New Holland. Cab 2 WD / 4 WD TS-100A, TS-115A, TS-125A, TS-135A. ASSEMBLY MANUAL

Battery Holder Relocation

Battery Holder Relocation:

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.

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

Figure 1

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

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 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

Figure 2

now this will protect battery and cover.

Figure 3

Figure 4

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

Section 5 - 2

Exhaust / Muffler Relocation

Exhaust / Muffler

Relocation:

Remove The Exhaust . The Exhaust reloca-

tion kit will include a new mounting bracket, Bolting

Tractor Factory

Exhaust pipe to

hardware, replacement exhaust pipe from turbo to

Turbo

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).

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-

Figure 5

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).

Install Replacement Exhaust Pipe. Install

the replacement exhaust pipe using the new clamp

furnished in kit. Fasten the new exhaust pipe to the

new exhaust bracket using the two factory u-Bolts

that were used on the original exhaust pipe (See

Figure 8).

Reinstall the muffler to the exhaust pipe us-

ing the factory bolts and hardware. Check all the

bolts and components to the exhaust for tightness

Factory Exhaust

and fit.

Mount Bracket

Figure 6

Replacement

New Exhaust Pipe

Exhaust Bracket

Figure 8

P/N 02980917

Figure 7

P/N 02980933

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

Section 5 - 3

Fuel Tank Replacement

Fuel Tank Replacement:

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).

Remove Tractors Factory Fuel Tank and

Remove RH

Mounting Brackets. The LH factory step will have to

Rear Tire &

be removed from the tractor before attempting to

Wheel

remove the fuel tank, the step will not be reused.

The factory fuel tank will need to drained of fuel. Use

an appropriate and safe method for pumping out

Figure 9

tank and for the storage of the fuel removed. The

Tank is removed by loosening and removing the

retaining straps that you will see around the tank

from the out side. DO NOT Attempt to remove tank

with fuel in it.

Store the fuel tank in an appropriate safe place away

from flames, extreme heat and or dusting dirty

conditions. The Fuel Pickup and Gauge sending unit

will need to be removed from the factory tank to be

installed in the new replacement tank later (See

Figure 10).

Install Replacement Fuel Tank Mounting

Brackets. Remove the factory fuel tank mounting

brackets, there are two new mounting brackets that

will be supplied to mount the new tank. There is a

Figure 10

front and a rear bracket (See Figure 11 & 12).

Front Fuel Tank

Rear Fuel Tank

Bracket P/N

02982206

02982207

Holes

Hole

Here

Figure 11

Figure 12

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

Section 5 - 4

Fuel Tank Replacement

Install Pick Up Tube & Gauge Sending Unit in

new Tank. The Pickup gauge sending unit from the

factory tank will be installed into the new tank. This is

recommended to be done before mounting the new

Front

Pick Up Tube Unit

tank to the tractor (See Figure 13). The new tank will

have a fuel capacity of 51 gallons

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 & 13). The

P/N 02982198

Mounting

rear bracket will have 1 hole in the outer end (same

Tabs

as the tank, See Figure 12 & 13)

Figure 13

Install The new Fuel tank onto Tractor. The

Rear

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)

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)

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

Figure 14

step is painted yellow for clarity only (See Figure

16).

Rear

Bracket

(1 Bolt)

Front

Bracket

Figure 15

(2 Bolts)

Figure 16

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

Section 5 - 5

Frame Installation

Under Mount frame Asy:

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.

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

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

Weight.

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

plus attaching hardware assembled to it.

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.

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.

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

to prevent them from falling

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.

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

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

connected correctly the swing will not function correctly.

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

Section 5 - 6

Frame Installation

Under Mount Frame Asy

30 ft model only

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

LH Counter Weight

Turret Asy, Machined

Turret / Boom Mount Pin

Lift Cyl Pin

Weight Attaching Pin, Long Pin

Boom Mount Attaching Pin, Long Pin

Turret Cylinder Link

Center Section Frame Weldment

Boom Mount Attaching Pin, Medium Pin

Boom Mount Attaching Pin, Short Pin

Boom Mount, Machined

Swing Cylinders

Swing Cylinder Pivot Bushings

Swing Cylinder Trunnion Mount Weldment

Swing Cylinder Cover

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

Section 5 - 7

Frame Installation

Frame Installation:

Frame Components. The frame will include

the rear axle mounts, a LH & RH Frame rail. Two

front frame mounts, a LH & RH. One center frame

LH Rear Frame

weldment. (See Figure 17, 18, 19, 20 & 21)

Mount Weldment

P/N 02982006

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

20 mm bolts. Each 3/4" & 20 mm bolt will use

hardened flat washers, one on the head side when

bolts go into the tractor castings. Two washers

used when bolts use a nut and go through the

Figure 17

frame. These hardened washers are important.

