floor mat should be pulled up and out of the way while cutting the hole See Figure 4 2 Reinstall cabs Rubber Floor Mat Put the rubber floor mat back down an
40. igure 4 Mounting Bolts Pump Mount Weldment Tractor Bolster L Mounting Bolts NHTS 100A 115A 125A 1 35A Asy Man 07 04 2004 Alamo Group Inc Page 4 3 Pump amp Driveshaft Installing Driveline Half to Pump 1 Install Driveline Half to Pump Install the clamp yoke of the tube half of driveline onto the pump slide the clamp yoke on pump shaft until you have about 1 8 to 1 4 gap between yoke and pump Do not install yoke so far on pump shaft that yoke will rub against pump in anyway Tighten the two bolts and nuts on clamp yoke atthis time See Figure 5 Pump Suction Port Driveline Tube Half with Clamp Yoke Pump Pressure Ports Installing Pump to Pump Mount Weldment 1 Install Pump to Pump Mount Weldment The Pump has the tube half of driveline attached and clamp yoke tightened To install the pump and driveline half it is best to use an assistant or overhead hoistto help you align the drivelines halves as they are slid together the Driveline must be timed universal joints aligned the same as shown inthe pump 8 driveline schematic on See Figure 6 7 8 amp 9 Slide Driveline half and pump together until the shoulder on the pump slide in the hole on the pump mount weldment When installing the pump always keep ports sealed to keep them clean and free of contamination The pump MUST be turned correctly The suction Port side with single port must be to the left side sitting in tra
41. igure 7 M Figure 8 Control Valve NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 4 5 Pump 8 Driveshaft Pump 8 Driveline Schematic Tractor Engine Pulle Time Universal Joints 9 y Pump End Pulley Adpater w Mounting Bolts amp Washers 4 bolts Clamp Yoke Driveline Asy l P N 02980398 4 Driveline Mounting Bolts Driveline Cover 9 Driveline Cover Mounting Bolts Flatwashers amp Lockwashers 4 P N 02980666 Pump Mount Weldment Bolts To Suction Tractor Bolster Port Pump Mounting Bolts Use Existing Hardware Mounting Bolts Pump Reference Pump Pressure Ports large port to motor small portto cyl control valve supply NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 4 6 Pump 8 Driveshaft Installing Pump Hoses 1 Install Pump Hoses The Pump hoses are connected to the cutter valve the cylinder control valve and the hydraulic tank The suction hose LH side of pump will connect to the hose Suction Hose barb at the top of the hydraulic tank See Figure Z from Tank 10811 There are two hoses connected to the RH side of the pump the pressure hose top or larger hose at pump goes to the cutter valve The smaller or lower hose goes to the cylinder control valve as the pressure supply See Figure 128 13 Itis very important that these hoses do not get mixed up damage will occur if hoses are connected wrong 2 ConnectHosesto t
42. in that there is full from tractor hydraulic system to control valve Refer to tractor manual Read and fill out customer pre delivery check list on following page Go over these details with the customer and operators before delivery the unit is recommended Shoe the operator where all lubrication points are Where the Oil level is checked the safety decals located on the unit and the operational decals Operator should be completely familiar with the unit before operating it NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 7 6 Customer Pre Delivery Check List Is oil level in the tank even with the sight gauge on the tank Has the proper oil been used in the system Proper oil is Universal Tractor Hyd Oil Boom machine movement matches operation decal Swing Lift Dipper amp Tilt Is control valve and auxiliary control cables free and not stick Are all hoses tight and do not leak See hose fitting torque chart in general information section Are all decals in place See operators manual for decal description and placement Does tractor pass Alamo Industrials Mower Stability Test Proper weights added Have all grease points been adequately greased Are all bolts tight See bolt torque chart in the general information section Have all hoses been properly routed so that hoses do not kink or bind when boom is articulated through all motions Does starter lockout device work correctly on machine Tractor
