Page 1 REPAIR MANUAL Thomas 85 loader Publication No. 53322/1 March, 2009...
Page 2 AND WILL THEREFORE APPLY EVEN IF PURCHASER ALLEGES THAT THERE IS A TOTAL FAILURE OF THE PRODUCT. N.B. Read and practice your Thomas operating and servicing instructions. Failure to do this may void your warranty. Publication Number 53322 rev. 1...
Page 3 It is important when ordering replacement parts or making a service inquiry to provide both the model number and serial number of your Thomas loader. The serial number plate is located at the rear of the machine on the left hand side hydraulic oil tank. In the event that the serial number plate is missing, the serial number is stamped on under the engine.
Page 4 SAFETY PRECAUTIONS Practically all Service work involves the need to drive the FOOT PROTECTION loader. The Owner’s / Operator’s Manual, supplied with Substantial or protective footwear with each loader, contains safety precautions relating to reinforced toecaps will protect the feet from driving, operating and servicing that loader.
Page 5: Safety Precautions
SAFETY PRECAUTIONS HAND TOOLS Many cuts, abrasions and injuries are caused by HOUSEKEEPING defective tools. Never use the wrong tool for the Many injuries result from tripping or slipping job as this leads either to injury or to a poor job over, or on, objects or materials left lying around done.
Page 6 SAFETY PRECAUTIONS OPERATIONAL CONSIDERATIONS Always lower equipment to the ground when leaving the loader. Stop the engine, if at all possible, before To avoid personal injury, service the loader with performing any service. the arms down and the bucket or attachment on the ground.
Page 7 SAFETY PRECAUTIONS SERVICE TECHNIQUES When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before A. SERVICE SAFETY tightening the connection. Clamps should be tightened sufficiently to hold the hose without crushing and to Appropriate service methods and proper repair prevent chafing.
Page 8 SAFETY PRECAUTIONS E. BEARINGS Bearings which are considered suitable for further service should be cleaned in a suitable solvent and immersed in clean lubricating oil until required. Installation of a bearing can be classified into two (2) ways: press fit on rotating parts such as shafts and gears, push fit into static locations such as reduction gear houses.
Page 9: Table Of Contents
TABLE OF CONTENTS Section 1 Hydraulic System Hydraulic Circuit ........1.1 Gear Pump .
Page 10 TABLE OF CONTENTS Section 5 Electrical General Information ........5.1 Wiring Schematics .
Page 11 SECTION 1 HYDRAULIC SYSTEM Hydraulic Circuit Layout pg.1-2 ..............Schematic .
Page 12: Hydraulic Circuit 1.1
HYDRAULIC CIRCUIT 1.1 C5274 Hydraulic fluid comes out the port closest to the spool NOTE: Foot pedal control operated machine illustrated. end of the valve when the spool is pushed in. Hydraulic fluid received at the fixed end of the cylinder pushes it out.
Page 13 HYDRAULIC SCHEMATIC 1.1...
Page 14 SPECIFICATIONS & MAINTENANCE 1.1 Hydraulic Specifications Pump Type ...........Gear Pump Capacity (theoretical) .
Page 15 GENERAL INFORMATION 1.1 Hydraulic System Gear pump Location Oil is drawn from the hydraulic oil reservoir through a 100 micron element. From there it travels to the main hydraulic pump. (fig. C5003). •The hydraulic pump is a gear type which is driven by a shaft and coupler through the hydrostatic drive pump at engine speed.
Page 16: Gear Pump 1.2
GEAR PUMP 1.2 Replacement Start the gear pump removal procedure by removing any attachment, raising the boom arms and engaging the Remove bolts boom support pins. Shut off the engine. WARNING To prevent personal injury do not work under the boom arms without the boom supports engaged.
Page 17 GEAR PUMP 1.2 Disassembly Screws 1. General Hyd. lines The following is a detailed procedure for disassembly and assembly of the D series hydraulic gear pump. Prior to proceeding it may be necessary to prepare some sub- assemblies separately. The details for preparing each subassembly are given in the following section, as well as some general recommendations.
Page 18 GEAR PUMP 1.2 Disassembly 85 1. Gear Pump Assembly 2. Seal Kit 3. O-ring...
Page 19 GEAR PUMP 1.2 Start up Procedure Screws Mount the gear pump to the loader. (fig. C5003) Connect the hydraulic lines. Start the engine and idle for 3 minutes @ zero pressure, (auxiliary not engaged). Engage auxiliary. Half speed at zero restriction. b.
Page 20: Control Valve
CONTROL VALVE 1.3 Testing and Adjusting the Relief Valve Pressure Hoses and gauges required for this test must be capable Auxiliary couplers of withstanding 3000 psi (207 bar) continuous pressure, and hydraulic flow meter capable of measuring 30 gallons per minute. (113 l/min) (fig. C5004) This test also checks the status of the gear pump capacities.
Page 21 CONTROL VALVE 1.3 Repeat steps 2 and 3 if necessary. Allow the loader to operate at this setting until the oil temperature has increased to 160° F (71ºC), operating temperature. Turn the flow control valve further to restrict the oil flow to no flow.
Page 22 CONTROL VALVE 1.3 Disconnect the return line from the control valve and remove the adapter fitting. Plug and cap all open ports Install valve to mount and hose ends. Remove the 3 nuts holding the control valve to the mount and remove the control valve. Remove any fittings left in the control valve.
Page 23 CONTROL VALVE 1.3 Control Valve Disassembly 85 Control valve, No Auxiliary (Up to S/N LB002671, excluding LB002578 1-13...
Page 24 CONTROL VALVE 1.3 Control Valve Disassembly 85 Diagram Legend Seal kit Control, spring return Detent, spring return kit Section, inlet Section, outlet Bolt Mount Relief valve Spool, tilt Spool, lift Solenoid, coil Solenoid and lock kit Connector Seal kit, spring return side...
Page 25 CONTROL VALVE 1.3 Disassembly / Repair 85 O-ring seals Remove the hydraulic control valve as outlined in the removal section, page 1-7. Ensure all openings are plugged to prevent solvents and dirt from contaminating the control valve assembly. Before disassembling the hydraulic control valve, clean the body with a suitable solvent and dry with compressed air.
Page 26 CONTROL VALVE 1.3 Disassembly / Repair 85 Remove screws (cont’d) 4. Remove the screws retaining the lock adapters to the control valve assembly. (fig. C2372). C2372 Scraper seal plate 5. Remove the plate and adapter from the control valve and spool. fig. C2373, C2374) C2373 6.
Page 27 CONTROL VALVE 1.3 Disassembly Repair 85 (cont’d) Spool O-ring shim 9. Lubricate the spool O-ring shim with system oil and install over spool seal. (fig. C2376). C2376 10. Lubricate the section O-ring seal with system oil and Section O-ring seal install to the lock adapter assembly.
Page 28 CONTROL VALVE 1.3 Disassembly / Repair 85 Tilt spring return cap (cont’d) 13. Note: The plastic cap over the tilt spring has flat washers to distribute the load of the mounting screws to Mounting screws prevent cap damage. (fig. C2380). Be sure to install the flat washers when reassembling to the control valve.
Page 29 CONTROL VALVE 1.3 Disassembly / Repair 85 (cont’d) 17. Install the O-ring spacer shim to the spool O-ring seal. (fig. C2384). C2384 18. Install the flat washer over the O-ring spacer. (fig. C2385) The spring return side of the control valve is now complete.
Page 30 CONTROL VALVE 1.3 Disassembly / Repair 85 (cont’d) Loosen section bolts 20. Section seals may be replaced without removing spools and spring return mechanisms. Loosen the bolts retaining the control valve sections together. (fig. C2388). Upon assembly follow the torque specifications given Section 8.
Page 31 CONTROL VALVE 1.3 Disassembly / Repair 85 O-ring seals 24. Remove and discard the O-ring seals between the sections. Replace with new. Be sure to replace the O-ring seal spacer shim upon assembly. (fig. C2392, C2393). Spacer shims Lubricate the seals with system oil upon assembly. When reassembling the control valve sections, follow the torque specifications in section 8.