RH Rear Frame

Mount Weldment

P/N 02982005

RH Front Frame

Mount Weldment

P/N 02982015

Figure 18

Figure 19

Center Frame

Weldment

P/N 02981168

LH Front Frame

Mount Weldment

P/N 02982014

Figure 20

Figure 21

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

Section 5 - 8

Frame Installation

Install Rear Frame Mount Rails. Rear frame

rails consist of a LH & RH. We have started with the

Left Hand Rail. The three point lift stabilizer brackets

will need to be unbolted on both sides. In the illustra-

tion for the LH side we installed the frame with the

LH rear tire and wheel still removed, this was done

LH Rear Frame

for clarity not because the wheel needs to be re-

Mount Weldment

moved. Using a floor jack to lift the rail up under the

P/N 02982006

rear axle (Stabilizer brackets for three point have

been unbolted). Install the bolts up and into the three

point stabilizer bracket and the tractors rear axle

housing and snug the bolts down. Support the frame

rail with a jack stand (or leave the floor jack under it).

(See Figure 17 & 22).

The RH Rear Frame Rail will basically install

the same, bolts up under the tractor axle housing

with the three point stabilizer bolt back up under

Figure 22

frame rail (See Figure 18 & 23). The RH Rail looks

different at the rear because the boom rest will bolt

here later.

RH Rear Frame

Mount Weldment

Install Front Frame Mount Rails. The Front

P/N 02982005

Frame mount rails will consist of a RH & LH (See

Figure 19, 20, 24 & 25) These will only fit one way as

they have a gusset reinforcement on one side that

will be showing to the outside when installed. These

can be lifted by the technician installing them. The

LH and RH will install the same way, Using 4 bolts

each that screw into tractor casting on the side of

the tractor (See Figure 24). Make certain that all 3/4"

3 Point Stabi-

and 20 mm bolts have hardened flatwashers on

lizer Bracket

them.

Figure 23

LH Front Frame

Mount Weldment

RH Front Frame

P/N 02982014

Mount Weldment

P/N 02982015

Figure 24

Figure 25

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

Section 5 - 9

Frame Installation

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

& RH side). The Center frame must be installed with the two openings (See Figure 26) toward the front

of the tractor. These openings are to allow for the movement of the swing cylinders when moving the

boom to the boom rest position.

IMPORTANT NOTE: When bolting the center frame up to the front and rear frame mounting

rails the bolts on the RH turret side must have the bolts installed from the bottom with the bolt heads on

bottom under center under frame and the nuts on top (See Figure 27 showing nuts on top). The reason

the nuts must be on top is 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 & 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

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

of Tractor

4" bolts in these 4 places

Front Mounting

Holes use 3/4" X

Rear of

2-1/4" bolts in

Tractor

these 8 places

Install with these

openings to front

of tractor

LH Side of

Front of

Tractor

P/N 02981168 Center Section Under Mount Frame Wldmnt

Rear Mounting Holes use 3/4" X

3-1/2" bolts in these 8 places

Rear View

Figure 26

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

boom are not the same (See Figure 29). The boom rest weldment bolts to the RH Side on the Rear

Frame mount weldment behind the tractor axle weldment (See Figure 30). It is recommended that this

be installed using an overhead hoist and supported by the hoist until boom rest and support brace

(See Figure 28 & 30) are completely installed. The Boom Rest Support also serves as the top axle

strap for the RH Axle mount (See Figure 30).

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

Section 5 - 10

Frame Installation

Install LH Axle Strap. The Axle Strap bolts

down over the top of the Axle (LH Side) and bolts run

Shown from LH

through the Rear Frame rails. The RH Side the axle

side of tractor

strap is part of the boom support brace weldment

and also bolts down over the axle with the bolts

through the rear frame rail (See Figure 30 & 31)

Front

Make certain that all the bolts mounting the

frame components and the boom rest are properly

torqued, see the bolt torque chart.

Reinstall LH Rear Tire and Wheel. Reinstall

the LH rear Tire and Wheel now if it has not already

Rear

been done. Use a hoist to lift and secure the rear

tires is recommended 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

P/N 02982025

(f/ 30 ft. boom)

Bolts to top of

Figure 29

Figure 28

tractor axle

Boom Rest Support

LH side of tractor Upper

& Axle Strap

axle strap

Weldment

P/N 02980694

Figure 31

Boom Rest

Figure 30

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

Section 5 - 11

Frame Installation

Counter Weight Installation 24 & 30 Foot Boom:

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

Frame Weldment. Its is retained with three pins, the long pin on top, the short pin at the rear and a short

pin at the front. Using a hoist or other sufficient lifting device align the weight with the frame. The Frame

for the weight will slide over the under frame until the upper long pin is aligned with the mounting tube of

the weight and the mounting tubes of the under frame. Install the long mounting pin. The front and rear

pin holes should be aligned, install the short pins front and rear. The short pins are retained using a nut

and bolt. The long pin uses two large cotter pins, install cotter pins and bend end of them to secure them.

