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Thomas 135 Repair Manual

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REPAIR MANUAL
135
137
153
1300 ProTough
Publication No. 49702
September , 2004
THOMAS

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Do you have a question about the 135 and is the answer not in the manual?

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Skip Garland
April 10, 2025

Need a electrical digram

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1 comments:
Mr. Anderson
April 10, 2025

The electrical diagram for Thomas part number 135 is included in the manual under the section titled "Hydraulic Circuit Electrical Diagram." It provides wiring schematics and details related to the electrical system, including instrumentation, ignition switch, starter circuit, auxiliary electrical, battery system, electrical panel, and charging system.

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Summary of Contents for Thomas 135

  • Page 1 REPAIR MANUAL 1300 ProTough Publication No. 49702 September , 2004 THOMAS...
  • Page 2 THE WARRANTY IS A CONDITION OF SALE OF THE PRODUCT TO PURCHASER 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 49702...
  • 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 into the main frame inside the rear door.

  • Page 4: Safety Precautions

    SAFETY PRECAUTIONS Practically all Service work involves the need to drive the falling objects. loader. The Owner’s / Operator’s Manual, supplied with each loader, contains safety precautions relating to SPECIAL CLOTHING driving, operating and servicing that loader. These For certain work it may be necessary to wear precautions are as applicable to the service technician as flame or acid resistant clothing.
  • Page 5 SAFETY PRECAUTIONS HAND TOOLS HOUSEKEEPING Many cuts, abrasions and injuries are caused by Many injuries result from tripping or slipping defective tools. Never use the wrong tool for the over, or on, objects or materials left lying around job as this leads either to injury or to a poor job. by a careless worker.
  • Page 6 SAFETY PRECAUTIONS OPERATIONAL CONSIDERATIONS the ground. If it is necessary to service the loader with the boom arms raised, be sure to engage the boom supports. Never work under or Stop the engine, if at all possible, before around a loader with raised boom arms without performing any service.
  • 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: Quick - Tach

    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: Hydraulic Circuit

    TABLE OF CONTENTS Section 1 Hydraulic System Hydraulic Circuit ........1.1 Gear Pump .

  • Page 10: Cylinder Head

    TABLE OF CONTENTS Section 5 Electrical Specifications ......... .5.1 Wiring Schematics .

  • Page 11: Gear Pump

    Gear Pump Disassembly (1300/135) .......pg. 1-15 ~ 17 Gear Pump Reassembly (1300/135) ....... .pg. 1-18 ~ 20 Control Valve Testing / Adjusting the Relief Valve .

  • Page 12: Auxiliary Circuit

    HYDRAULIC LAYOUT 1.1 C4224 Auxiliary Circuit Hydraulic fluid comes out the port closest to the spool Tilt Circuit end of the valve when the spool is pushed in. Lift Circuit Hydraulic fluid received at the fixed end of the cylinder NOTE: Foot pedal control operated machine illustrated.
  • Page 13 HYDRAULIC SCHEMATIC 1.1 C4475...

  • Page 14: Oil Filter

    ....... . . 1300/135 (Eaton) / 1.2 cu in (19.7cc)

  • Page 15: Oil Reservoir

    GENERAL INFORMATION 1.1 Refer to figure C2018 on page 1-2. Oil is drawn from the hydraulic oil reservoir through a 100 micron element. From there it travels to the main hydraulic pump. •The hydraulic pump is a gear type which is driven by a Gear pump location shaft and coupler through the hydrostatic drive pump at engine speed.