Page 32 CONTROL VALVE 1.3 Disassembly / Repair 85 (con’t) 27. Replace the spring and detent mechanism in the reverse order. (fig. C2396). Install spring bushing. Lubricate the spring bushings with Castrol Spheerol grease or equivalent. Spring bushing C2396 28. Install sleeve bushing. (fig. C2397). Lubricate the bushing with Castrol Spheerol grease or equivalent.
Page 33 CONTROL VALVE 1.3 Disassembly / Repair 85 (con’t) Remove cover 31. Remove the cover. (fig. C2405). C2405 Remove washer 32. Remove the spring washer. (fig. C2406). C2406 33. Remove the spring. (fig. (C2407). Inspect the spring Remove spring for broken or sacked coils. Replace the detent spring return with a new kit if spring damage is apparent.
Page 34 CONTROL VALVE 1.3 Disassembly / Repair 85 (con’t) Inspect cup, sleeve and balls 35. Separate the sleeve and cup assembly. (fig. C2409). Inspect the tapered cup, balls and sleeve for wear. Replace with new detent kit assembly if wear is evident.
Page 35 CONTROL VALVE 1.3 Control Valve Disassembly 85 Control Valve, Manual Auxiliary (S/N LB002672 onward & S/N LB002578) C4894 C4893 1-25...
Page 36 CONTROL VALVE 1.3 Control Valve Disassembly 85 Diagram Legend Valve Assy. Manual Auxiliary Spool ring Spool lock assy. Solenoid lock assy. Spool lock kit Flange w/ seal Relief valve complete Check valve Centering manual auxiliary kit Aux spool spring Tilt spool end cap...
Page 37 CONTROL VALVE 1.3 Control Valve Disassembly 85 Control Valve, Electric Auxiliary (S/N LB002672 onward & S/N LB002578) C4894 C4892 1-27...
Page 38 CONTROL VALVE 1.3 Control Valve Disassembly 85 Diagram Legend Valve Assy. Manual Auxiliary Spool ring Spool lock assy. Solenoid lock assy. Spool lock kit Solenoid Assy. Auxiliary solenoid Relief valve Check valve Tilt spool Tilt spool end cap Tilt spool spring...
Page 39 CONTROL VALVE 1.3 Disassembly / Repair 85 Removing the relief valve Before disassembling the hydraulic control valve, clean the body with a suitable solvent and dry with compressed air. WARNING To avoid eye injury, use safety goggles when cleaning with compressed air.
Page 40 CONTROL VALVE 1.3 Disassembly / Repair 85 (con’t) 4. Remove the lock block from the valve. (fig. C2241) C2241 5. Remove the spring return / centering cap from the Remove washer end of the spool. (fig. C2237) C2237 Grease detent and balls 6.
Page 41 CONTROL VALVE 1.3 Disassembly / Repair 85 8. When replacing the spool to the control valve, use new O-ring seals and apply system oil to the O-rings and spools. (fig. C2251). Spool O-ring C2251 Beveled seal washer 9. Fit the seal washer to the control valve with the beveled side of the washer facing the control valve.
Page 42 CONTROL VALVE 1.3 Disassembly / Repair 85 (con’t) Apply Loctite 252 11. When installing the detent to the control valve spool, apply Loctite type 252 to the threads. Tighten the detent to the spool at 24 Nm (17.7 lbs / ft).
Page 43: Hydraulic Cylinders 1.4
HYDRAULIC CYLINDERS 1.4 85 Lift cylinder shown 8,a, b 8c 8d 1. Cylinder assembly 2. Nut 3. Piston 4. Rod 5. Grease fitting 6. Cap 7. Tube 8. Seal kit C2796 General Information All cylinders are a double acting, designed to extend and The gland nut seal is of an “O”...
Page 44 HYDRAULIC CYLINDERS 1.4 Testing the Piston Seals Before performing this test, ensure the control linkages Fixed end are not binding and the hydraulic control valve spools are centering in the neutral position. Check the hydraulic circuit for external leaks. These conditions will give the same symptoms as a worn piston seal.
Page 45 HYDRAULIC CYLINDERS 1.4 Lift Cylinder Replacement Disconnect hoses WARNING To prevent personal injury never repair or tighten hydraulic hoses while the engine is operating or the system is under pressure. The following procedure will assist you in cylinder removal. For removal of the boom cylinders: C5008 IMPORTANT Remove bolt...
Page 46 HYDRAULIC CYLINDERS 1.4 Tilt cylinder Replacement For tilt cylinder removal: Lower the boom arms, remove any attachment and Bolts extend the tilt cylinders. Shut off the engine and cycle the controls to relieve excessive back pressure in the hydraulic system. Loosen or remove the hydraulic hoses from hydraulic tubing under the boom arm step if you are changing the hoses also.
Page 47 HYDRAULIC CYLINDERS 1.4 Cylinder Disassembly Before Attempting repairs to the hydraulic cylinder, clean the body with a suitable solvent. Ensure all openings are plugged to prevent solvent from entering the cylinder. Remove the cylinder as outlined previously. Place the base end of the cylinder in a vise or on a pin held in the vice and support the front end of the body.
Page 48 HYDRAULIC CYLINDERS 1.4 Depending on the design of the rear piston, non threaded type, remove and discard the o-ring seal from O-ring seal the end of the cylinder rod. (fig. C127) C127 Remove the gland nut assembly from the cylinder rod.
Page 49 HYDRAULIC CYLINDERS 1.4 Cylinder Inspection Inspect the cylinder rod for scratches, dents and other damage. Minor rod damage may be repaired using a fine abrasive. Major scratches or dents are not repairable and the rod must be replaced. The chrome surface must be intact to provide a rust resistant surface.
Page 50 HYDRAULIC CYLINDERS 1.4 Install a new o-ring seal on the cylinder rod (if used). Some cylinder rods are fully threaded to accommodate a threaded type rear piston part. (fig. C133) Install new wear rings and piston seal to the the 2 C133 piece piston assembly.
Page 51: Hydraulic Oil Filter 1.5
The hydraulic oil filter is a spin on type with a 5 micron rating. The filter material is a synthetic media which features an accordion pleated design to provide maximum filtration area. Only Thomas approved filters should be C5000 used.
Page 52: Hydraulic Oil Reservoir 1.6
HYDRAULIC OIL RESERVOIR 1.6 General Information Hydraulic oil reservoir The hydraulic oil reservoir is located at the rear of the loader on the left hand side. (fig. C5012) The reservoir is completely separated from all chain and gear drives to eliminate contamination.
Page 53 HYDRAULIC OIL RESERVOIR 1.6 Servicing The Oil Reservoir Hydraulic reservoir drain Change the hydraulic oil, change the suction screen element and clean the magnet in the tank after every 1000 operating hours or if the oil has become contaminated or after any major hydrostatic drive system repair.
Page 54: Trouble Shooting 1.7
TROUBLE SHOOTING 1.7 Problem Cause Corrective Action Section Loss of hydraulic Reservoir low on oil. Check for leaks. Fill the reservoir to the proper level. power (no flow from Universal joint between Inspect and replace the damaged parts as required. 7.11 the gear pump).
Page 55: Torque Chart 1.8
TROUBLE SHOOTING 1.7 Problem Cause Corrective Action Section Check control linkage and control valve spool spring Control valve spools 1.3/4 Hydraulic cylinders centering devise. not centering. will not support a load. (leak down) External leak Inspect and repair. between control valve and cylinders Cylinder seal(s) failure Check seals.
Page 56: Conversion Chart 1.9
CONVERSION CHART 1.9 CONVERSION FACTORS U.S. To Metric MULTIPLY TO OBTAIN Area: sq. foot 0.092 903 square meter Force: pound force 4.448 222 Newton Length: inch 25.4 millimeter foot 0.304 8 meter mile 1.609 344 kilometer Mass: pound 0.453 592 kilogram ounce 28.35...
Page 57: Hydrostatic Drive System
SECTION 2 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Circuit Schematic ......... . . pg. 2-2 Specifications Chart .