(See Figure 32 , 33 & 34)

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

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

Figure 32)

Weight Attaching Pin,

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 Attaching Pin,

Weight Used on

Short Pin front side

30 ft boom models

Figure 32

only

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

mounted counter weight, they both must be used together, the 30 foot boom will have an additional frame

counted counter weight bolted on, (See Figure 32). All these weight are in addition to adding liquid weight

into the Left rear tire. The proper amount of counter weight is not complete until all these weight have been

installed.

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

Section 5 - 12

Frame Installation

Figure 33

Figure 34

Turret Assembly Installation 24 & 30 Foot Boom:

1. Turret Assembly. Theturret assembly is

Turret Mount

Center Section

shipped assembled with the hydraulic swing cyl-

Under Frame

inders, hoses, pivot bearing assembly, boom

Attaching Pin,

Weldment

mount weldment and mounting pins installed

Long Pin

(See Figure 35 & 36).

2. Under Frame Weldment. The Under frame

weldment center section is designed for the turret

assembly to mount on the RH side. Remove the

one long mounting pin and the front and back

short mounting pins (See Figure 36 & 37). Check

to make certain the mounting bolts mounting the

center ubder frame weldment are installed with

the bolt heads unter frame weldment and nuts are

on top visible looking down, if they are in wrong the

swing cylinders will hit the bolts causing damge to

Turret Mount

cylinders and bolts. (See Figure 37)

Attaching Pin,

Long Pin

Turret Attach-

ing Pin, Short

Pin, one Front

side and one

rear side.

Figure 35

Figure 36

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

Section 5 - 13

Frame Installation

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

under frame (See Figure 36 & 37) . Using a hoist (or other lifting device) lower the turret assembly until

it is level with the underframe. Slide the turret assembly inward toward the under frame until the retaining

pin tube on under frame an turret assembly align. Installthe long upper retaining pin and then the two small

front and rear pins. The long upper pin is retained with two cotter pins that need to be bent over on the

ends. The short pins are retained with nuts and bolts (See Figure 36 & 38).

Figure 37

Figure 38

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

it. The grease fittings are 120° apart, this is to make certain that the bearing will be greased all the way

around because of the large diameter of the bearing. This bearing must be greased before unit is put into

service. It is easier to get to grease fittings now than after boom has been installed. On the under side

of the turret assembly are the grease fittings for the swing cylinder pivot mounts, these need to be

greased before operating the unit. Also there is a bolt on cover on the under side of turret that will be

installed (See Figure 40) at a later time. Greasing the cylinder pivots will need to be done before the cover

is installed (See Figure 39) and the boom swing stop will need to be adjusted, but this cannot be done

until a later time making it best to leave this cover of until then. After greasing components at assembly

of unit operator should consult the operators manual for maintenance requirements.

Figure 39

Figure 40

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

Section 5 - 14

Front Axle Stabilizer Installation - 30 FT Model (Standard)

Front Axle Stabilizer Kit Installation:

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

Engine side

the boom, the upper pressure supply hose (# 4 hose with

New front axle

blue plastic tie) is tee'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

Back side

cylinder and is connected to the tank return hose at the

tank. Install the cylinder with the rod end toward the axle

P/N 02983144

and the base end of cylinder up to the bracket (item 3)

New front axle

bolted to tractor frame. Number 4 hose with a blue plastic

bracket (bottom)

tie at the front side of tank (See Figure 41 through 48).

The Brackets bolt to the tractor axle and form a

RH Front

clamp around front axle housing (item 1 & 2). The Stabi-

lizer cylinder is charged only when the boom lift cylinder is

Tire side

activated and is controlled automatically with the boom lift

Figure 41

controls.

The three axle brackets are as follows

Item Part No

Qty Description

P/N 02982320 Cyl Sup-

port Weldment

(In-

02983143

Top Axle Bracket

cluded in Front Axle Sta-

02983144

Bottom Axle Bracket

bilizer Kit Only)

02982330

Stabilizer Support Bracket

02981316

Hydraulic Cylinder

See Mount Kit & Component ID section for Axle Stabilizer

complete component and hardware kit list.

When installed correctly the three components

should be aligned as show (See Figure 44). The upper and

lower bracket should have the same gap between them in

front as in the back to make certain brackets are even.

Check the hose connections and all mounting bolts for the

Figure 42

axle stabilizer kit.

P/N 02981316 Cylinder Assembly

Upper Cyl

3456

(Included in Front Axle Stabilizer Kit Only)

23456

Mount Bolt

123456

Lower Cyl

Pressure Hose End

123

Mount Bolt

3456

23456123456

123456

123

Return Hose End

234

123

Upper Clamp

Axle End

Mount Bolt

Support Bracket End

234

1234

123

Figure 44

Figure 43

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

Section 5 - 15

Optional Lexan RH Door Kit Installation

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

RH Lexan Door Kit. Option

P/N 02980888

Remove & Dis-Assembly of Factory Stock

Glass Door.

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 & 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.