  • Page 16: Boom Support

    GEAR PUMP 1.2 Replacement Reservoir filler spout Start the gear pump removal procedure by removing any attachment, raising the boom arms and engaging the boom support pins. Shut off the engine. Vacuum hose WARNING To prevent personal injury do not work under the boom arms without the boom supports engaged.
  • Page 17 GEAR PUMP 1.2 Disassembly 1. General 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 137/153 C4347 1. Screws 8. Drive Shaft 2. Cover Assembly 9. Wear Plate 3. Seal Ring 10. Load Ring 4. Wear Plate 11. Preload Ring 5. Gear Plate 12. Seal Ring 6. Dowel Pin 13. Body Assembly 7.
  • Page 19 GEAR PUMP 1.2 Disassembly 137/153 6. Procedure 1. Clamp the unit in a vice from the flange side Vice (fig. C4348). Make sure the vice jaws are clean and have smooth surfaces to prevent damage to the pump. Caution must be used when using a vice to avoid distorting any parts or damaging the mounting pilot.
  • Page 20 GEAR PUMP 1.2 Disassembly 137/153 (cont’d) Wear Plate 6. Procedure Seal Ring 4. Place the cover assembly on the work bench (fig. C4352). Inspect the wear plate for evidence of extrusion or marks caused by overheating. Replace if necessary. Remove the wear plate and seal ring on the cover assembly.
  • Page 21 GEAR PUMP 1.2 Disassembly 137/153 (cont’d) Remove Wear Plate 6. Procedure 8. Inspect the wear plate for evidence of extrusion, or marks caused by overheating. Remove the wear plate from the body assembly. (fig C4356) Replace if necessary. Remove the load ring, pre-load ring and seal ring.
  • Page 22 GEAR PUMP 1.2 Assembly 137/153 1. Have the entire seal kit available and lay out neatly on the table (fig. C3980). Compare the old seal kit to the new one to ensure you have the correct one. Lightly coat all seals with seal grease. The grease is needed to adhere the seals in their grooves.
  • Page 23 GEAR PUMP 1.2 Assembly 137/153 (cont’d) Wear plate with 0.25” pressure hole 6. Place the load seal directly on top of the pre-load seal (blue E-ring). 7. Find the wear plate with a 0.25” diameter pressure hole and no oblong holes on the inlet side. Place the wear plate on top of the load ring with the bronze side facing up towards the gear.
  • Page 24 GEAR PUMP 1.2 Assembly 137/153 (cont’d) 10. Place the cover assembly on a bench with the Seal ring machined surface facing up. Place the rubber seal ring in the cover seal ring groove. (fig C4362) 11. Find the wear plate with the 0.625” diameter pressure hole and two oblong holes on the inlet side.
  • Page 25 GEAR PUMP 1.2 Disassembly 1300/135 1. Front Plate Assembly 9. Shaft Seal 2. Back Plate 10. Washer 3. Body Assembly 11. Cap Screw 4. Drive Gear 12. Back up Gasket 5. Idler Gear 13. Seal 6. Plug 14. Key for Straight Shaft Models 7.
  • Page 26 GEAR PUMP 1.2 Disassembly 1300/135 Pump in vise Remove the gear pump as outlined on page 1-6. Work in a clean area. Thoroughly clean the outside of the gear pump before disassembly. Remove the adapter fittings from the gear pump and drain the oil.
  • Page 27 GEAR PUMP 1.2 Disassembly 1300/135 (cont’d) Separate the body Plastic hammer Remove the idler gear assembly from the body. To separate the body from the plate, replace the drive gear assembly in the gear pocket and tap the protruding end with a plastic hammer. (fig. C1897)
  • Page 28 GEAR PUMP 1.2 Assembly 1300/135 It is important that the relationship of the back plate, body, wear plate and front plate is correct upon reassembly. Note the 2 (two) half moon shaped cavities in the body. The smaller half moon port cavity must be on the pressure side of the gear pump.
  • Page 29 GEAR PUMP 1.2 Assembly 1300/135(cont’d) Dip the gear assemblies with system oil and slip the gears into the front plate bushing and body. (fig. C2004) C2004 Install a new O - ring in the groove of the back up plate. (fig. C2005)
  • Page 30 GEAR PUMP 1.2 Assembly 1300/135 (cont’d) O-ring 12 Install a new O - ring onto the gear pump mounting surface. (fig. C2090) C2090 13 Install the adapter plate, new O - ring and shaft Coupler coupler. (fig. C2091) 14 Install the gear pump to the loader as outlined on O-ring page 1-6.
  • Page 31 CONTROL VALVE 1.3 Testing and Adjusting the Relief Valve Pressure Hoses and gauges required for this test must be capable Flow Meter/Pressure Tester of withstanding 5000 psi (345 bar) continuous pressure, and hydraulic flow meter capable of measuring 30 gallons per minute.