43. is mount kit Also be aware that the 10 00 16 max front tire will steer within 3 8 of the mainframe while turning to the left The clearance between the Versa frame and exhaust pipe is equally as close on the 4 cyld model Finally due to the presence of the Versa frame on the TS100A the hinge motion of the battery box will be limited However the battery can still be accessed and even removed with the assistance of one additional person NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 8 2 These mount kits include the Neapco style driveline with double U joints An additional hole must be drilled through the cast rib of the front bolster just below the radiator in order to install the driveline half which fastens to the crankshaft pulley This process takes forty five minutes to an hour and should not affect the structural integrity of the bolster The Neapco driveline kit includes a pump box which shifts the hydraulic pump approximately 6 1 4 forward Though it is structurally sound Engineering recommends the use of a pump guard to protect your investment Optional wheel weight kits are designed to fit flanged rims only Other rim styles may reguire a wheel weight adapter to be provided at the dealer customer s expense Lexan window insert 02966458 can not be installed with the side screen kit due to the extreme curvature of the glass door The Versa frame and stabilizer have been designed to provide
44. lts through the control stick for the Lift Cylinder operation Second insert through the control stick for Tilt Cylinder control Third insert the Cut off Switch mounting Bracket over the three bolts The Motor cut off switch can be mounted else k where if wanted mounting here is a recommen dation See Figure 13 Figure 8 NH TS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 5 4 Cross Screw Cylinder Control Cables 11 Adjust the Control Handles to a Neutral Position The Handles can be adjusted to a neu tral position by going to the control valve Loosen the flange bolts and the jam nut at the top of the flange sleeve Turn the flange sleeve and this will move the control handles The will allow the control handles to be aligned evenly Tighten the jam nut and flange bolts when the handles are adjusted to the desired position See Figure 1 12 Check the Three Retaining Bolts The threaded portion of the three retaining bolts will stick out of ther nuts at the RH hand side of control handle mount these can be cut off with a hack saw if desired Threaded Cable End Figure 10 NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Threaded Plunger 5 Rod Figure 9 Cross Screw Hole M Screw a tim 4 Cross Sch 1 Retaining R Figure 11 l t Da Conduit Sleeve Lift Cyl Control Tilt Cyl Control A Off ke 1
45. n all hydraulic hoses and fittings prior to installing them onto the tractor or mower If dirt or material is seen in any of the parts they should be washed and cleaned thoroughly with an oil compatible solution Do not blow the material further into a hose since this sometimes does not remove the foreign material and can cause damage to hydraulic components down stream NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 2 2 General Information 3 Be sure your Mount Kit shipment agrees with the In stallation Make certain that you have been sent the correct Mount Kit for your tractor Make sure that all hydraulic fittings are not damaged or open to the elements if any of the hydraulic components are contaminated do not use them until they are cleaned or replace them Dur ing Assembly or operation a damaged fitting could cause a leak severe enough to drain the hydraulic fluid and cause the Versa to fail The tools you will need at the assembly site are as follows A welding setup including correct head gear eye shields and protective clothing Impact wrench or socket and ratchet set Rubber mallet Box end allen and crescent wrenches Drift pins Phillips and straight blade screwdrivers Forklift or hydraulic floor jacks with rolling back boards Small crane hoist or block and tackle 1 2 3 4 5 6 7 8 9 Multidirectional Levels Paint Scraper Safety shoes safety glasses