Figure 1

Disconnect the gas shock (it is inside) from

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

With someone supporting the door at the

bottom and some one to hold the nuts inside loosen

the upper hinge bolts and the lower hinge bolts (See

figure 1) CAUTION! The lower hinge bolts also hold

the Pipe brace to the window, with these hinge bolts

removed DO NOT lift or hold window by using this

brace, it could put glass window under stress caus-

ing it to break. When Removing Bolts from hinges

make a note of the large rubber washer and the large

steel washer and there location as they will be reused

in the same location and order they are in. (See

Figure 1).

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

2) This is the Latch and retaining bolts, nuts & washers for the latch assembly, remove them. When

removing the latch you will need to lift and turn it in away that you can get the inside handle rod (connected

to item 5) pulled out of its hole in the latch not the handle item 5. (Item 3) Remove the upper retaining nut

and flat washer (this flat washer will not be reused) (Item 4) Remove the lower handle retaining bolt , there

will be rubber washer (that will not be reused) under the steel washer. (Item 5) The outer door handle can

be removed now, there will be rubber pad at the upper (larger portion) end between the glass and the

handle that will have a thin pipe type spacer in it. Also the lower handle mounting bolt will have a smaller

rubber pad with a metal insert in it that is between the glass and handle. (Item 6) This is the inner door

handle and WILL NOT be removed from the pipe brace weldment. (Item 7) This is the pipe brace weldment

and extends from latch / door handle to the lower hinge bolts. At the lower hinge bolts there will be a rubber

pad between glass and metal plate, this pad will be reused. (Item 8) This is the lower mount for the pipe

brace (See Figure 4 & 5 for fastener) and will be the last fastener removed, this fastener takes a special

tool to remove it. See your New Holland Dealer for instruction & Removal Tool.

Section 6 - 2

Optional Lexan RH Door Kit Installation

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

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

protected surface (here we used Bubble Wrap Packing

material). Install the push-on weather seal material (P/

N 02980889) with the soft rubber side up as shown. This

weather seal is designed to push-on with out adhesive,

but you can use adhesive if you wanted. Where the two

end meet an adhesive should be used to jion the two end.

Use an adhesve that is rubbery and dries to the touch.

The 3M Co. makes a good Black weather strip adhesive

that will work well for this (See Figure 3)

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

This is the lower fastener

(See Figure 4 & 5) and will

need to be installed first, make certain to put the rubber

The two ends

washer back on fastener, install the fastener untill the

meet here

Figure

shoulder of the fastener is into the hole in the door. DO

NOT Tighten Fastener at this time.

Install Outer Door Handle and fasteners. (Item

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

Item 10 must be modified (Item 10) This is the upper

mount of handle rubber pad. There is a shoulder on it that

must be cut off before it can be used, using a sharp knife

cut this shoulder off, The tube Spacer shown with item

3 goes through the hole of item 10 and then slide over

threads of item 9.

Push the lower rubber (with steel insert in it)

into the hole of the door, holding the handle in place fron

the bottom start the bolt & washer item 4, there was a

rubber washer used under item 4 bolt. In some cases

it can not be reinstalled, check bolt engage ment to see

if it can be used.

Figure

Inner Latch

Actuater Rod

Figure 6

Figure 5

Section 6 - 3

Optional Lexan RH Door Kit Installation

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

Insert Handle into door from bottom, make

certain item 3 tube spacer is inserted through hole of

door and through hole of pipe brace, there is a rubber

pad to reinstall between pipe brace plate at upper

Latch

latch and door (See Figure 6) Install item 3 Nut onto

handle, Note when disassembled there was a large

flat washer here. The flat washer WILL NOT be used

Inner

in reassembly. Snug the item 3 nut but DO NOT

Latch

tighten.

Actuater

Latch Retaining

10.

Lifting the Latch and turning to the correct

Rod

Bolt, Washer &

angle slide the latch actuated rod through the hole on

Nut

the latch. Turn and lower latch in place. Using the

original Bolts, Washers and nuts bolt on the latch to

Inner Rubber Pad

pipe brace (See Figure 7). These can be tightened at

Figure 7

this time.

11.

Prepare the Door Hinges which are still on

Large Rubber

tractor (See Figure 8) by making certain the round

Washers

rubber washers are in place, the ID of washer will

have the shoulder of the hinge sticking through it as

shown (See Large Rubber Washers Figure 8). The

lower hinge uses a two hole oblong rubber pad

between door and pipe brace.

Lower Hinge

Upper Hinge

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 carefully making certain the shoulder oh hinge

goes through hole in door. DO NOT over tight these

bolts. Tighten the other fasteners on the door brace

and latch handle. If Door is not fitting right the door

striker bolt on the inner cab frame is adjustable by

loosing it up and moving it in or out as needed. USE

CAUTION when cleaning the Lexan door, DO NOT

use any cleaner that is harmful to plastic, Read all

directions for cleaner use befor using it, if using it for

the first time on the Lexan door, test it in a small out

of the way place. DO NOT use rough material such

Figure 9

as paper towels to clean Lexan Door.