  • Page 32 CONTROL VALVE 1.3 Repeat steps 2 and 3 if necessary. Allow the loader to operate at this setting until the oil temperature has Relief valve increased to 160° F (71ºC), operating temperature. Turn the flow control valve further to restrict the oil flow to no flow.
  • Page 33 CONTROL VALVE 1.3 Disconnect the return line from the control valve and Control valve mounts Mounting plate remove the adapter fitting. Plug and cap all open ports and hose ends. Remove the 3 nuts holding the control valve to the mount and remove the control valve.
  • Page 34 CONTROL VALVE 1.3 Control Valve Disassembly 137/153 Diagram Legend 1. Main relief valve 2. O ring seal 3. Ring 4. Positioner kit joint 5. Positioner kit spacer 6. O ring seal 7. Lift positioner kit 8. Lock assembly 9. 12 VDC coil 10.
  • Page 35 CONTROL VALVE 1.3 Control Valve Disassembly 1300/135 Diagram Legend 1. Main relief valve 2. O ring seal 3. Ring 4. Positioner kit joint 5. Positioner kit spacer 6. O ring seal 7. Lift positioner kit 8. Lock assembly 9. 12 VDC coil 10.
  • Page 36 CONTROL VALVE 1.3 Disassembly / Repair 137/153 Control Valve Before disassembling the hydraulic control valve, clean the body with a suitable solvent and dry with compressed air. (fig. C3696) WARNING To avoid eye injury, use safety goggles when cleaning with compressed air. Ensure all openings are plugged to prevent solvents and C4254 dirt from contaminating the control valve assembly.
  • Page 37 CONTROL VALVE 1.3 Disassembly / Repair 137/153 (cont’d) Remove the control box from the spool linkage end. (fig. C3709) The box needs to be tilted upward towards the valve to release the hardened ball from the hole in the spool end, and then pull away from the valve. C3706 Spool Linkage C3709...
  • Page 38 CONTROL VALVE 1.3 Disassembly Repair 137/153 Spool O-Ring (cont’d) When replacing the spool to the control valve, use new O-ring seals and apply oil to the O-rings and spools. (fig. C3718). C3718 Fit the seal washer to the control valve with the beveled side of the washer facing the control valve.
  • Page 39 CONTROL VALVE 1.3 Disassembly / Repair 137/153 Spool spring and bushing Detent (cont’d) 11 Install the spring return / centering cover and tighten the mounting screws evenly to 4.9 ft lbs (6.6 Nm). Install the end cap to the cover and tighten to 7.2 ft lbs (9.8 Nm) .
  • Page 40 CONTROL VALVE 1.3 Disassembly / Repair 137/153 (cont’d) Remove the solenoid assembly from the control valve. (fig. C4242) C4242 Remove the screws and the bottom end cap from auxiliary section.(fig.4243) C4243 Remove the solenoid spool assembly from the control valve. (fig. C4244) Note the effort required to remove the spool from the spool bore.
  • Page 41 CONTROL VALVE 1.3 Disassembly / Repair 137/153 (cont’d) Allen Wrench Hold the spool with a Hex allen wrench while removing retaining screw. (fig. C4246) Remove the spring and spring bushing from the spool assembly. (fig. C4247) When installing the spring assembly to the spool, apply Loctite 542 to the threads and tighten the screw to 17.7 ft lbs (24 Nm).
  • Page 42 CONTROL VALVE 1.3 Disassembly / Repair 1300/135 Before disassembling the hydraulic control valve, clean the body with a suitable solvent and dry with compressed air. (fig. C3744) WARNING To avoid eye injury, use safety goggles when cleaning with compressed air.
  • Page 43 CONTROL VALVE 1.3 Disassembly / Repair 1300/135 (con’t) Remove the control box from the spool linkage end. The box needs to be tilted up towards the valve to release the hardened ball on the control box pin from the hole in the spool end and pull it away from the valve.
  • Page 44 CONTROL VALVE 1.3 Disassembly / Repair 1300/135 Spool O-Ring (con’t) When replacing the spool to the control valve, use new O-ring seals and apply oil to the O-rings and spools. (fig. C3718). C3718 Fit the seal washer to the control valve with the beveled side of the washer facing the control valve.
  • Page 45 CONTROL VALVE 1.3 Disassembly / Repair 1300/135 (con’t) Apply Loctite 542 10 When installing the detent to the control valve spool, apply Loctite type 542 to the threads. Tighten the detent to the spool at 17.7 ft lbs (24 Nm). (fig. C2254)