Page 58 HYDROSTATIC CIRCUIT 2.1 Hydrostatic Circuit and System Pressure Schematic High Pressure Relieved at 5000 psi (345 bar) Aux. Press. Relief Set at 2400 psi (165.5 bar) System Charge Pressure 200 psi Minimum (13.8 bar) Return Pressure Suction Line (Vacuum) 4 - 6 Hg @ 160ºF (71ºC) C5275...
Page 59: Specifications 2.2
SPECIFICATIONS 2.2 Hydrostatic Tandem Pump Pump Type ....... Variable Displacement, Reversible Piston Brand Name of Pump .
Page 60: General Information 2.3
GENERAL INFORMATION 2.3 Pump case drain Pump charge line Motor case drain G-pump suction G-pump outlet C4838 When the swashplate begins to move the check valve on The driveshalft of the piston pump is rotated by the the discharge, or pressure, side seats because of the high- engine.
Page 61: Trouble Shooting 2.4
TROUBLE SHOOTING 2.4 Symptom: Neutral Difficult Or Impossible To Find Inspect external control linkage Defective Repair or replace Symptom: System Operating Hot Check charge Check oil level pressure in reservoir Below level Fill to proper level Check system Inspect charge Inspect inlet pressure relief valve...
Page 62 TROUBLE SHOOTING 2.4 Symptom: Operates In One Direction Only Inspect external Inspect system control linkage relief valves Defective Defective Repair or Repair or replace replace Symptom: System Response Sluggish Inspect Check charge motor pressure Defective Repair or replace Replace pump Inspect inlet Check system Inspect charge...
Page 63 TROUBLE SHOOTING 2.4 Symptom: System Will Not Operate In Either Direction Check external Check charge Check oil level control linkage pressure in reservoir Below level Defective Fill to proper Repair or level replace Check system Inspect charge Inspect inlet pressure relief valve screen or filter Clogged...
Page 64 TROUBLE SHOOTING 2.4 System Diagnosing Steps And Special Tools 1 Check oil level in reservoir: 0 - 5000PSI (345Bar) 0 - 500PSI (34.5Bar) a .fill to proper level as marked on site tube. 2 Inspect external control linkage for: a. misadjustment or disconnection b.
Page 65: Pressure Tests 2.5
PRESSURE TESTS 2.5 The following photos show the various port locations available on the hydrostatic tandem pump for checking system pressure. Completing these pressure tests will diagnose any mechanical problem in the hydrostatic system. WARNING Outlet Port Use caution when dealing with hydraulic fluid under pressure.
Page 66: Towing Procedure
TOWING 2.6 Towing Procedure In an event the loader has malfunctioned or failed, the loader may be moved a short distance by following the procedure below. WARNING Failure to follow the proper towing procedure may cause damage to the hydrostatic drive system. Park the loader on level ground.
Page 67: Flushing The Hydraulic System 2.7
FLUSHING THE HYDRAULIC SYSTEM 2.7 General Information The best way to remove contaminates from the hydrostat- Contamination in the hydraulic system is a major cause of component failure. Contamination can enter the hydraulic ic drive system is to disassemble each component and system in any of the following ways.
Page 68 FLUSHING THE HYDRAULIC SYSTEM 2.7 Cleaning The System The first step in cleaning the hydraulic system is to deter- Hydraulic reservoir mine if you have visible or microscopic contamination. If the contamination is visible, do the following steps: Change the hydraulic oil by removing the drain plug Oil drain plug in the bottom of the hydraulic oil reservoir.
Page 69 FLUSHING THE HYDRAULIC SYSTEM 2.7 For flushing water from the hydraulic system, perform the following procedures: Reservoir drain plug IMPORTANT Be sure attachments are removed and liftarm are in the lowered position. Remove any attachment. Make sure all cylinders are fully retracted. Change the hydraulic fluid.
Page 70: Start-Up Procedure 2.8
START-UP PROCEDURE 2.8 The following start-up procedure should always be Reservoir filler cap adhered to when starting up a new installation or when restarting after pump repairs have been made. Fill the hydraulic oil reservoir to the proper level. ( fig. C5006 ) WARNING This start-up procedure must be made with the loader securely raised off the ground.
Page 71: Gear Pump Replacement 2.9
GEAR PUMP REPLACEMENT 2.9 Start the gear pump removal procedure by removing any Not exactly as shown attachment, raising the boom arms and engaging the boom support pins. Shut off the engine. Remove the seat and hydrostatic shield. Reservoir filler spout WARNING Vacuum To prevent personal injury do not work under the...
Page 72: Tandem Pump Replacement 2.10
TANDEM PUMP REPLACEMENT 2.10 Begin the pump removal by removing any attachment, raise the boom arms and engage the boom support pins. Remove Shut off the engine. Remove the seat, the rear filler shield and the battery access panel.(fig. C5100) WARNING To prevent personal injury do not work under the boom arms without the boom supports engaged.
Page 73 TANDEM PUMP REPLACEMENT 2.10 Upon reassembly, inspect the outside area of the tandem pump housing for damage that may have occurred in tran- sit or handling. Attach a lifting device to the tandem pump. Install the pintle levers onto the pump, grease the rear spline.
Page 74: Tandem Pump Parts Diagram 2.11
TANDEM PUMP PARTS DIAGRAM 2.11 29 30 C2785 2-18...
Page 75 Inner race For further service instructions refer to an Eaton O- Ring Dealer and request Service / Repair Manual Part Trunnion cover Number , or order P / N 44232 from a local Thomas Screw Dealer. O- ring cover Washer...
Page 76: Drive Motor 2.12
DRIVE MOTOR 2.12 General Information C155 The basic geroter design uses a combination of mechani- cal and hydraulic principles that are utilized in the high torque, low speed motors. The outer ring ( fig. C153 ) of the geroler assembly is similar to an internal gear that is held in a fixed position by securing it to the motor housing.
Page 77 DRIVE MOTOR 2.12 A drive shaft is used to transmit the rotation of the star to the output shaft. The drive shaft has crowned external splines to match the internal splines in the star and output shaft. This type of drive is used because the star center line continuously changes during rotation.
Page 78 DRIVE MOTOR 2.12 The geroler (fig. C2299), is both a fluid displacement motor and a gear reducer. It provides 6 times (the number of star points) greater power per revolution than a gear, vane or piston type motor. This means that 6 times the greater torque can be developed at one eighth the speed without further gear reduction.
Page 79 DRIVE MOTOR 2.12 For smooth and continuous motor output rotation, the torque motor utilizes a disc valve which operates in syn- chronization with the geroler star. The disc valve arrange- ment consist of a stationary balance plate, rotating disc valve and a stationary valve plate. The disc valve contains an inlet fluid passage port for each star valley and a return fluid passage point.
Page 80 DRIVE MOTOR 2.12 Removal Remove any attachment, raise the boom arms and engage the boom support pins. Upper fill check WARNING To prevent personal injury do not work under the boom arms without the boom supports engaged. Raise the loader securely off the ground using prop- erly rated jack and stands.
Page 81 DRIVE MOTOR 2.12 Removal Nuts 12 Remove the jam nuts, mounting nuts and lock wash- Nuts ers from the 4 mounting bolts retaining the drive motor to the final drive housing. (fig. C5115) Hold the head of the bolts from inside the final drive housing. (fig. C5075) 13 Remove the drive motor.
Page 82: Final Drive
DRIVE MOTOR 2.12 Replacement Not exactly as shown Clean the mounting areas thoroughly that need to be sealed with silicone. (fig. C2079, C5074) C2078 Clean sealing area C5074 Apply a bead 1 / 4 of an inch thick around the drive Apply silicone motor bearing retainer and around each mounting hole.
Page 83 DRIVE MOTOR 2.12 IMPORTANT When making repairs to the hydraulic system, keep the work area and parts clean. Use caps and plugs on all open line and ports. IMPORTANT Inspect fitting o-rings and flares for marks or dam- age. Replace if necessary. C5114 Install the adapter fittings to the drive motor.
Page 84 DRIVE MOTOR 2.12 Parts Illustration Fig. C1892 shows an exploded view of the hydraulic torque motor. Before disassembling the torque motor, clean the outer surface of all loose dirt and grease and dry with compressed air. Be sure all openings are plugged to prevent solvent or soap entering the torque motor.