Section 6 - 4

Rear Wheel Counter Weight

Fill Left Rear Wheel with Liquid:

The Left Rear Wheel must be filled with liquid. Alamo Industrial recommends a Calcium

Chloride Water Mixture. The recommended Ratio of a 30 / 70 mix (30% Calcium Chloride and 70%

Water), this mixture will add weight at about 10.5 lbs per gallon. Follow the Mixture procedures

furnished by the Manufactured of the Brand of Calcium Chloride that you are using. It is also

recommended that a trained person installs the calcium Chloride. Calcium Chloride must be added

in addition to the Steel Wheel Weight and the Counter Weight that hangs on the Left Side. It is Not

recommended to use straight Water in the Wheel as this would not provide protection against freezing.

A 30/70 Calcium Chloride Water mixture provides antifreeze to approx -50 deg. F. below 0.

Rotate Washer to Match Bolt

Circle dia. and Washer fits into

Wheel Weight Slot.

Bolt is shown extra long in

drawing for illustration only

Item Part No.

Qty Description

02979603

Hex Head Bolt, 7/8" NC X 16"

02971569

Wheel Weight Washer, Special

02970758

Wheel Weight Casting, 1400 lbs.

5JRC1490

Locknut, Top Lock 7/8" NC

Note: some Older Units used a All Thread Rod with Hex Nuts Lock Nuts, with Flat Washer

and Lock washer. This was replaced with the Bolt Type shown above. These Bolt and Nut

combinations will replace the old All Thread type.

Figure 1

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

Section 7 - 2

Rear Wheel Counter Weight

Installing Wheel Weight

This Wheel Weight is 1400

lbs. Always use caution when

working with it.

Locate the three Holes in

LH Rear Wheel. Make sure these

holes are 15/16" dia. if not, they

must be reamed out.

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.

Using a forklift, lift Wheel

Weight into Wheel. When Wheel

Weight is centered in Wheel Se-

cure Forklift and Set Parking Brake

on Forklift. Insert one of the three

bolts through Weight and Wheel

Wheel Weight Mntg

(Rotate Wheel to align holes if

Locknuts

needed). Install a Hex Lock Nut on

inside. Insert the other two Bolts

through Weight and Wheel and

Figure 2

start the other two Locknuts. Do

not tighten yet. (See Figure 2)

Looking at the outside

make sure the three special Wash-

Wheel Weight

ers (Figure 1 Item 2) are aligned

1400 lbs.

with the Slots in the Wheel Weight.

Special Washers

Tighten the three Bolts now. You

Part # 02971569

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)

Remove forklift away from

Wheel and Weight. Recheck tight-

ness of Wheel Weight retaining

Bolts. Bolts should torque to 500

Figure 3

ft. lbs.

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

Section 7 - 3

Auxiliary Rear Wheel Counter Weight

Installing Auxiliary Wheel Weight Kit.

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

Auxiliary Weight weighs approx 136 lbs. When all three are installed on the existing 1400 lb. weight it

will increase the wheel weight by 408 lbs. This makes the total bolt on wheel weights equal 1800 lbs.

This will not include the amount of weight to the tire from the installed liquid which, will vary with the size

of the tire and the liquid that is added.

Auxiliary. Wheel Weight Kit No. 02976671

Qty Part No.

Description

00012200

Lockwasher, 7/8"

00012300

Nut, 7/8" NC

00760266

Bolt, 7/8"-NC X 5-1/2 GR8

02976644

Auxiliary Wheel Weight Plate, 136 lbs Each

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

weight. There are two slots in the large weight that the 7/8" bolt heads will slide into. It is recommended

that the tractor wheel is in position so these two slots has one facing front and one to the rear. Slide the

two 7/8" bolts into the slots, the slots will prevent the heads of the bolts from turning. The Bolts in the

large wheel weight will have to be aligned to the proper distance apart, to match the distance of the holes

in the auxiliary weights. Slide the auxiliary weight over the two bolts, do this with all three weight for this

kit. Install the lockwashers and hex nuts. Tighten the bolts to required tightness. See bolt torque charts

in tractor preparation section.

Wheel Weight

P/N 02970758

Auxillary Weight

Figure 5

Figure 4

Attaching Stots

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

Section 7 - 4

Joystick / Electrical Mounting

Installing Wiring Harness and Joystick:

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

Not perform any work on Tractor or Boom Electronics unless this has been done. Raise the Floor Mat

up on the RH Side by the RH Door, You will need to fold it back approx. 12 to 14 inches (See Figure 1

& 2). DO NOT Tear or Cut any Holes in Rubber Floor Mat, as it will NOT be required.

You may find a rubber plug or you may have to cut a hole with a hole saw, this will have to be decided

during installation. If you need to cut a hole, check the under side of cab for any obstruction or any

component that might be damaged before you cut the hole. The hole is going to have to be oblong in

order for the plug to go through it. Measure Wire Harness plug Coded G1 to determine the size hole.