  • Page 46: General Information

    HYDRAULIC CYLINDERS 1.4 T 153 Shown Lift cylinder 1. O-Ring 9. Piston part B (front) 2. Wiper seal 10. Grease fitting 3. Rod seal 11. Cylinder barrel 4. Gland O-Ring 12. Cylinder end cap 5. Wear ring 13. Cylinder rod 6.
  • Page 47 HYDRAULIC CYLINDERS 1.4 Testing the Piston Seals Remove cylinder to be tested Before performing this test, ensure the control linkages 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 48 HYDRAULIC CYLINDERS 1.4 Lift Cylinder Replacement Remove 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: C4251 IMPORTANT Cap all open lines and ports to prevent...
  • Page 49 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.(fig. C3649) Loosen or remove the hydraulic hoses from hydraulic tubing under the boom arm step if you are changing the hoses also.
  • Page 50 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 51 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. C3732) C3732 Remove the gland nut assembly from the cylinder rod.
  • Page 52 HYDRAULIC CYLINDERS 1.4 Cylinder Inspection Gland Nut Inspect the cylinder rod for scratches, dents and other damage. Minor rod damage may be repaired using a fine O-Ring abrasive. Major scratches or dents are not repairable and the rod must be replaced. The chrome surface must be Rod Seal intact to provide a rust resistant surface.
  • Page 53 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. C3737) O-Ring Install new wear rings and piston seal to the the 2 C3737 piece piston assembly.

  • Page 54: Rear Door

    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 C4223 used.
  • Page 55 HYDRAULIC OIL COOLER 1.6 General Information 10 Replenish the hydraulic fluid as required. Check for The hydraulic oil cooler is mounted to the inside of the system leaks and check the fit of the shroud seal to the rear door. (fig. C4255) Oil returning from the control engine radiator.
  • Page 56 HYDRAULIC OIL RESERVOIR 1.7 General Information Hydraulic oil reservoir The hydraulic oil reservoir is located at the rear of the loader on the left hand side. (fig. C4214) The reservoir is completely separated from all chain and gear drives to eliminate contamination.
  • Page 57 HYDRAULIC OIL RESERVOIR 1.7 Servicing The Oil Reservoir 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. Lower the boom arms, shut off the engine and engage the parking brake.

  • Page 58: Trouble Shooting

    TROUBLE SHOOTING 1.8 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 7.11 Universal joint between Inspect and replace the damaged parts as required. the gear pump).

  • Page 59: Torque Chart

    20 to 22 24 to 26 30 to 33 50 to 60 40 to 44 72 to 80 70 to 77 125 to 135 82 to 90 160 to 180 55 to 60 200 to 220 1 1/4 120 to 132...

  • Page 60: Conversion Chart

    CONVERSION CHART 1.10 CONVERSION FACTORS U.S. To Metric MULTIPLY TO OBTAIN Area: sq. foot square meter 0.092 903 Force: pound force Newton 4.448 222 Length: inch millimeter 25.4 foot meter 0.304 8 mile kilometer 1.609 344 Mass: pound kilogram 0.453 592 ounce gram 28.35...
  • Page 61 NOTES 1-51...

  • Page 62: Hydrostatic Drive Circuit

    SECTION 2 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Circuit Schematic ......... . . pg. 2-2 Specifications Chart .

  • Page 63: Hydrostatic Circuit

    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) C4224...

  • Page 64: Specifications

    Hydrostatic Repair Manual ........
  • Page 65 Hydrostatic Repair Manual ........