Page 85 DRIVE MOTOR 2.12 Parts Illustration Eaton 4000 series motor 1. Torque motor 2. Front retainer 3. Seal kit 4. Key 5. Shaft and bearing assembly 6. Bearing housing 7. Main drive shaft 8. Geroler sub assembly 9. Valve plate 10. Valve drive shaft 11.
Page 86 DRIVE MOTOR 2.12 Disassembly Place the drive motor in a vise with the output shaft Mark sections facing down. Clamp the motor to the vise, holding it by the mounting flange area. Do not clamp the motor on the housing as excessive pressure will cause distortion. Mark a line across the various sections of the drive motor to assist in reassembly.
Page 87 DRIVE MOTOR 2.12 Disassembly (cont’d) Remove the two balance springs, balance ring and the valve (fig. C255). Remove the inner and outer face seal from the balbance ring. C255 Remove the valve plate, seal and the valve drive (fig. C256). C256 remove the geroler and lock assembly (fig.C257).
Page 88 DRIVE MOTOR 2.12 Disassembly (cont’d) Remove the shaft and bearing assembly from the housing (fig. C265). The shaft may have to be pressed out. Remove the shaft face seal from the bore of the bearing housing. Be careful not to damage the bore of the bear- ing housing.
Page 89 DRIVE MOTOR 2.12 Inspection (cont’d) Inspect the valve plate (fig. C258 and fig. C259) for scratches or wear. C258 C259 Inspect the valve (fig. C260 and C261) for scratches or wear. C260 C261 2-33...
Page 90 DRIVE MOTOR 2.12 Inspection (cont’d) Inspect the balance plate for scratches or wear (fig. C262). Inspect the splines on the valve drive and geroler drive for wear. Inspect the keyway and chamfers on the output shaft for sharp edges or burrs which could damage the shaft seal.
Page 91 DRIVE MOTOR 2.12 Assembly (cont’d) Install the shaft and bearing assembly in the housing. (fig. C265) A press may be required to install the shaft and bearing assembly. Do not damage the shaft face seal. C265 3 Apply light grease to the bearing housing seal (fig. C266).
Page 92 DRIVE MOTOR 2.12 Assembly (cont’d) If available, install two studs in the housing (fig. C269) to assist in alignment of parts during assembly. 10 Apply a light film of light grease on the housing seal and install the seal in the housing. (fig. C269) C269 11 Install the geroler drive shaft in the housing (fig.
Page 93 DRIVE MOTOR 2.12 TIMING STEP NO. 1 Locate the largest open pocket in the geroler(fig. C272). Mark the location of the pocket on the outside edge of the geroler. Install the valve drive shaft in the geroler (fig. C272) 16 Apply a light film of light grease on the valve plate seal.
Page 94 DRIVE MOTOR 2.12 Assembly cont’d. 23 Apply light grease to both the outer and inner face seals. Install the face seals on the balance ring(fig. C275). IMPOTRTANT The face seal must be installed as shown in figure C275 or the motor will not op0perate properly. C275 Insert your finger through the port of the valve hous- ing (fig.
Page 95 DRIVE MOTOR 2.12 Assembly (cont’d) Install the shuttle valve assembly in the valve hous- ing (fig. C279). For correct motor operation the shuttle valve must be assembled in the proper sequence. C279 TORQUE CHART 2.13 NOTE: all torque specifications are in ft lbs. (Multiply by 1.36 = Nm) Hydraulic Fittings HOSE SIZE 37º...
Page 96 NOTES...
Page 97: Axle Assembly
SECTION 3 FINAL DRIVE Specifications & Maintenance Chart ............pg. 3-2 Lubrication Checking the Oil .
Page 98 SPECIFICATIONS & MAINTENANCE 3.1 Specifications Chain Size..............ANSI 60 Approved Chain Manufacturer ........Tsubaki Lubricating Oil ......10W30 API Classification SJ Oil Capacity (each)........1.9 gal (7 Liters) Torque Specifications: Motor Sprocket Nut........240 ft lbs (325 Nm) Wheel Nuts ......100 - 110 ft lbs (135 - 149 Nm) Tire Pressure...........
Page 99: Lubrication 3.2
LUBRICATION 3.2 Checking The Oil Level The loader has 2 independent final drive housings. When checking the oil level ensure the loader is on a level sur- Upper check plug face. Remove any attachment, raise the boom arms and engage the boom support pins. Shut off the engine. Remove the top (upper) check plug located between the 2 tires at the very front of the loader.
Page 100: Drive Chain 3.3
DRIVE CHAIN 3.3 Checking The Drive Chain Remove inspection cover The drive chain must be checked for adjustment after the first 50 hours of service and every 150 hours thereafter. Correct chain tension must be set to 1/4 to 3/8 inches (6 to 9mm) free play.
Page 101: Removal
DRIVE CHAIN 3.3 Chain Removal Remove any attachment, raise the boom arms and engage the boom support pins. Shut off the engine. Block the loader securely with all 4 wheels clear of the ground. Remove the wheels from the side of the loader the chain is to be removed.
Page 102: Installation
DRIVE CHAIN 3.3 Chain Installation Chain wrap Wrap the chain in a “Z” pattern as shown in fig. C2273. Install the wrapped chain into the final drive housing. C2273 Inside chain Place one end of the chain over the top of the axle sprocket.
Page 103: Drive Motor Sprocket 3.4
DRIVE MOTOR SPROCKET 3.4 Replacement The torque motor drive sprocket can be removed from the loader without removing the drive motor from the final drive housing. Place the loader on a level surface, engage the park- ing brake and shut off the engine. Raise the loader securely from the ground and remove the wheels on the side to be worked on.
Page 104: Axle Assembly 3.5
AXLE ASSEMBLY 3.5 Axle Assembly 85 Axle Bearing Drive sprocket Sprocket Chain Stud Axle spacer Chain 10 Nut Seal 11 Cotter pin Bearing 12 Drive sprocket nut C5126...
Page 105 AXLE ASSEMBLY 3.5 Axle Removal Remove any attachment, raise the boom arms and engage the boom support pins. Shut off the engine. Block the loader securely with all 4 wheels clear of the ground. Lower the restraint bar to retract brake pins from rear axle sprockets.
Page 106: Inspection
AXLE ASSEMBLY 3.5 13 Attach a special axle puller tool, Thomas P/N Rear sprocket Front sprocket 955283, to the axle flange wheel studs using the wheel nuts that are on the loader. (fig. C501) 14 Using the slide hammer action of the special puller, remove the axle.
Page 107 Be sure to support the axle up off the wheel studs to prevent damaging the wheel studs. (fig. C223) C223 Place 3 seal installation tools, Thomas P/N 955281, Equally spaced around the axle flange, behind the seal as shown in (fig. C4275). (approximately 120º increments).
Page 108 AXLE ASSEMBLY 3.5 Place the axle sprocket into the final drive housing with the hub facing toward the bearing race area. (out- side) 10 Apply gasket sealant to the outer edge of the bearing housing. (fig. C212) Take care, make sure none gets on the bearing surface.
Page 109 AXLE ASSEMBLY 3.5 13 Tighten the castle nut and guide the axle into the Place washer on axle and star castle nut final drive housing as straight as possible to prevent dam- aging the seal. Tap the axle flange with a hammer if nec- essary to assist the installation.
Page 110: Stud Replacement
AXLE ASSEMBLY 3.5 Axle Stud Replacement Lower the boom arms and shut off the engine. Raise and block clear of the surface the loader side of the loader the wheel studs are to be changed on. Remove the wheel the studs are to be replaced on. Remove the damaged or broken stud by rotating the axle so the damaged stud is at the 12:00 o’clock position as shown in fig.
Page 111: Parking Brake 3.6
PARKING BRAKE 3.6 General Information The parking brake is a mechanical system that uses spring loaded pins engaging axle sprockets to prevent the wheels from turning. When the restraint bar is up, pins are engaged into holes in the rear axle sprockets, this prevents the loader from moving.