In Figure 2 below the tractor had two holes from the tractor manufacturer, technician removed the

rubber plugs and cut the space between the two holes to open it into one oblong hole. Check to make

certain the installation will not interfere with the operators normal functions.

(See Figure 1 & 2). Floor

mat can be reinstalled by over wire harness with out cutting any holes in floor mat..

Pull Floor Mat

loose here

Cut Hole in flor of

cab if not one

already in it.

FIGURE 2

FIGURE 1

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

harness can be run down through and under top panel and will be covered when the panel is put back

on (See Figure 3). Isert the end of the interior wire harness with the pug coded G1 down into the panel

from top and out bottom of panel (See Figure 3 & 4).

FIGURE 4

FIGURE 3

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

Section 8 - 2

Joystick / Electrical Mounting

Locating Joystick and electrical components:

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

attached to it when you received the joystick.

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.

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

one to mount E-Stop Switch and Joystick.

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.

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 components that will be hit and damaged by saw. DO NOT use a torch to

cut holes in cab floor.

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:

Replace RH Factory Arm Rest. The fac-

tory seat RH arm rest will be replaced with a

weldment designed to serve as the armrest and

mount for the emergency stop switch and the

joystick assembly (See Figure 5, 6 & 7). Unbolt the

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

FIGURE 5

6) See the bottom of the welded replacement arm

rest. It may be required to use a die grinder in slotted

hole th help with alignment of retaining bolt. (See

Figure 6).

Under Side of

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 &

Locate Joystick Assembly. The joystick

assembly has a flange around the bottom, it uses 4

screws to mount joystick to the arm rest. Lower the

wiring of joystick down through hole in arm rest.

Make certain the three plugs are in the hole and not

FIGURE 6

being pinched. (See Figure 9 & 12).

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

Section 8 - 3

Joystick / Electrical Mounting

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

connected to it as an assembly. (See Figure 7 & 8) The Interior wire harness plug has 2 connectors

on it A 9 Pin Connector (labeled J1) and a 6 Pin Connector (labeled P1) . These two connections will

plug into the interior wire harness with the same code

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

Rear

8). The Interior harness is run under the RH side Panel

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.

Interior Wire Harness. The interior wire har-

ness has all the connections needed to connect interior

components. The RH side interior panel of cab will need

to be loosened and/ or removed, this allows mounting of

the XS module (See Figure 6 & Next pages for wiring

schematics) continued in step 6

FIGURE 7A

Switch

Switch Mounting Nut

Wire Fasteners (4)

Depth Control Clip

Knob

Switch Asy Complete

Knob Retaining

Screw

Knob Plug

FIGURE 8

FIGURE 9

FIGURE 10

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

Section 8 - 5

Joystick / Electrical Mounting

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

shows the wire harness as it is run through the cab. The XS Module will need to be mounted inside the

cab, the best place is behind the RH side panel (See Figure 6, 9 & 12). The wire harness will need it be

put under this panel, also with the connectors in the

appropriate place to connect with the interior components.

The harness to the joys stick will need to be run along the

panel at the back of the cab. 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 & Figure 14

wire CC1).. The plug (G1) will need to run through the floor

to the exterior of the cab, it will connect to the plug (G2) of

the exterior harness. (See figure 11, 12, 13 & 14). Secure

wires under arm rest.

FIGURE 11

Joystick P/N 02981347

with Resister Harness

FIGURE 12

To Activate Trigger Push In

P-1

PCB

XS Module P/N 02981533. The XS module

(See Figure 13) mounts in side the tractor cab

behind the right hand side panel (See Figure 13 &

14). The Connections (Three Separate Pugs, Can 1,

Can 2 & D) will be inside the side panel after it is

reinstalled and will not be visible unless you remove

the side panel (See Figure 14 , 16, 17 & 18 ). The XS

Module does not have a mount bracket, it will need to

be mounted by the assembly technician inside

panel where it will be out of the way, not interfere with

any tractor components and be secured. It can be

tied in or bolted. The Only Plugs protruding from

XS Module

behind RH Interior panel shoud be the plugs for the

display control box (See Figure 14, 16, 17 & 18).

FIGURE

P/N 02981533

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

Section 8 - 6

Interior Wire Harness Schematic P/N 02981375B

Remove console cover, tie strap

J1 Joystick Connection (9 Pin)

XS Module P/N 02981533 inside

console

P1 Joystick Connection (6 Pin)

D ( XS Module

Connector)

Can 1 ( XS

Module

Connector)

CC1 +Pos.

Key Switch

Connection

CC2 - Neg.