  • Page 66: General Information

    GENERAL INFORMATION 2.3 Variable displacement Clockwise input piston pump shaft rotation Case drain High pressure Charge pressure inlet Fixed displacement drive motor Case drain C4447 Brake Line When the swashplate begins to move the check valve on The drive shaft of the piston pump is rotated by the the discharge, or pressure, side seats because of the high- engine.
  • Page 67 TROUBLE SHOOTING 2.4 Symptom: Neutral Difficult Or Impossible To Find Inspect external control linkage Defective Repair or replace Symptom: System Operating Hot Inspect heat Check charge Check oil level exchanger pressure in reservoir Below level Defective Fill to proper Repair or level replace Inspect charge...
  • Page 68 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 Inspect charge Inspect charge...
  • Page 69 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 Inspect charge Inspect charge Inspect inlet pump relief valve screen or filter Defective...
  • Page 70 TROUBLE SHOOTING 2.4 System Diagnosing Steps And Special Tools 1 Check oil level in reservoir: 0 - 500psi (34.5bar) 0 - 5000psi (345bar) a .fill to proper level as marked on site tube. 2 Inspect external control linkage for: a. misadjustment or disconnection b.

  • Page 71: Pressure Tests

    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. LH Side And Top View Port C Port A WARNING Port D...

  • Page 72: Towing Procedure

    A service override for the brake valve has been incorporated for use by Thomas Dealers. The normal position of the plunger is down and turned into the locked Brake valve position.

  • Page 73: Flushing The Hydraulic System

    FLUSHING THE HYDRAULIC SYSTEM 2.7 General Information Contamination in the hydraulic system is a major cause of The best way to remove contaminates from the hydrostat- component failure. Contamination can enter the hydraulic ic drive system is to disassemble each component and system in any of the following ways.
  • Page 74 FLUSHING THE HYDRAULIC SYSTEM 2.7 Cleaning The System Hydraulic reservoir The first step in cleaning the hydraulic system is to deter- 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 in the bottom of the hydraulic oil reservoir.

  • Page 75: Foot Pedals

    FLUSHING THE HYDRAULIC SYSTEM 2.7 For flushing water from the hydraulic system, perform Reservoir drain plug the following procedures: 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 76: Start - Up Procedure

    START-UP PROCEDURE 2.8 The following start-up procedure should always be 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. C1878 ) WARNING This start-up procedure must be made with the loader securely raised off the ground.

  • Page 77: Gear Pump Replacement

    GEAR PUMP REPLACEMENT 2.9 Start the gear pump removal procedure by removing any Reservoir filler spout attachment, raising the boom arms and engaging the boom support pins. Shut off the engine. Remove the seat and hydrostatic shield. WARNING To prevent personal injury do not work under the boom arms without the boom supports engaged.

  • Page 78: Tandem Pump Replacement

    TANDEM PUMP REPLACEMENT 2.10 Begin the pump removal by removing any attachment, Tandem case drain hose raise the boom arms and engage the boom support pins. Shut off the engine. Remove the seat and hydrostatic shield. WARNING To prevent personal injury do not work under the High pressure hoses boom arms without the boom supports engaged.
  • Page 79 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 lower charge pressure inlet fitting to the tandem pump and attach the brake valve hose.
  • Page 80 13 Connect the charge pressure outlet line from the tan- Charge line dem pump to the hydraulic brake valve. (fig. C2072) NOTE: NOTE: Brake valve The 137 / 153 use a Sauer Danfoss M44Tandem Pump. The 1300 /135 use a M35 Tandem Pump. C2072 2-19...

  • Page 81: Restraint Bar

    19 Make adjustments to the steering controls, steering The 137/ 153 use a Sauer Danfoss M44 Tandem locks, and restraint bar cables as required. Follow the pro- Pump. The 1300 /135 use a M35 Tandem Pump. cedures for control adjustments in Section 4 2-20...

  • Page 82: Tandem Pump Parts Diagram

    TANDEM PUMP PARTS DIAGRAM 2.11 Sauer Danfoss Series 40 / M35 Rear Pump 25 26 C1881 2-21...
  • Page 83 For further service instructions refer to a Sauer Bearing Danfoss Dealer and request Service / Repair Manual Drive shaft Part Number BLN 9992, or order P / N 44232 from a Bolt local Thomas Dealer. Cover O-ring seal Bearing Plug Swashplate seal...
  • Page 84 TANDEM PUMP PARTS DIAGRAM 2.11 Sauer Danfoss Series 40 / M35 Front Pump C2007 2-23...
  • Page 85 For further service instructions refer to a Sauer Bearing Danfoss Dealer and request Service / Repair Manual Drive shaft Part Number BLN 9992, or order P / N 44232 from a Bolt local Thomas Dealer. Cover O-ring seal Bearing Plug Swashplate seal...
  • Page 86 TANDEM PUMP PARTS DIAGRAM 2.11 LN000500 onward shown C-2875 2-25...
  • Page 87 10 Seal, Input Drive 11 Spacer 12 Bolt 13 Washer, Flat For further service instructions refer to a Sauer Sundstrand Dealer and request Service / Repair Manual Part Number BLN 9992, or order P / N 44232 from a local Thomas Dealer. 2-26...