46. nc O O NOO BON a 2 OR DN sch sch SSNNNaAS as SOS pes 11 12 13 Description New Holland TS A Tractor Chassis Front Mount Plate LH Side Front Mount Plate RH Side Rear Mount Plate LH or RH Side Versa Frame Weldment Plate Versa Weld On Flat Axle Mount Bracket Stabilizer Rear Axle Mount Pump Mount Weldment Pump Asy Bolt 3 4 NC X 2 1 4 Gr 8 Nut 3 4 NC Heavy Lockwasher 3 4 Hardened Flatwasher 3 4 Bolt M20 P2 5 X 50 mm Gr 10 9 Lockwasher 20 mm Lockwasher 18 mm Bolt M18 1 5 X 60 mm Gr 10 9 3 Point Stabilizer Bracket On New Holland Tractor Page 3 2 Versa Frame 1 Versa Frame Mounting Components Shown in Figure 1 are the parts needed to mount the versa frame to the tractor Follow instructions listed below and reference back to figure 1 as needed 2 Remove The factory Brackets There is a factory mounting bracket on each side of the tractor which if for mounting options on the trac tor The one on the RH side bolts behind the battery box and the LH side it bolts behind the fuel tank These bracket will be removed and not used See Figure 2 3 Install Versa Frame Mounting Brack ets The bolt holes in the tractor frame will be used to mount the front and the rear versa frame mounting brackets The Rear Mounting Brackets P N 02980739 LH or RH same bracket The front mounting brackets has a RH P N 02980738 amp LH P N 02980737 make certain that
47. nstalling a Versa Boom additional counterweight wheel weights calcium chloride in tires etc must be installed to insure stability and safe operation To install the Axle Mount Weldment attach Cage Axle Mount Brackets to Axle Mount Weldment with hardware provided in your Mount Kit Attach Axle Mount Weldment and strap to Axle Mount to Tractor Axle with Hardware provided Level axle mount weldment and weld to Boom Mount Weldment Attach Valve Mount Weldment to Basic Tractor Mount with hardware provided Refer to your Installation Drawing provided in your Mount Kit See Figure 9 To attach Versa Boom Cage Weldment first lower Cage on tractor with a forklift or crane Bolt Cage to Axle Mount using straps and hardware provided in your Mount Kit See Figure 10 NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 7 Optional Heads Available 5 Attach Boom Rest to axle of tractor w fasten ers found in your Mount Kit Refer to your Insta llation Drawing for part numbers and quantities See Figure 11 Recommended torque chart for proper torque of bolts located in General In formation Section With a forklift or hoist raise the Boom Weldment and lower onto the King Post Turning Arm Align the Boom Weldment and Turning Arm with an Aligning Pin Insert Main Pin Bolt P N 02960837 into Boom Weldment and Turning Arm Attach 1 1 8 lockwasher p n 00748000 and 1 1 8 nut p n 02921700 to bolt and tighten wi
48. plate 9 1 4 on the right hand Versa Frame Weldme side as shown in Figure 6 This measurement Fiaure 5 is important and must be correct in order for mower to operate correctly The Versa Frame should be lower in the front by approximately 1 8 than in the back this allows the mower to operate with the front of the mower a little lower Tack than the rear Once the measurements are cor Weld rect check the versa frame for level These level checks can be done on the LH side using a bubble level See Figure 8 if leveled correctly then tack weld the versa frame to the mounting plate on both sides of the tractor the tack welds need to be strong enough to hold the versa frame up Recheck all measurements See Fig ure 6 Make certain that the RH side Shown and the LH side mount plate is tack welded to 91 44 the Versa Frame The Tack weld must be suffi Figure 6 cient enough to support the versa frame to the mounting plate when unbolted Tractor RH 7 Install Frame Stabilizer to Axle and Axle Housing Versa Frame There is a stabilizer weldment P N 02980750 that connect to Versa Frame and tractor rear axle Front of the stabilizer will bolt to a flat bracket P N 02879100 that will be tack welded to the Versa Frame Rear axle will keep the factory 3 point stabilizer bracket bolted back up below the stabilizer bracket See Fig Stabilizer ure 7 After bolting the flat stabilizer mounting Stabilizer Weldment
49. r Hose f From Pump from Motor Here ao Return Hese Fiaure 31 nn From Cylindr Return Hose 9 Control Valve Fig ure 32 From Motor NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 3 10 Section 4 VERSA MOWER Pump Driveshaft Cyl Control Valve amp Cutter Valve New Holland Tractor TS 100A 115A 125A amp 135A Page 4 1 Pump 8 Driveshaft 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 Tractor must be disabled to prevent accidental engine start and prevent damage to compo nents All Fittings Hose Cylinders Tank must be kept plugged at all times No part of the Hydraulic System can be left open at any time during mounting process this will keep system clean All Tools Work Area Components and Workers Hands must remain Clean when working on any part of the Hydraulic System 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 Identify the front Bolster access holes Remove the two rubber plugs that should be in the existing large holes of bolster The Air Pre Cooler lower plate can be removed if wanted The shaft part of the d