Can 2 ( XS

Chasis

Module

Ground

Connector)

X1 ( Control

K3 ( Control Box Display

Box Display

Connection

G1 (Connects to G2 Plug

of Exterior Wire Harness)

Code Connection

Can 1

XS Module Can1 Connection (2 of 3 Connections)

Can 2

XS Module Can 2 Connection (3 of 3 Connections)

CC1

+ Positive Key Switch Connection (MUST Connect to key switch wire)

CC2

- Negative Chasis Ground

XS Moudule C1 Connection (1 of 3 Connections)

Exterior Harness G2 Plug (coonnects Interior & exterior Harness)

Joystick Resister Harness (9 Pin Plug)

Control Box Display Connection (1 of 2 Connections)

E-Stop Switch (use A or B of Switch)

Control Box Display Connection (2 of 2 Connections

FIGURE 14

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

Section 8 - 7

Joystick / Electrical Mounting

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

will need to be used together to install the wire harness. The interior Harness and the exterior harness

will connect together with one plug connection. Figure 14, 16,17, 18 & 19) pertain to the interior harness,

Plugs have codes on them to identify where they connect, the connections will have codes on them to

identify where the connection goes. The code on the plug and the code on the connection may not be the

same, see the code connection listings in the illustrations to identify the connection location.

Plugs for Display Control Box. The wire plugs for

Can1

Can2

the display control box will come up through the small

cover on top of the right hand side panel (See Figure 16,

17, 18 & 19). When the small cover is replaced the plugs

and wires need to be moved to the back of the panel near

the RH rear cab post (See Figure 17 & 18). Cut a notch in

the panel at the rear so the cover will fit down around the

wire harness plugs (See Figure 17 & 18). Also the rear

XS Module

tractor panel will need a notch cut in it to allow the wire

harness to be installed between the side and rear panel.

P/N 02981533

Cut this notch near the bottom of the rear panel (See

Figure 19)

FIGURE 15

Cut Notch in Small cover panel to

allow harness to fit through

Display Control

Box Connections

FIGURE 16

FIGURE 17

Rear

Panel

Display Control

Box Connections

FIGURE 18

FIGURE 19

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

Section 8 - 8

Interior XS Module & Display Control Box

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

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

CAUTION:The positeve wire (CCI) MUST be connected to the wire from the key ignition switch

of tractor for an electrical power supply. DO NOT connect the power supply wire (CC1) to any

other power supply as it could cause interference with the electronic components due to a

power surge

10.

Tractor RH Side Panel reinstalled. When the

tractor side panel is reinstalled the plugs (2 Plugs K3 &

X1) for the Display control box will be sticking up out from

be hind the panel (See Figure 21), Run the wiring harness

in from behind panel, use caution to not let wire harness

interfere with or be in a position to damage or be damaged

by other tractor components behind panel.

11.

Install Display Control Box Mount Bracket. The

Display Control

display mount control box mount to the Rh rear cab post

Box Connections

(See Figure 22 & 23) . There are two plastic plugs in the

plastic cover over cab post. Remove these two plug to

FIGURE 21

expose two 10 mm bolt holes in cab post. Position the

mounting bracket with the bent end at the post and using

P/N 02982324 Mount

the 10 mm bolts furnished bolt the bracket to the post.

Plate - (Iqan) Display

Control Box Mount

12.

Install Display Control Box. The display control

box will bolt to the mount plate P/N 02982324 that is

mounted to the RH Rear Cab corner post (See Figure 22,

23 & 24). There is a wire setion on disply control box that

will pug into the two plugs on the interior harness plug KS

& X1 (See Figure 21 & 22)

The display control box cannot be tested until the interior

Cab RH Rear

and exterior wiring harness installation has been com-

Corner Post

pleted and all the other installations of unit have been

done. DO NOT reconnect battery cables at this time, the

electrical wiring is NOT done.

FIGURE 22

Display

Control Box

Bend Upward 60° Here

P/N 02982324 Mount

Plate - (Iqan) Display

Control Box Mount

FIGURE 23

FIGURE 24

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

Section 8 - 10

Exterior Wire Harness Schematic P/N 02981375A

13.

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

It will include the wiring for the sensors at the pump. The connections for the valve actuator assemblies.

The electronic modules that are mounted to the right side of the tank and the module on the front of the

valve. The plugs have codes labeled on them, there is a matching code on them where the plugs are

connected. Some plugs have instructions and/or color codes. Read the next pages of this manual to

become familiar with the wire harness connections. There are two electronic modules bolt on the tank

assembly in the front of the tractor. The XT2 module bolted on the right hand side of the tank and the XP2

bolt on the LH side in front of the 6 spool valve. (See Figure 25, 27 & 28). The exterior wiring harness should

be laid out and connections need to be start at the first connection coming from the tractor cab connection,

this allows the harness to be moved around and under components as needed.

NOTE; V1 Pump Solenoid 2 is only used when the Timbercat Head is installed and will be installed into

plug next to Pump solenoid 1 which is used with all heads. Note: Unless the timbercat head is used only

Solenid 1 will be installed which is Plug V1, leave plug T1 tie to othrer plug out of the way.