Page 112: Brake Cable Replacement
Brake Pin Replacement, con’td. 9-1/8” Apply locktite 242 (blue) to threads and screw pin onto cable. Adjust to the intial length and tighten the jam nut.. (fig. C5625) Insert this assembly into the transmis- sion bushing pushing the pin into the hole in the axle sprocket.
Page 113: Trouble Shooting 3.7
TROUBLE SHOOTING 3.7 Problem Cause Corrective Action Section Final drive noisy. No lubricating oil. Check oil level. Add 10W30 SJ oil to cor- rect level. Chain is loose. Check chain and sprockets for wear. Replace as needed. Axle has too much end Check and adjust the bearing pe-load on the play.
Page 114 NOTES 3-18...
Page 115 SECTION 4 CONTROLS Steering Steering Control System Illustrations ....... pg. 4-2 ~ 4-3 Neutral Adjustment .
Page 116: Steering 4.1
STEERING 4.1 Up To LB003362 C5568 1 Left Control Lever 17 Control Rate Limiter 2 Handle 18 Bushing, Isolator 3 Right Control Lever 19 Isolator 4 Bolt 5 Washer 6 Boot 7 Plate 8 Hydroback Assembly 9 Bushing Spacer 10 Nut 11 Pintle Lever 12 Split Pin 13 Right Control Rod...
Page 117 STEERING 4.1 LB003363 Onward C5569 1 Left Control Lever 17 Control Rate Limiter 2 Handle 3 Right Control Lever 4 Bolt 5 Washer 6 Boot 7 Plate 8 Hydroback Assembly 9 Bushing Spacer 10 Nut 11 Pintle Lever 12 Split Pin 13 Right Control Rod 14 Left Control Rod 15 Rod End...
Page 118: Neutral Adjustment
STEERING 4.1 Neutral Adjustment Remove seat assembly IMPORTANT If you are unfamiliar with the control operations of the loader, read the Owner’s / Operator’s Manual beforehand. The steering levers are equipped with a spring centering device called a hydroback. The hydroback returns the steering lever to neutral position when the steering levers are not being operated.
Page 119: Hydroback Replacement
STEERING 4.1 Neutral Adjustment (con’t.) Hydroback 2 Detent jam nuts Loosen the 2 jam nuts next to the main body. (fig. C1638, 5015) Turn the 2 nuts away from the main body of the hydroback. Cycle the control lever several times. Push the control lever rearward until you feel resis- tance.
Page 120 STEERING 4.1 Neutral Adjustment Before performing the neutral adjustment make sure Pintle levers the hydro back is functioning and adjusted properly. Refer to page 4-5. IMPORTANT If you are unfamiliar with the control operations of Rod end bushings the loader, read the Owner’s / Operator’s Manual beforehand.
Page 121: Tracking Adjustment (Speed)
Refer to Section 7 to verify engine rpm. Using an rpm measuring tool ( fig. C1837 Thomas P/N 43981) check wheel speed on side in the forward and reverse direction. Repeat for opposite side. (fig. C2445) Correct wheel speed is set at 69 rpm forward and 60 rpm.
Page 122: Control Lever Replacement
STEERING 4.1 Control Lever Replacement Remove control lever handle Raise the boom arms, engage the boom supports and shut off the engine. Raise the loader securely off the ground to prevent accidental engagement of the drive functions upon restarting the engine. WARNING Never work under the boom arms without the boom supports engaged.
Page 123: Control Rate Limiter Adjustment
STEERING 4.1 Control Rate Limiter Adjustment Raise the boom arms, engage the boom supports and Rear set shut off the engine. collar Remove the seat. Control rate limiter WARNING Never work under the boom arms without the boom supports engaged. Loosen front and rear set collars on right hand control rod.(fig.
Page 124: Foot Pedals 4.2
FOOT PEDALS 4.2 1. Cover 12. Pin 2. Foot pedal support assy. 13. Bar 3. Weather seal washer 14. Nut 4. Screw 15. Washer 5. Foot pedal assy. 16. Flat washer 6. Auxiliary pedal 17. Cover 7. Pipe 8. Foot pedal assy. 9.
Page 125: Cable Replacement 85
FOOT PEDALS 4.2 Cable Replacement 85 Check cable ends, eyelets or rod ends, and mounting pins Clevis pin for wear before removing the cable. Replace worn parts when replacing new cables. Cable ends should be inspect- ed every 150 hours of operation.
Page 126: Angle Adjustment 85
FOOT PEDALS 4.2 Angle Adjustment 85 Cable clevis After changing the control cable the foot pedal angle will need to be verified and / or adjusted to provide operator Jam nut comfort and proper pedal travel clearance. Note: If the operator feels discomfort due to current pedal angles, they may be adjusted to their preference.
Page 127 FOOT PEDALS 4.2 Foot Pedal Replacement 85 If the foot pedals or shaft need replacement due to dam- age or wear: Raise the boom arms, engage the boom supports and shut off the engine. WARNING Never work under the boom arms without the boom supports engaged.
Page 128: Hand Controls 4.3
HAND CONTROLS 4.3 Hand Operated Control Lever 85 Optional electric control handle 9 10 C3274 Control lever assembly Isolator Control lever Handle Collar Spacer Handle Control rate limiter Swivel block Screw Linkage Control lever Washer Bolt Boot Washer Swivel block...
Page 129: Angle Adjustment
HAND CONTROLS 4.3 Angle Adjustment Checking the base angle After changing the control cable the control lever angle will need to be verified and / or adjusted to provide oper- ator comfort and proper travel clearance. Make sure the rod ends are screwed onto the rod threads a minimum of 3/8’’...
Page 130: Hand Controls 4.3
HAND CONTROLS 4.3 Control Lever Replacement Remove control handle Raise the boom arms, engage the boom supports and shut off the engine. WARNING Never work under the boom arms without the boom supports engaged. Remove the seat. C5017 Remove the control handle from the steering lever by removing the retaining bolt and dis-connecting the handle transfer rod.
Page 131: Throttle
THROTTLE 4.4 14 15 1. Throttle knob 15. Washer 2. Throttle handle 16. Flat washer 3. Boot 17. Bolt 4. Bolt 18. Throttle crank sheet 5. Friction pad 19. Throttle rod engine bar 6. Nut 20. Clip 7. Flat washer 21.
Page 132 THROTTLE 4.4 Adjustments Tension spring location The throttle system can be adjusted for tension and total travel. (stroke) If the throttle system can not maintain a constant, steady, engine speed then the throttle handle tension spring may need to be adjusted. Raise the boom arms, engage the boom supports and shut off the engine.
Page 133 THROTTLE 4.4 Throttle Rod Replacement Seat assembly Raise the boom arms, engage the boom supports and Safety switch shut off the engine. wiring connector WARNING Never work under the boom arms without the boom supports engaged. Remove the seat. C5097 Remove the set collar connecting the throttle rod to the throttle handle.
Page 134: Restraint Bar 4.5
RESTRAINT BAR 4.5 Diagram C5574 Legend 1. Restraint bar assembly 2. Bolt 3. Gas strut 4. Lock washer Bushing 6. Insulator 7. Cable 8. Nut C5574 4-20...
Page 135 RESTRAINT BAR 4.5 Restraint Bar Strut The restraint bar is held up, over head, by means of a gas pressurized strut. If the seal in the strut has deteriorated and failed, or the strut rod has been damaged, the restraint bar will not stay in the upright position due to gas pressure loss.
Page 136: Restraint Bar 4.5
RESTRAINT BAR 4.5 Restraint Bar Replacement Raise the boom arms, engage the boom supports and shut off the engine. Remove cotter pin and brake cable eyelet along with nylon bushings from resraint bar. (fig. C5619) Remove the nut from the upper gas spring pivot ball. (fig.
Page 137: Parking Brake
PARKING BRAKE 4.6 General Information The parking brake is a mechanical system that uses spring loaded pins engaging axle sprockets to prevent the wheels from turning. When the restraint bar is up, pins are engaged into holes in the rear axle sprockets, this prevents the loader from moving.
Page 138 PARKING BRAKE 4.6 Cable Replacement & Cotter pin & washer Adjustment Raise the boom arms, engage the boom supports and shut off the engine. Keyhole slot Remove the seat and the battery access panel. With the restraint bar in the raised position, remove cotter pin and washer that hold cable eyelet in place.