  • Page 88: Drive Motor

    DRIVE MOTOR 2.12 General Information C1129 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 89 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 90 DRIVE MOTOR 2.12 The geroler (fig. C2299), is both a fluid displacement 8 point star Roller (9) motor and a gear reducer. It provides 8 times (the number of star points) greater power per revolution than a gear, vane or piston type motor. This means that 8 times the greater torque can be developed at one eighth the speed without further gear reduction.
  • Page 91 DRIVE MOTOR 2.12 C1891 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.
  • Page 92 DRIVE MOTOR 2.12 Removal Upper fill check Remove any attachment, raise the boom arms and engage the boom support pins. WARNING To prevent personal injury do not work under the boom arms without the boom supports engaged. Raise the loader securely off the ground. Oil drain plug Remove the wheels on the side to be repaired.
  • Page 93 DRIVE MOTOR 2.12 Removal Nuts 12 Remove the jam nuts, mounting nuts and lock wash- ers from the 4 mounting bolts retaining the drive motor to the final drive housing. (fig. C2081) Hold the head of the bolts from inside the final drive housing. (fig. C2077) 13 Remove the drive motor.
  • Page 94 DRIVE MOTOR 2.12 Replacement Clean sealing area Clean the mounting areas thoroughly that need to be sealed with silicone. (fig. C2078, C2076) C2078 Clean sealing area C2076 Apply a bead 1 / 4 of an inch thick around the drive Apply silicone motor bearing retainer and around each mounting hole.
  • Page 95 DRIVE MOTOR 2.12 IMPORTANT Apply sealing gasket 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.
  • Page 96 DRIVE MOTOR 2.12 Parts Illustration C1892 Danfoss OMT FL Diagram C1892 Index 1. Name plate 2. Bolts 3. Valve housing 4. Spring washer 5. Spacer 6. O-ring seal 7. O-ring seal 8. Valve drive shaft 9. Channel plate 10. Disc valve 11.
  • Page 97 DRIVE MOTOR 2.12 Parts Illustration C1893 Danfoss OMT FL Brake Diagram C1893 Index 1. Bearing nut 2. Bearing, small 3. Screw 4. Bearing housing 5. O-ring seal 6. Spring 7. Spring 8. Piston 9. O-ring seal 10. Ring 11. O-ring seal 12.
  • Page 98 Remove restrictor C2289 Remove the 4 bolts from the drive motor valve hous- Remove section bolts ing. (fig. C2290) Upon reassembly, torque the bolts in a criss cross pattern at 130 ~ 135 ft lbs. (177 ~ 183.5 Nm) C2290 2-37...
  • Page 99 DRIVE MOTOR 2.12 Disassembly (cont’d) Remove shuttle valve plugs Insert a small screwdriver into the mounting holes of the valve housing assembly and remove the 2 shuttle valve plugs, one each side. (fig. C2291, 2293) C2291 Shuttle valve plug C2292 Insert a small screwdriver into the shuttle valve plug Shuttle valve springs hole and retrieve the springs.
  • Page 100 DRIVE MOTOR 2.12 Disassembly (cont’d) Carefully lift the valve housing straight up. (fig. C2295) Place your fingers under the valve housing to hold the channel plate in place. C2295 10 Remove the channel plate. (fig. C2296) Channel plate Disc valve C2296 11 Remove the disc valve and balance plate from the Valve housing...
  • Page 101 DRIVE MOTOR 2.12 Disassembly (cont’d) 13 Separate the geroler section from the rest of the motor. (fig. C2300, C2303) Place your fingers between the sections as you lift the geroler section to prevent the rollers and gear from spilling out. C2300 C2303 14 Inspect the gears and rollers for wear such as scratch-...
