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Thomas 95 Repair Manual

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REPAIR MANUAL
95 / 105 / 115
Publication No. 46847
Date: February, 2001
THOMAS

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Summary of Contents for Thomas 95

  • Page 1 REPAIR MANUAL 95 / 105 / 115 Publication No. 46847 Date: February, 2001 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 46847 February 2001...
  • 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 right hand side fuel tank. In the event that the serial number plate is missing, the model number and serial number are both stamped into the main frame inside the rear door, next to the hydraulic control valve.

  • Page 4: Safety Precautions

    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: Battery

    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 some injury or to a by a careless worker.
  • Page 6 SAFETY PRECAUTIONS OPERATIONAL CONSIDERATIONS If high lift attachments are installed on a loader, beware of overhead power and telephone lines when travelling. Drop attachment near to ground Stop the engine, if at all possible, before level to increase stability and minimize risks. 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 THOMAS...

  • Page 10: Table Of Contents

    TABLE OF CONTENTS Section 1 Hydraulic System Hydraulic Circuit ................1.1 Gear Pump ..................1.2 Control Valve ..................1.3 Hydraulic Cylinders................1.4 Oil Filter.....................1.5 Oil Cooler ..................1.6 Oil Reservoir ..................1.7 Trouble Shooting ................1.8 Torque Chart ..................1.9 Section 2 Hydrostatic Drive System Hydrostatic Drive Circuit ..............2.1 Specifications..................2.2 General Information................2.3 Trouble Shooting ................2.4...
  • Page 11 TABLE OF CONTENTS Section 5 Electrical General Information................5.1 Wiring Schematics ................5.2 Instrumentation ..................5.3 Ignition Switch...................5.4 Engine Glow Plugs................5.5 Battery....................5.6 Electrical Panel ..................5.7 Starter Circuit..................5.8 Charging Circuit ................5.9 Safety Circuit ..................5.10 Cooling Fan Circuit ................5.11 Auxiliary Circuit ................5.12 Accessory Circuit................5.13 Trouble Shooting ................5.14 Section 6 Main Frame Quick - Tach..................6.1...
  • Page 12 THOMAS...
  • Page 13 SECTION 1 HYDRAULIC SYSTEM Hydraulic Circuit Schematic ............pg. 1-2 Specifications .

  • Page 14: Hydraulic Circuit 1.1

    HYDRAULIC CIRCUIT 1.1 Lift Cylinders Auxiliary Couplers Tilt Cylinders Control Valve Outlet C1008 NOTE: Foot pedal control operated machine illustrated. Hydraulic fluid comes out the port closest to the spool end of the valve when the spool is pushed in. Hydraulic fluid received at the fixed end of the cylinder pushes it out.
  • Page 15 SPECIFICATIONS & MAINTENANCE 1.1 Hydraulic Specifications Pump Type ........Gear, 0.61 cu. in. (11cc) Pump Brand .

  • Page 16: General Information

    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. C2353). The hydraulic pump is a gear type which is driven by a shaft and coupler through the hydrostatic drive pump at engine speed.
  • Page 17 GENERAL INFORMATION 1.1 THOMAS...

  • Page 18: Gear Pump

    GEAR PUMP 1.2 Replacement Hydrostatic shield Start the gear pump removal procedure by removing any attachment, raising the boom arms and engaging the boom support pins. Shut off the engine. WARNING To prevent personal injury, never work under the boom arms without the boom supports engaged. Remove the seat and hydrostatic shield.

  • Page 19: Start Up Procedure

    GEAR PUMP 1.2 Start up Procedure Screws Mount the gear pump to the loader. (fig. C2353) Hyd. lines Connect the hydraulic lines. Torque fittings and lines according to the torque chart section 1.8. Start the pump and run for 3 minutes each @ a.

  • Page 20: Control Valve 1.3

    CONTROL VALVE 1.3 Testing and Adjusting the Relief Valve Pressure NOTE: This test also checks the status of the gear Auxiliary couplers pump capacities. Hoses and gauges required for this test must be capable of withstanding 3000 PSI (207 Bar) continuous pressure, and hydraulic flow meter capable of measuring 30 gallons per minute.

  • Page 21: Control Valve Removal

    CONTROL VALVE 1.3 Control Valve Removal Remove any attachment, lower the boom arms, engage the parking brake and shut off the engine IMPORTANT Clean the work area prior to repair. Cap all open lines, fittings and ports to prevent contamination. Solenoid coil mounting nuts C2348...