50. ractor solenoid activation wire will need to be cut and rerouted through these two brown wires Connect the two wires at the starter solenoid See Figure 14 8 15 d 4 Connect Wiring to Cutter Valve Solenoid Figure 16 j The plug for the cutter valve solenoid will plug onto the solenoid without any modifications to plug or solenoid See Figure 16 5 Connect Cutter switch electrical supply The red wire to power switch supply will be connected to a power supply that is only active when the ignition key is in the on position Also make certain that it is connected to source that will not interfere with the switch or that the switch will interfere with other components of the trac tor 6 Connectthe Ground Wire The ground wire will need to be connected to the tractor where it will have a good uninterrupted connection NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page5 7 NOTES NH TS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group Inc Page 5 8 Section 6 VERSA MOWER Optional Heads New Holland Tractor TS 100A 115A 125A amp 135A 4 Page 6 1 Optional Heads Available Versa Flail Mower Attachment Optional Head 1 The basic mounting of the flail mower to the extension arm will be the same as the rotary head with exceptions that may be listed below With a Hydraulic Jack raise the Extension Arm Assembly to a level position Using a Forklift or hoist raise V
51. raulic tank since most oils even from a sealed barrel have contaminants that must be removed before operating the hydraulic sys tem See Figure 4 5 amp 6 NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 7 3 Filling Hydraulic System 4 Fill Hydraulic Tank to Sight Guage Fill the Hydraulic Reservoir until the fluid is visible through the sight guage See Figure 7 5 Fill Suction Hose with Oil To Prevent the pump from a dry start up remove the suction hose at the tank this clamp should have been left loose from earlier See Figure 6 Fillthe Suction Hose with hydraulic fluid so that the oil will run down into the pump and reinstall on Hydraulic Tank Tighten hose clamp securely See Figure 8 8 9 Oil Level Sight 6 When Hydraulic Tank Is Full When the hydraulic tank has been filled and the mower unit properly assembled the unit should be started up NOTE Make sure that no materials tools or jacks have been left under the mower head Make sure the front and rear of the mower are properly guarded to prevent any foreign objects from being thrown by the mower All other workers should keep a safe distance from the unit before the mower is started T IMPORTANT Change the return fil ter in tank and suction filters after the first 200 hours of operation Change the filters again at 700 hours then change the oil and filters at 1600 hours After that continue to change the filter every
52. riveline that has to slide in Tractor through the bolster from the engine side of the 4 l radiator the flange yoke will be in so it can be Bolster E i connected to the pulley adapter See Figure 1 A E A 199 Holes have 7 fubber Plugs in 2 Install Pulley Adapter The Pulley adapter P N 02980699 is a round plate with Y 4threaded holes andfournon threaded holes A them in it Notice this pulley adapter will nothave a center hole in it See Figure 2 The fournon threaded holes are usedto mountthe Adapter to the Crankshaft Pulley using bolts P N 02980720 12 mm X 40 mm long and Four lockwashers P N 00754566 12 mm that i Threaded are supplied in mount kit The four threaded Holes 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 iflonger 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 NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 4 2 Pump amp Driveshaft nsta att Half of Driveline wi Flange Yoke Note the driveline universal Flange Yoke joints should be timed See Figure 3 Slide STEM oh Zee Shaft End the two driveline half assemblies apart and Tube End lay the tube
53. roperly assembled 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 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 movements agree with the valve operation decal Make Sure Boom Movement operates as expected and is smooth and under control no air in the control system Look for any unusual or excessive noise or vibrations Make sure the left rear wheel of the tractor stays on the ground when the Head is fully extended horizontally with 200 Ibs 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 Torques specif