  • Page 102 DRIVE MOTOR 2.12 Disassembly (cont’d) Cardan shaft (drive) 15 Remove the cardan (drive) shaft (fig. C2304). 16 Remove the intermediate spacer (fig. C2305) . Replace the seal with new item at time of assembly. C2304 Intermediate spacer C2305 Special tool 17 A special tool will be required as shown in fig.
  • Page 103 DRIVE MOTOR 2.12 Disassembly (cont’d) Special tool 18 Place the special tool on the bearing nut and remove the bearing nut. (fig. C2308, C2309). C2308 Bearing nut C2309 19 Remove the drive motor from the vise and remove Retaining screws the screws retaining the front cover to the bearing hous- ing.
  • Page 104 DRIVE MOTOR 2.12 Disassembly (cont’d) Output shaft and large bearing 20 Use a press and appropriate sized arbor to push the output shaft from the bearings. (fig. C2312). C2312 21 Remove the small bearing from the housing. (fig. Small bearing C2313).
  • Page 105 DRIVE MOTOR 2.12 Disassembly (cont’d) Bearing housing 24 Remove the bearing housing (fig. C2316). Seal C2316 25 Remove the brake springs from the brake piston. (fig. Inner and outer spring C2317) There are inner and outer springs. C2317 26 Remove the piston from the housing by pushing Piston through from the output shaft side.
  • Page 106 DRIVE MOTOR 2.12 Assembly Output shaft and bearing Install the output shaft to the housing. (fig. C2321) C2321 Install the front cover to the housing and torque the Front cover screws to 8.9 ft lbs (12 Nm). (fig. C2322). Use new seals when assembling the motor.
  • Page 107 DRIVE MOTOR 2.12 Assembly (cont’d) Add steel plate second Continue adding plates, 12 fibre, 11 steel plates, to the housing. (fig. C2323, C2319) C2323 Brake discs C2319 Install the piston to the housing, over the brake discs. Piston (fig. C2318) Use new seals when assembling the motor. Align one of the piston spring pockets with the hydraulic inlet port opening in the housing.
  • Page 108 DRIVE MOTOR 2.12 Assembly (cont’d) Install the bearing housing bolts and torque to 46.5 ft lbs. +/- 2 ft lbs. (63 Nm +/- 3 Nm) (fig. C2314) Housing bolts C2314 Install the small bearing to the output shaft (fig. Small bearing C2313) in the following sequence: a.
  • Page 109 DRIVE MOTOR 2.12 Assembly (cont’d) 10 Install the intermediate plate to the housing. (fig. C2326). Note the alignment pin used to locate the plate to Notch the notch in the housing. C2326 11 Install two studs if available to assist assembly. (fig. Studs C2327).
  • Page 110 DRIVE MOTOR 2.12 Assembly (cont’d) Install geroler section 14 Install the geroler section the housing. (fig. C2330) Place a hand under the geroler to prevent the pieces from falling out. The following procedures must be followed closely for proper motor rotation. C2330 15 Mark the gearwheel set rotor at the point where the Mark the gearwheel...
  • Page 111 DRIVE MOTOR 2.12 Assembly (cont’d) Seal 18 Install the channel plate to the geroler section. Install new seals when assembling the motor. (fig.C2334) Note the alignment dowel pin and oil passage hole. Hole Dowel pin C2334 19 Install the disc valve to the valve drive. (fig. C2335) Align timing mark with hole Align the mark on the valve drive with a hole in the outer rim.
  • Page 112 DRIVE MOTOR 2.12 Assembly (cont’d) Spacer 22 Apply petroleum jelly to the spacer. (fig. C2337) Install the spacer to the valve housing. (fig. C2338) C2337 Spacer C2338 23 Install the valve housing to the drive motor. (fig. Valve housing C2339). C2339 24 Install the shuttle valve piston.
  • Page 113 Seal Shuttle valve plug C2292 27 Install the bolts to the drive motor and torque in a crisscross pattern to 135 ft lbs. (183 Nm).( fig. C2290). Torque bolts C2290 28 Install the restrictor and replace the plug. (fig. C2289).