Page 139 TROUBLE SHOOTING 4.7 Symptom Cause Corrective Action Section Loader creeps, Neutral adjustment Adjust linkage won’t center Worn, loose linkage Replace, tighten parts Binding, dragging parts Repair, replace Steering jerky Worn, loose linkage Replace Binding linkage Repair, replace Linkage adjustment Adjust Low charge pressure Repair, replace Loader doesn’t track straight Limiter stops...
Page 140 NOTES 4-26...
Page 141 SECTION 5 ELECTRICAL Specifications General Information..............pg. 5-2 Wiring Schematic ROPS Harness ................ pg. 5-3 ~ 4 Engine Harness............... pg. 5-5 ~ 6 Instrumentation Left Hand Dash Panel..............pg. 5-7 Switch and Bulb Replacement ..........pg. 5-7 ~ 8 Fuel Gauge ..................pg. 5-8 Fuel Sender ...................
Page 142 SPECIFICATIONS 5.1 Ignition ............12 Volts Grounding ............. Negative Alternator Brand ........Nippondenso Alternator Rating ..........40 Amp Alternator Type ......Internal Regulator Battery (std) ............ One (1) Battery Rating ..........730 CCA, ........125 Reserve Minutes (each) Battery Type ..........SERV 3478 Starter Brand ..........
Page 143: Wiring Schematics
WIRING SCHEMATIC 5.2 ROPS Harness Connector Diagram C2459 Legend. Shown is the wire color and function of each pin terminal in the connector plug. WIRE COLOR FUNCTION Purple Eng. Oil pressure sender Orn / Blue Fuel level sender Grey Alternator Grey / Wht Brake switch to light Blue...
Page 144 WIRING SCHEMATIC 5.2 ROPS Electrical Wiring 85 C3257 C3257...
Page 145 WIRING SCHEMATIC 5.2 Engine Harness Connector Diagram C1741a Legend. Shown is the wire color and function of each pin terminal in the connector plug. WIRE COLOR FUNCTION Starter relay Seat belt Wht / Ppl Spare Brown Sol aux. switch Wht / Brn Horn Yl / Red Spare...
Page 146 WIRING SCHEMATIC 5.2 Engine Electrical Wiring 85 C3256...
Page 147: Instrumentation 5.3
INSTRUMENTATION 5.3 C5088 Legend for fig. C5088, C5087 Boom Support Pin Rods Indicator Panel Work Light Switch Electric Auxiliary Fuel gauge / Hour meter Ignition Switch LH Directional Signal Electric Auxiliary Engaged -Not used- 10 Work Light Indicator 11 RH Directional Signal Indicator 12 Hydraulic Oil Temperature High Indicator 13 Parking Brake On Indicator C5087...
Page 148 INSTRUMENTATION 5.3 Replacement To replace a faulty gauge, meter or switch in the dash panel: Disconnect the battery cable connection. (fig. C5105) Remove the 6 screws retaining the dash panel to the dash pod. Access the rear of the dash panel. (fig. C5090) Remove the wiring from the effected part.
Page 149 INSTRUMENTATION 5.3 Testing the Fuel Sender With the ignition switch off, connect an ohmmeter between the positive and negative terminals of the fuel sending unit. (fig. C306) An ohmmeter reading of 50 to 500 is normal. A read- ing higher or lower means a faulty sender and will need replaced.
Page 150: Ignition Switch 5.4
IGNITION SWITCH 5.4 Ignition Switch Testing The ignition switch is a 4 position switch. OFF, PRE- HEAT, RUN and START. Turning the key counterclock- wise will engage the PREHEAT. To activate the starter, turn the key clockwise. When the key is released it will return to the RUN position.
Page 151: Engine Glow Plugs 5.5
ENGINE GLOW PLUGS 5.5 Testing the Glow Plugs Glow plug location Before performing any test on the glow plugs, disconnect the ground wire from the battery. Connecting bar TEST 1: GLOW PLUGS. With the ignition switch off, connect one end of the ohm- meter lead to the manifold heater terminal and the other lead end to a clean ground.(fig.
Page 152: Battery 5.6
BATTERY 5.6 Removal and Inspection The batteries are located in the ROPS behind the opera- Seat switch harness tors seat. To remove the battery: Remove the seat mount retaining bolts and discon- nect the seat switch wiring harness. (fig. C5097) Pull up and toward the front of the loader and remove the seat.
Page 153 BATTERY 5.6 Removal and Inspection Inspect the battery case for cracks that may allow electrolyte to leak into the environment. Check and clean Inspect the battery on a regular basis for damage such as cracks or a broken case. Inspect the battery cables for tightness and corrosion. Remove any corrosion and coat the terminals with a dielectric grease.
Page 154: Electrical Panel 5.7
ELECTRICAL PANEL 5.7 The loader is equipped with a 12 volt, negative ground electrical system. The fuse and relay panels are located in the engine compartment, attached to the back of the bat- tery box, over the engine cover. (fig. C5214) To access the electrical panel: Open the rear door and raise the engine cover.
Page 155 STARTING CIRCUIT 5.8 C5226 5-15...
Page 156: Charging Circuit 5.9
CHARGING CIRCUIT 5.9 C5221 5-16...
Page 157: Safety Circuit 5.10
SAFETY CIRCUIT 5.10 Circuit 50 30 Breaker Fuse Panel Battery Solenoid Valve Starter Lock Connector Wht/Red Lt. Grn Org / Wht Wht / Red Wht/Red Diode Restraint Bar Restraint Bar Switch Lt. Grn / Brake Switch Control Valve Locks Stop Timer Safety Belt Switch Stop Solenoid Seat Switch...
Page 158 SAFETY CIRCUIT 5.10 General Information Seat switch The loader is equipped with 3 inter - connected safety switches. These switches operate 2 electric solenoid con- trolled lock devices and a starter interlock system. One (1) pair of solenoid coils on the hydraulic control valve . The operation of the solenoid coils and loader functions will be prevented if one of these safety switches are open.
Page 159 SAFETY CIRCUIT 5.10 Switch Replacement Set height equal Remove the seat. Raise the restraint bar. Remove wires from the switch to be replaced. Remove the rubber boot from the switch. Remove the upper nut, and drop the switch out of the bracket mount.
Page 160: Auxiliary Circuit
ELECTRIC AUXILIARY CIRCUIT 5.11 C5227 5-20 5-20...
Page 161 The Ergonomic Handle contains 3 switches: 1 rocker switch and 2 push button switches. (fig. 2945) The handle is normally installed only on the left hand control lever for the 85 loader. When installed on the LH lever: The rocker switch controls the electric aux. func- tions.
Page 162 ACCESSORIES CIRCUIT 5.12 C5228 5-22 5-22...
Page 163 TROUBLE SHOOTING 5.13 STARTING SYSTEM Problem Cause Corrective Action Section Starter will not Battery discharged. Check the battery and charge or replace. engage. Loose or disconnected Verify continuity of starting circuit. Check and repair. wiring. Defective ignition Check the switch and replace if necessary. switch.
Page 164: Trouble Shooting 5.13
Defective regulator Check charging output. Replace if necessary. Kubota repair heats. manual (see Kubota repair manual Thomas p / n 40916) Low or no output Drive belt slipping. Check and adjust. voltage from alterna- Faulty wiring or con- Check and repair or replace.
Page 165 SECTION 6 MAIN FRAME Quick - Tach Illustration, Universal Type............pg. 6-2 Preventative Maintenance .............. pg. 6-3 Removal..................pg. 6-4 Installation ..................pg. 6-4 Disassembly..................pg. 6-5 Assembly ..................pg. 6-5 Boom Arms Removal..................pg. 6-6 Installation ..................pg. 6-6 Boom Support Boom Arm Supports...............
Page 166: Quick - Tach 6.1
QUICK - TACH 6.1 C2513 Quick - Tach Assembly Spring Pin, Lever Assembly Hinge Pin Assembly Washer, Tension Washer, Nylon Tip, Vinyl Plastisol Spring Housing Assembly Collar, Spring...