54. rsa Frame Step will be welded to the side of the versa frame See Figure 9 Align the step to where it will not interfere with the tractor compo nents and is accessible for the operator Tack weld it to the versa frame Weld on Step Tank Mounting Lugs to be welded to Versa Frame Inner Hyd Tank Mounting Lugs NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 3 5 Versa Frame 10 Remove and Weld Versa Frame The Versa frame will need to be unbolted and re moved This will allow for welding the mounting plates tank mount lugs the step and the axle stabilizer mounting bracket to the versa frame The welds need to welded securely to the frame weld both sides of the mounting components See Figure 12 Touch up the paint around the welded areas while the versa frame is off the tractor 11 Reinstall Welded Versa Frame With all the mounting components welded to the versa frame bolt the versa frame back onto the tractor Make certain that the bolts are installed on both sides There are six bolts on each side that mount the mounting plates to the tractor front amp rear mount plates See Figure 13 Bolt the axle stabilizer weldment to the mounting bracket that was welded to the versa frame See Figure 14 12 Torque the Mounting Bolts The mount ing bolts for the versa frame must be torqued to specifications this will require a large torque wrench and two a person operation See
55. s wear SAFETY SHOES SAFETY GLASSES and GLOVES A HARD HAT should be worn by anyone working under a Crane Hoist or Block and Tackle WARNING When working with or on the machine take care and stay alert Always be careful Always be alert for hazards Watch out for others CAUTION ALWAYS USE GLOVES WHEN HANDLING THE BLADES Before re moving or installing blades make sure that the head is leaned back past the vertical position If the head is not the blades can come off suddenly when the bolts are removed WARNING Block up or securely support components before working under or around lifted components Inadvertent falling can cause serious injury or death The operator should not leave his seat with this valve engaged or with the tractor engine running Allow approximately 60 seconds for the blades to come to rest after turning the switch off before dismounting NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 2 5 NOTES NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 2 6 Section 3 VERSA MOWER Mainframe Assembly New Holland Tractor TS 100A 115A 125A amp 135A Page 3 1 Versa Frame 11 12 13 14 Part No Qty 02980737 02980738 02980739 02887200 02978816 02879100 02980750 02980666 02961826 02959390 00000200 00003901 5312316 02975692 02971158 02970066 02977576 NH TS 100A 115A 125A 135A Asy Man 07 04 O 2004 Alamo Group I
56. ter Motor Control Valve 2004 Alamo Group Inc Page 3 9 Versa Frame 18 Connect the Head Tilt Cable to Head The Tilt cylinder lifts the frame weldment and the frame weldment is attached to the head with a cable and clevis assembly See Figure 29 Unscrew the clevis and attach it to the deck lifting lug and tighten it See Figure 29 19 Connect the Motor Hoses to the Cut ter Valve The Motor has two hose connected to it and running through the hose ring on exten sion arm toward the cutter valve It is important to ID which hose is which through the sleeving as these hose must correctly be attach to the cutter valve The two hoses one is on the front side and one is on the back side of the mower deck The one on the back side toward the rear 1 Pressure Hose of the deck is the pressure side See Figure from Cutter Valve 30 Connect the Pressure hose to the upper g fitting of cutter valve these are the two large fittings pointing toward mower head See Figure 31 amp 32 Note the Cylinder Control valve return hose is routed through the cutter valve it is the smaller hose that connects into the bottom of the cutter valve The return hose will need to be routed so that it clears the front tire of tractor as well as the frame components See Figure 31 Me the Pressure Hose 4 Retufn Hose o Pressure Hose To Motor To Tank from Mot r Here La Connect the d ef f Pressure Hose Returt