  • Page 114: Torque Specifications

    20 to 22 24 to 26 30 to 33 50 to 60 40 to 44 72 to 80 70 to 77 125 to 135 82 to 90 160 to 180 55 to 60 200 to 220 1 1/4 120 to 132...
  • Page 115 SECTION 3 FINAL DRIVE Specifications & Maintenance Chart ............pg. 3-2 Lubrication Checking the Oil .
  • Page 116 Torque Specifications: Chain Tightener Clamp Nuts ....150 lbs / ft (203 nm) Motor Sprocket Bolt........25 lbs /ft (34 nm) Wheel Nuts......100 - 110 lbs /ft (135 - 149 nm) Tire Pressure..........50 psi (345 Kpa) Maintenance Initial Check (hrs) Check Every (hrs) Tire Pressure......

  • Page 117: Lubrication

    LUBRICATION 3.2 Checking The Oil Level The loader has 2 independent final drive housings. When Upper check plug checking the oil level ensure the loader is on a level sur- 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 118: Drive Chain

    DRIVE CHAIN 3.3 Checking The Drive Chain 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 Remove inspection cover to 9mm) free play.

  • Page 119: Chain Tightener

    DRIVE CHAIN 3.3 Adjusting The Drive Chain Remove shield After checking the chain for proper free play, you may need to make an adjustment. Access the chain tightener located at the front of the operators compartment, just above the foot rests, by removing the cover shield.
  • Page 120 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 121: Drive Motor Sprocket

    DRIVE CHAIN 3.3 Chain Installation Make sure the chain tightener and adjuster are clear Chain wrap rearward in the adjustment slots. Wrap the chain in a “Z” pattern as shown in fig. C2273. Install the wrapped chain into the final drive housing. C2273 Place one end of the chain over the top of the rear axle sprocket.
  • Page 122 CHAIN TIGHTENER 3.4 Flange nut Chain Tightener Removal Adjuster plate Remove any attachment, raise the boom arms and engage the boom support pins. Shut off the engine. Support plate Block the loader securely with all four wheels clear of the ground. Remove the wheels from the side of the loader to be Tightener bracket repaired.
  • Page 123 CHAIN TIGHTENER 3.4 Chain Tightener Installation Assemble the left and right chain tightener assem- blies as shown in fig. C233 on the previous page. Make sure to place both spacer washers next to the side of the tightener where the bolt screws in. (Always toward the outside of the loader).
  • Page 124 DRIVE MOTOR SPROCKET 3.5 Replacement Remove inspection cover 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 125: Axle Assembly

    AXLE ASSEMBLY 3.6 C1172 Axle Assembly T - 135 S Axle Wheel Stud Wheel Nut Seal Axle Sprocket Bearing 10 Washer Race 11 Castle Nut Axle “Tower” 12 Cotter Pin 3-11...
  • Page 126 AXLE ASSEMBLY 3.6 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. Remove the wheels from the side of the loader the chain is to be removed.
  • Page 127 AXLE ASSEMBLY 3.6 15 Attach a special axle puller tool, Thomas P/N 955283, to the axle flange wheel studs using the wheel nuts that are on the loader. (fig. C228) 16 Using the slide hammer action of the special puller, remove the axle.
  • Page 128 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. C224. (approximately 120º increments).
  • Page 129 AXLE ASSEMBLY 3.6 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 axle oil seal. (fig. C212) Take care, make sure none gets on the bearing surface.
  • Page 130 24 Install the inspection cover using silicone to seal the matting surfaces. Do not over tighten the retaining nuts. 15 lbs/ft maximum. (20 nm) 25 Install the wheels. Torque the wheel nuts to 100 to C219 110 lbs/ft. (135 to 149 nm). 3-16...
  • Page 131 (fig. C211) Replace the wheel and torque the wheel nuts to 100 to 110 lbs/ft. (135 to 149 nm) Torque the wheel nuts IMPORTANT daily to prevent stud and/ or wheel damage.
  • Page 132 Wheel studs shearing Wheel nuts loose. Replace the wheel studs. Check wheel off. nut torque daily. Torque wheel nuts at 100 to 110 lbs/ft. (135 to 149 nm) Wheel stud threads Wheel nuts over tight- Replace the wheel studs. Check wheel stripped.

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