Page 167: Preventative Maintenance
QUICK TACH 6.1 Preventative Maintenance Remove any attachment from the loader, lower the liftarms, roll the q-tach out to the position shown, engage the parking brake and shut off the engine.(fig. C5639) Clean any dirt build up around the linkages. Inspect the linkages for loose nuts or bolts.
Page 168: Removal
QUICK - TACH 6.1 Removal Remove any attachment and lower the boom arms. Start the engine and extend the hydraulic tilt cylin- ders approximately 12 inches. (fig. C5108) Shut off the engine and engage the parking brake. Remove the bolts retaining the upper pivot pins to the quick - tach frame.
Page 169: Disassembly
QUICK - TACH 6.1 Disassembly Follow the exploded schematic on the 2nd page of this section to assist in taking apart the locking mechanism, and to assemble the system back together. Please note that the quick - tach does not have to be removed to service or replace locking mechanism parts.
Page 170: Boom Arms 6.2
BOOM ARMS 6.2 Removal Lower the boom arms and shut off the engine. Turn the ignition key to the “RUN” position and cycle the boom and tilt controls to relieve hydraulic backpressure. Lock the boom lift control in the float position. Return the key to the “OFF”...
Page 171: Boom Support
BOOM SUPPORTS 6.3 Boom Arm Supports For safety while performing regular service or mainte- nance work, the loader is equipped with boom supports. (fig. C1823) The boom supports, when extended, prevent the boom arm from lowering when servicing the hydraulic system, controls or other repair work while the engine is not operating.
Page 172: Rops 6.4
ROPS 6.4 Removal Main harness connections Lower the boom arms, shut off the engine and engage the parking brake. Battery Remove the seat assembly and the battery access cover and disconnect the battery terminals as outlined in Section 5. Disconnect the ground cable from the ROPS. Disconnect the main wiring harness plugs.
Page 173: Rear Door 6.5
REAR DOOR 6.5 Rear Door Rubber Grip Door Handle Bolt Bolt Rear door latch Bearing 10 Collar 11 Bolt 12 Nut 13 Neoprene, Closed Cell C2477 Removal Open the rear door and using a hoist, take the weight of the door off the mounting bolts. (fig. C5182) Remove the mounting nuts and bolts.
Page 174 SECTION 7 ENGINE Maintenance Lubrication System ..............pg. 7-2 ~ 3 Fuel System ................. pg. 7-4 ~ 5 Air Filter..................pg. 7-6 ~ 7 Cooling System ................pg. 7-8 ~ 9 Fan Belt ................... pg. 7-10 Universal Joint ................. pg. 7-11 Cylinder Head Valve Adjustment................
Page 175: Lubrication System
ENGINE MAINTENANCE 7.1 Lubrication System Engine Oil and Filter: Access the Engine oil and filter changes should be made with the engine engine warm. Change the engine oil and filter initialy at compartment 50 hours and then every 100 hours of operation. Park the loader on a level surface, lower the boom arms, engage the parking brake and shut off the engine.
Page 176 ENGINE MAINTENANCE 7.1 Lubrication System (cont’d) Engine oil fill cap Remove the oil fill cap located in the engine rocker arm cover. (fig. C5116) Add 3.75 qts (3.5 liters) of 5W40 API classification CG-4 or better engine oil. Replace the fill cap in the rocker arm cover.
Page 177: Fuel System
ENGINE MAINTENANCE 7.1 Fuel System Fuel Filter: Fuel The fuel filter is a spin on type and is located in the filter Fuel petcock engine compartment on the left side of the negine mounted to a frame bracket. Change the fuel filter every 400 operating hours. To change the fuel filter: Park the loader on a level sur- face, lower the boom arms, engage the parking brake and shut off the engine.
Page 178 ENGINE MAINTENANCE 7.1 Fuel System (cont’d) Bleeding the Fuel System: If the loader has been run dry of fuel, or the fuel filter has been changed, it may be necessary to bleed the air from the fuel lines. Replenish the fuel reservoir (tank) with a minimum of 10 gallons (45 liters) of fuel.
Page 179: Air Filter
ENGINE MAINTENANCE 7.1 Air Filter The loader is equipped with a dry cartridge, radial seal type filter element. (fig. C5279) The loader is equipped with an locking air restriction indicator (fig. 5118)that functions while the engine is operating. The indicator normally is green. When the indicator has changed to red, the air filter element requires servicing and/or changing.
Page 180 ENGINE MAINTENANCE 7.1 Air Filter (cont’d) Seal After removing the air filter element, carefully wipe out any excess dirt from the air cleaner housing. (fig. C5286) Check the air filter element seal before installing to the air cleaner housing. (fig. C5279) Be sure the seal is not damaged, torn or gouged.
Page 181: Cooling System
ENGINE MAINTENANCE 7.1 Cooling System Daily Checks: The loader is equipped with a liquid cooled diesel engine that requires daily coolant level checks and radiator ser- vice if necessary. The cooling system should always be checked when the engine is cool. Park the loader on a level surface, lower the boom arms, engage the parking brake and shut off the engine.
Page 182 (50 / 50 ratio) Add the mixed coolant to the engine radiator.The cooling system will hold approximately 1.8 gal (7 liter) for the 85. Never use Fuel pump coolant undiluted. Pure coolant does not absorb and pass heat efficiently.
Page 183: Maintenance 7.7
MAINTENANCE 7.7 Fan Belt Adjustment Engine cover The fan (alternator) drive belt should be checked daily for tension and wear. The drive belt should be replaced promptly when fraying of the belt cords or cracks in the Fan belt rubber are observed. Failure to replace the drive belt located could lead to slippage or complete failure, causing the behind...
Page 184: Universal Joint
ENGINE MAINTENANCE 7.1 Universal Joint The engine drive universal is located and accessed by removing the operators seat, and removing the service access cover. The universal joint should be serviced every 50 hours. Check the universal joint for wear and lubricate Remove seat with a standard grade of multi purpose grease.
Page 185: Cylinder Head 7.2
CYLINDER HEAD 7.2 Valve Adjustment Compression Testing Refer to Kubota Workshop Manual 97897-0116-5, Refer to Kubota Workshop Manual 97897-0116-5, Thomas P/N 040913SP, for instructions. Thomas P/N 040913SP, for instructions. NOTES 7-12...
Page 186 ENGINE REPLACEMENT 7.3 Removal Move the loader to a level surface. Raise the boom arms, engage the boom supports, apply the parking brake, shut off the engine and remove the ignition key. Remove the seat, U- Joint service access panel and the battery access panel..
Page 187 ENGINE REPLACEMENT 7.3 Removal (cont’d) Disconnect At the fuel filter assembly loosen the fuel line clamp and disconnect the fuel line coming from the tank. Plug the fuel line. Undo the fuel filter assembly bolts so the filter can be moved to access engine mount nuts.(fig. C5643) C5643 Fuel return line...
Page 188 ENGINE REPLACEMENT 7.3 Removal (cont’d) 14 Disconnect the throtlle handle rod at the engine swivel by removing nylok nut and bolt from the swivel rod end. (fig. C5649) Tie the throttle rod off to one side so that it will not interfer with engine installation. C5649 15 Attach a hoist chain to the engine through the lifting lugs on the engine.
Page 189 ENGINE REPLACEMENT 7.3 Installation Ground cable If the engine is being replaced with a new assembly, the engine will require some preparation. Remove the protective rust preventative coating from the flywheel. Use a solvent to remove. The flywheel must be clean with no nicks or burrs. Install the engine U- Joint adapter.
Page 190 ENGINE REPLACEMENT 7.3 Installation Not exactly as shown 14 Using a hoist, set the engine into the loader through the rear door opening.. (fig. C2214) Have a helper inside the cab to line up the engine U- Joint to the hydrostatic pump input shaft.
Page 191: Stop Solenoid
ENGINE REPLACEMENT 7.3 Stop Solenoid Wire The stop solenoid is energized only when the loader engine is being stopped. When the ignition key is turned from the run position to the stop position, the timer relay supplies power to the stop solenoid for 15 seconds. The stop solenoid pulls on the engine stop lever, stopping the engine.