57. ter the initial filling may result in oil being discharged through the air filter on top of the hyd tank Start the tractor and run it for 2 minutes and turn it off Again check the oil level in the sight gauge If the oil level isin the sight gauge the unit is ready to run If no oil seen add oil to bring the level up to the sight gauge NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 7 5 Initial Start Up Procedure 9 After hydraulic system is fully charged and functioning properly switch cutter units on then speed engine up to 540 RPM PTO speed Maintain this speed for about 5 minutes Check complete mower assembled components look for any leaks loose connections or anything that could cause premature wear or failure 10 FINAL CHECK Run Mower for about 1 2 hour at full speed Check for leaks and vibrations Frequently check oil temperature Make certain it does not exceed 180 deg NOTE When raising wings make certain there is no interference with mower frame cylinders or tractor Lift wings slowly CAUTION DO NOT leave unit unattended and COMPLY WITH ALL WARNING DECALS If unit starts to make unusual noise stop unit and check oil level Also check for frothy oil which would indicate a leak on suction side of system CAUTION ROTATING KNIVES Remove all foreign objects and stand clear of cutter units DO NOT A GET NEAR NOTE On tractor hydraulic powered circuit only make certa
58. th a forklift or hoist lower the Boom Weldment down on the X Frame Square Head Align the Boom Weldment with the X Frame Square Head Hitch Post Insert special bolts item 1 p n 02956972 and item 2 p n 00752405 into Boom Weldment and Hitch Post Attach nuts item 3 p n 02030300 and item 4 p n 00037200 to bolt and tighten securely Note Additional support may be needed at the end of the Boom to aid in installation See Figure 17 ATTACHMENT OF HYDRAULIC HOSES ON VERSA BOOM Attach the 1 1 4 Hoses from Solenoid Cutter Valve to Hydraulic Tubes on Boom Attach the 1 4 Hoses from the Control Valve to Lift Cylinder Attach the 1 2 Return Hoses from the Control Valve to the Pipe tee Attach the 1 2 Pressure Hose form the Hydraulic Pump to the Control Valve Attach the 1 4 Hoses from the Control Valve to the Swing Cylinder Attach the 1 4 Hoses from the Control Valve to the Dipper and Tilt Cylinder Refer to your Operator s Manual and Parts Listing for part numbers and pump driveshaft section of this manual for Hydraulic Schematic Tighten any leaking Hydraulic Fittings If fluid still leaks loosen the fitting apply a pipe thread compound to the threads and tighten Care must be taken when tightening Hydraulic Fittings Too much tightening can cause the fittings to crack and reguire replacement fittings Use recommended hose end torgue values See torgue chart in general information section See Figure 18 NH TS 100A 115A
59. th a 1 11 16 wrench until Boom Plates firmly contact King Post DO NOT OVER TIGHT EN See Figure 13 Note Additional support may be needed at the end of the Boom to aid in installation Note Hoses on 20 22 8 23 Booms are shipped folded back inside Boom Hoses must be routed in the end of Boom before installing Boom on the King Post See Figure 12 NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 8 Optional Heads Available Next raise the Lift Cylinder under the Boom Weldment and attach to King Post Lug with bolt P N 00755076 for 17 A Boom P N 00750479 for 20 23 8 28 A Boom washer P N 00749946 and nut P N 02030300 Make sure hydraulic fittings are facing towards the rear of the tractor Attach rod end of Lift Cylinder to Boom Weldment with bolt P N 00750479 washer P N 00749946 and nut P N 02030300 provided in your Mount Kit See Figure 14 Tighten until Locknut firmly contacts ears on Cylinder DO NOT OVER TIGHTEN The Swing Cylinder comes pre assembled on the Mainframe If itis a standard rear swing Boom the Swing Cylinder will be installed as in Figure 15 If it is a front swing Boom the Swing Cylinder will be installed as in Figure 16 If the Cylinder is mounted incorrectly reinstall in it s proper location NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 9 Optional Heads Available X Frame Square Head Attachment Wi
60. the Bolt Torque chart in the General information section of this manual or in the operators manual Itis recommended that the bolts be marked as they are torqued to show they have been done this can be dome with a marker paint or a method of your choice See Figure 15 Fue 15 NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 3 6 Versa Frame 13 Mount Hydraulic Tank to Versa Frame The hydraulic tank will be shipped fully assembled with the return filter suction tube and fittings See Figure 16 Using an over head hoist lift the tank to the tractor use caution notto hit the tractor with the tank See Figure 17 Lower the tank down onto the versa frame with the tank out away from the versa frame See Figure 18 then push the tank inward toward the tractor until the inner mounting lugs align See Figure 19 Install the inner mounting bolts and the outer mounting bolts into the tank torque these mounting bolts to specifications See Fig ure 20 Figure 16 Outer Tank Mounting Bolts F NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 3 7 Versa Frame 14 Install Extension Arm Frame The extension arm will be shipped with the hydraulic cylinders attached to it The lift lug and cable will Extension Arm be attached See Figure 21 Move the Exten Assembly with sion Arm into place on the right side of the e Hyd Cylinders tractor this is easily done wit