H1 & H2 ( Lock Valve Connection)

BB (Diverter Valve)

Y1 Connect to White Wire & Y2 Connect

Pump Solenoid

AA (See

to Black Wire ( Valve Filter)

T1 (Sol 2) & V1(Sol1)

Below)

W1 (Charge Filter)

G2 (Plug to Interior

Wire Harness)

R1 (Cooler Fan)

S1 (Temp Sensor)

E (XT2 Module)

X1 & X2

F (XP2 Module)

FIGURE 25

(Return Filter)

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

See Figure 18 & 18A)

AA2

Swivel

AA3

Tilt

AA4

Tilt

AA5

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 &

not electricl connections

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

Section 8 - 11

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

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

Solenoid Valve Connection for Diverter Valve

Connector XT2 Module

Connector XP2 Module

AA12

Exterior Harness to G1 Interior Harness

Lock Valve Connection

AA11

Lock Valve Connection

Cooler Fan Connection

AA10

Temperature Connection Sensor

AA9

Pump Solenoid 1 Connection

AA8

Pump Solenoid 2 (Only on Timbercat Head)

AA7

Charge Filter connection

Return Filter Connection

AA6

Common, Connect to White Wire at Filter

AA5

Signal, Connect to Black Wire at Filter

AA4

Negative Chasis Ground

AA3

AA2

AA1

FIGURE 27

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

Section 8 - 12

Exterior Wire Harness Schematic P/N 02981375A

Six Spool Control Valve

External Wire Connec-

tions for valve are marked

"A" and "B" on Valve &

AA1 thru AA12 on wire

harness connections

"B"

OR/

Return

Y/W

G/W

B/W

To Tank

"T"

R/W

Pressure

"A"

Supply

Port "P"

FIGURE 28

XT2 (Expansion, Transmission)

XP2 (Expansion, Power)

Bolts on LH side

in front of Valve

Bolts on RH side

FIGURE 30

on side of Tank

FIGURE 29

14.

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

wiring harness and will be marked with code BB. The plug and wire will run down the LH side of tractor

from the front mounted hydraulic pump / Tank. The diverter valve is bolted the the LH front Frame

Mount bracket. The holes are already in the bracket and the diverter valve should have already been

mounted. If valve has not been mounted it can be mounted now (See Figure 27, 28 , 31 & 38).

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

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 Through holes are

Diverter Valve "C2" Port

mounting holes

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.

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 & off automati-

cally. It set to run on a program

that will run the fan in the cool-

Exterior wire

harness connec-

ing rotation for a designated

tion marked R1

time, then stop, reverse the

connects here

rotation (cycle to clean debris

off of cooler, then stop and

reverse the fan again and be-

gin the cycle all over again.

The connection to the

FIGURE 32

cooler on the 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).

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

Section 8 - 14

Exterior Wire Harness Schematic P/N 02981375A

Maverick Sensor Connections:

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.

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

FIGURE 33

on the interface while the cutter circuit is operating.

The second, is to be used to control the electric fan

on the hydraulic cooler. At any time the fluid level

reaches 150° F. the fan is activated and remains

activated until fluid temperature drops to or below

the desired temperature (See Figure 33).

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

FIGURE

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 pressure filter

in the valve pressure circuit, between the closed

center load sense pump and the control valve (See

Figure 35). The sensor monitors the back pressure

created by the filter element when in use. When the

back pressure reaches a setting of 50 psi the switch

will trigger and prompt the operator for a filter

element change.

WARNING! This filter does not have a by-

pass. The element must be changed at the appropri-

FIGURE

ate time to avoid element damage and system

contamination.

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

Section 8 - 15

Exterior Wire Harness Schematic P/N 02981375A

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.

Oil Cooler & Fan Assembly. The oil cooler /

fan assembly bolts to the tank rail mount bracket

FIGURE

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.

FIGURE 37

Diverter Valve

Diverter Valve Plug

FIGURE 38

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

Section 8 - 16

Decal Mounting

Installing Warning and

Instruction Decals:

Always clean windows before installing

decals. Windows must be dry and free of any oil,

after cleaning do not touch windows before decals

are installed. Take precaution to make sure decals

are right side up and straight when installing them,

they cannot be taken off and redone.

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.

02967827

Decal No. Description

00763977

Notice to Owner

FIGURE

02964677

Important - Boom Rest

02963524

Attention - Boom Swing

02965093

Proper Engine Operating

02965262

Warning - Hose Burst

02967827

Multi - Hazard

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)

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)

02965262

FIGURE 40

Notice To Owner Decal. This installs on the

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

Figure 41)

Attention Boom Swing Decal. This installs on the

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

02963524

Figure 41)

00763977

Important Boom Rest Decal. This installs on the

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

Figure 41)

Proper Engine Operating Decal. This installs on

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

02964677

02965093

Figure 41)

FIGURE 41

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

Section 8 - 17

New Holland. Cab 2 WD / 4 WD TS-100A, TS-115A, TS-125A, TS-135A. ASSEMBLY MANUAL - page 2