Page 192 Radiator cap pressure setting........................12. 8 psi (88kPa) Thermostat rating ...........................Fully open 185°F (85°C) For complete engine service repair manual: Order P / N 97897-0116-5 from your nearest Kubota dealer, or order P / N 040913sp from your local Thomas dealer. 7-19...
Page 193 ENGINE TROUBLE SHOOTING 7.5 Symptom Cause Remedy Engine does not start No fuel Replenish fuel Air in the fuel Vent air Water in the fuel Change fuel and repair or replace fuel system Fuel pipe clogged Clean Fuel filter clogged Clean or change Excessively high viscosity of fuel or engine oil at Use the specified fuel or engine oil...
Page 194 ENGINE TROUBLE SHOOTING 7.5 PROBABLE CAUSE SOLUTION SYMPTOM Piston rings gap facing the same direction Shift gap direction Excessive lubricant oil consumption Oil ring worn or stuck Replace Piston ring groove worn Replace Valve stem and guide worn Replace Crankshaft bearing and crank pin bearing worn Replace Injection pump’s plunger worn Replace pump element or pump...
Page 195: Specifications
SECTION 8 MAINTENANCE & SPECIFICATIONS Maintenance Preventative Maintenance Schedule..........pg. 8-2 Service Access................pg. 8-3 ~ 5 Daily Service ..................pg. 8-6 50 Hour Service ................pg. 8-7 ~ 8 Trouble Shooting Hydrostatic Drive ................pg. 8-9 Hydraulic System ................pg. 8-10 Final Drive..................
Page 196: Maintenance 8.1
MAINTENANCE 8.1 8.1 Preventative Maintenance Service Schedule ITEM SERVICE REQUIRED Engine Oil Check level. If necessary add 5W40 API Classification CF-4 or better oil. Radiator Check level. If necessary fill with 50 / 50 mixture of ethylene glycol and water. (Water cooled only) Check for leaks, dirt build up and bent cooling fins.
Page 197: 8.1.2 Service Access
MAINTENANCE 8.1 WARNING To avoid personal injury, service repairs must be performed by an authorized Thomas dealer. 8.1.2 SERVICE ACCESS 1. 2A Boom Support For safety while performing regular service or mainte- nance work, the loader is equipped with boom support pins.
Page 198 MAINTENANCE 8.1 8.1.2 Service Access Battery access panel 1. 2C Battery Compartment The battery may be accessed by first removing the seat from the loader, removing the retaining screws and open- ing the access panel. (C5122) C5122 Final drive fluid level / drain plugs 1.2D Final Drive Fluid The final drive housing has an upper level and lower level, check and drain plug, located at the bottom front of...
Page 199 MAINTENANCE 8.1 8.1.2 Service Access Hydraulic reservoir sight gauge 1. 2G Oil Reservoir The oil reservoir is located at the rear, left side of the loader. It is part of the mainframe structure. The reservoir level is accessed by opening the rear door and visually checking the sight gauge.
Page 200: Daily Service
To prevent shearing of the wheel studs and rim damage check wheel nuts for proper torque 100 -110 ft lbs(136 - 149 Nm), and wheel bolts 80-85 ft lbs (108-115Nm) daily. After changing a rim, check wheel nuts/bolts hourly, until...
Page 201: Hour Service
MAINTENANCE 8.1 8.1.4 50 HOUR SERVICE CHECK Hydraulic/Hydrostatic 2.1 Hydraulic Oil Filter: The following service check is to be performed by your Change the hydraulic oil filter. Change the hydraulic dealer after the first 50 hours of operation. filter every 100 hours after the initial change. Engine Lubricate the filter cartridge seal with system fluid.
Page 202 4.4 Parking Brake: 7.2 Wheel Bolt Torque:Check and Torque wheel bolts to Check that the parking brake engages and completely 80-85 ft lbs (108-115 Nm) disengages. The park brake automatically engages with seat bar up. For loaders with wheel nuts, check and torque wheel nuts to 100 - 110 ft lbs (136 - 149 Nm).
Page 203: Troubleshooting 8.2
Disconnected Reconnect and adjust control linkage linkage. Internal pump or Consult your dealer or Thomas Service motor wear Groove pin Replace. Check caused by Dept. sheared on pintle lever for loose over speeding...
Page 204 TROUBLESHOOTING 8.2 8.2D Hydraulic System 8.2D Hydraulic System Symptom Cause Remedy Symptom Cause Remedy Loss of Reservoir low on Replenish with 10W30 Hydraulic Reservoir low on Replenish with 10W30 hydraulic fluid hose or fitting SJ oil. Check for action jerky API SJ oil.
Page 205: Control Levers
TROUBLESHOOTING 8.2 8.2E Control Levers 8.2F Electrical Symptom Cause Remedy Symptom Cause Remedy Control levers Linkage out of Adjust, check for wear at Engine will not Battery failure Check battery, charge will not center adjustment rod ends, loose counter crank over or replace nuts Battery cable fail-...
Page 206: Diesel Engine
TROUBLESHOOTING 8.2 8.2G Diesel Engine Symptom Cause Remedy Engine does not start No fuel Replenish fuel Air in the fuel Vent air Water in the fuel Change fuel and repair or replace fuel system Fuel pipe clogged Clean Fuel filter clogged Clean or change Excessively high viscosity of fuel or engine oil at low Use the specified fuel or engine oil...
Page 207: Special Tools 8.3
SPECIAL TOOLS 8.3 P / N Illustration Description Model 955280 T103 AXLE INSTALLATION TOOL - To install axle T135 in final drive housing. T133’S’ Quantity - 1 T137’S’ T153’S’ T103 SEAL INSTALLATION TOOL - To install axle 955281 T135 seal in final drive housing. T133’S’...
Page 208 SPECIAL TOOLS 8.3 P / N Illustration Description Model DRY LINER PULLER - Used for removing and 916-30042-01 Kubota installing the dry liner of the engine. 25197 Consists of: 304742 (64mm); 304743 (68mm); 30744 (75mm) 304745 (76mm); 304746 (82mm); 304747 (105mm);...
Page 209 SPECIAL TOOLS 8.3 Illustration Description Model 43979 CHAIN PULLER MODELS C1840 43980 SPANNER WRENCH 2’’ - 4 3/4’’ To repair hydraulic cylinders MODELS C1841 43981 PHOTO SENSOR / WHEEL SPEED MODELS TACHOMETER (Dual Function) C1837 T173HLS FORCE GAUGE, PUSH PULL For measuring restraint bar brake cable T173HLS II adjustment.
Page 210 NOTES 8-16...
Page 211: Specifications 8.4
SPECIFICATIONS 8.4 LOADER SPECIFICATIONS Dimensions : (With Standard Tires & Dirt Bucket) A. Overall operating height ........... . 124.25”...
Page 212 SPECIFICATIONS 8.4 Controls Vehicle: Steering direction and speed controlled by two hand operated control levers. Hydraulics: Lift and bucket tilt are controlled by separate foot or hand controls. Auxiliary hydraulics controlled by foot pedal or electric solenoid. Engine: Hand throttle, key type ignition switch and shutoff. Engine Make and model ............
Page 213: Torque Specifications
65 - 75 (88 - 102) 3/8 - 24 22 - 27 (30 - 37) 5/8 - 11 75 - 85 (102 - 115) 7/16 - 14 30 - 35 (41 - 47) 5/8 - 18 100 - 110 (136 - 150) Hydraulic Fittings: Specifications listed in ft lbs.
Page 214 DECALS 8.5 85 DECAL CHART 8-20...
Page 215 DECALS 8.5 85 DECAL CHART 8-21...
Page 216 85 Designation T85 SERIES DECAL PARTS LIST 23325 49273 Common Decals 35885 23308 39196 37059 23307 43776 42107 41045 38043 39191 23324 31291 46301 41065 35886 23326 23312 85 (Kit) 37060 41066 36841 85 (Kit) 23301 23309 23321 39192 35935...

Thomas 85 Repair Manual

Table of Contents

Section 3 Final Drive

Section 4 Controls

Section 6 Main Frame

Section 7 Engine

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Thomas 85

Summary of Contents for Thomas 85

Table of Contents