61. through their limits right and left swing them up and down Look for interference between tires and any part of the mower or frame components If interfer ence occurs shims not furnished must be welded to axle pivot stop or steering arm to limit the movement enough to avoid interference Tractors with an adjustable front axle may require an outward or inward adjustment of the wheels 6 To fill the hydraulic reservoir with new clean hydraulic oil follow the steps below Refer to the Operation and Maintenance Section for specifications See Figure 10 A Avoid hyd contamination by filtering the hyd oil while filling the hyd tank B Filter buggies or carts are commercially available for hydraulic system cleanup These consist of a high efficiency high capacity filter a circulating pump a drive motor and hoses for connecting the overhauled machine s hydraulic system After the frame and mower is completely assembled to the tractor and with the mower head onthe ground fill the mower hydraulic tank above the oil level sight gauge approximately 5 or 1 below the top of the tank 8 With mower ON OFF switches in ON posi tion A tractor fuel cut off crank engine for 30 to 45 sec onds to push oil to the pump and mo tor Check the oil level in the sight gauge If no oil is seen add oil to bring the level up to the sight gauge NOTE Do not fill the tank with oil above level of sight gauge Over filling tank with oil af
62. ury Relieve pressure before unhooking hydraulic or other lines Tighten all connec tions before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gan grene may result ATTACHMENT OPTIONAL FLAIL MOWER ON VERSA BOOM 1 With a forklift or hoist lower the Boom Weldment down in the Ditcher Head Align the Boom Weldment with the Ditcher Head Hitch Post together Insert special pins p n 02958929 into Boom Weldment and Hitch Post Attach with washer P N 00749185 and roll pin P N 00610600 NOTE Adaitional support may be needed at the end of the Boom to aid in installation See Figure 38 Attach Hydraulic Hoses as illustrated See Figure 38 Tighten any Hydraulic Fittings If fluid still leaks loosen the fitting apply a pipe thread compound to the threads and tighten Care must be taken when tightening Hydraulic Fittings Too much tightening can cause the fittings to crack and require replacement Use recommended hose end torque values found in the general information section Note The two hoses connecting the main boom to dipper arm are used to connect the Versa Ditcher motor The 90 degree fit tings attach to the fittings on the main boom and the straight fittings attach to the 90 degree fittings
63. ween the bush ing flange and Check sheave allignment and runout sheave after wobble screw are tight Continue careful alternate and progres sive tightening of cap screws to 10 ft Ib Figure 40 Maximum torgue should achieved on each individual bolt only two times CAUTION ALWAYS USE GLOVES WHEN HANDLING THE BLADES BLADES INSTALLATION Before removing or installing blades make sure that the A head is leaned back back past the vertical position If the head is not the blades can come off suddenly when the bolts are removed See Figure 41 Attention Tilt head back past the vertical position before removing or installing blades NH TS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 6 19 NOTES NHTS 100A 115A 125A 135A Asy Man 07 04 2004 Alamo Group Inc Page 5 20 Section VERSA MOWER Filling Hydraulic System And Initial Start up Instructions New Holland Tractor TS 100A 115A 125A 8 135A 4 Page 7 1 Filling Hydraulic System Check Attchment of Hydraulic Hoses WARNING Once pumps are installed DO NOT start the tractor which will turn the pumps unless the hydraulic circuits are completed and filled with the specified Universal Tractor Hydraulic oil and the pump has been primed Running pumps A without oil will cause non warrant able damage It is important that pipe thread sealant be used only on pipe threads never on connections or on straight thread

Versa Mower/NH TS-100110115125135A - Assembly Manual

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