  • Page 22: Control Valve Installation

    CONTROL VALVE 1.3 Control Valve Installation Install valve to mount When installing a new control valve, always inspect the exterior for shipping or other damage, such as bent brackets, broken spring return caps or damaged spool lock mechanism. Repair all damaged parts before installation to the loader.
  • Page 23 THOMAS 1-11...
  • Page 24 CONTROL VALVE 1.3 Salami Model to S / N LC001080 C1079 1-12...
  • Page 25 CONTROL VALVE 1.3a Diagram C1079 Legend Auxiliary spool spring return Tilt spool spring return Lift spool spring return Plate Washer Seal shim Seal Outlet / lift section body Mounting bracket Section seals Knurled nut Seal Solenoid coil Spool lock solenoid post Spring Lock pin Electrical connector...
  • Page 26 CONTROL VALVE 1.3 Disassembly / Repair 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 27 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) Remove screws Remove the screws retaining the lock adapters to the control valve assembly. (fig. C2372). C2372 Scraper seal plate Remove the plate and adapter from the control valve and spool. (fig. C2373, C2374) C2373 Remove the O-ring seals and seal shim.
  • Page 28 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) Spool O-ring shim 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. (fig. C2377). C2377 11 Figure C2378 shows the completely resealed lock Lock adapter assembly...
  • Page 29 CONTROL VALVE 1.3 Disassembly Repair (cont’d) Tilt spring return cap 13 Note: The plastic cap over the tilt spring has flat washers to distribute the load of the mounting screws to prevent cap damage. (fig. C2380). Be sure to install the flat washers when reassembling to the control valve.
  • Page 30 CONTROL VALVE 1.3 Disassembly / Repair (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 31 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) 20 Section seals may be replaced without removing spools and spring return mechanisms. Loosen the bolts Loosen section bolts retaining the control valve sections together. (fig. C2388). Upon assembly follow the torque specifications given Section 8.
  • Page 32 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) 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 shim Lubricate the seals with system oil upon assembly. When reassembling the control valve sections, follow the torque specifications in Section 8.
  • Page 33 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) 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 34 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) Remove cover 31 Remove the cover. (fig. C2405). C2405 32 Remove the spring washer. (fig. C2406). Remove washer 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 35 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) 35 Separate the sleeve and cup assembly. (fig. C2409). Inspect cup, sleeve and balls Inspect the tapered cup, balls and sleeve for wear. Replace with new detent kit assembly if wear is evident. C2409 36 Remove the spring washer.
  • Page 36 THOMAS 1-24...
  • Page 37 CONTROL VALVE 1.3 Screw Walvoil Model, S / N LC0001081 onward Washer Screw Spring Screw Ball Holder Block Screw Block Bushing Detent Spring Detent Bushing Bushing Spring Check Valve Spring Bushing Anti-cav O-ring O-ring Main Body Coil O-ring O-ring Seal Washer Lift Spool Post Lock Pin...
  • Page 38 CONTROL VALVE 1.3 Disassembly / Repair Removing the relief valve Before disassembling the hydraulic control valve, clean the body with a suitable solvent and dry with compressed air. To avoid eye injury, use WARNING safety goggles when clean- ing with compressed air. O-ring seal C2975 Ensure all openings are plugged to prevent solvents and...
  • Page 39 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) Remove the lock block from the valve. (fig. C2241) C2241 Remove the spring return / centering cap from the Remove the spring centering / return assembly end of the spool. (fig. C2237) C2237 Pull out the spool.
  • Page 40 CONTROL VALVE 1.3 Disassembly Repair (cont’d) 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 Fit the seal washer to the control valve with the beveled side of the washer facing the control valve.
  • Page 41 CONTROL VALVE 1.3 Disassembly / Repair (cont’d) 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). C2254 12 Install the spring return / centering cover and tighten the mounting screws evenly to 6.6 Nm (4.9 lbs / ft).

  • Page 42: Hydraulic Cylinders 1.4

    HYDRAULIC CYLINDERS 1.4 Lift cylinder shown 1. O-ring Piston part “B” (front) 2. Wiper seal 10 Grease fitting 3. Rod seal 11. Cylinder barrel 4. Gland O-ring 12. Gland nut 5. Wear ring 13. Cylinder rod 6. Piston seal 14. Lock nut 7.

  • Page 43: Testing Piston Seals

    HYDRAULIC CYLINDERS 1.4 Testing the Piston Seals Fixed end If the boom or bucket cylinders drift down with the control valve spools in the neutral position, and with no external leaks in the hydraulic system, the following test will indicate if oil is leaking by the cylinder piston seals. With the hydraulic oil at operating temperature and a fully loaded attachment, check that the cylinders do not drop more than 1.5 inches every 3 minutes with the...

  • Page 44: Lift Cylinder Replacement

    HYDRAULIC CYLINDERS 1.4 Lift Cylinder Replacement Disconnect hoses IMPORTANT When making repairs to the hydraulic system, keep the work area and parts clean. Use caps and plugs on all open lines and ports. The following procedure will assist you in the cylinder removal.

  • Page 45: Tilt Cylinder Replacement

    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 46: Cylinder Disassembly

    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 and support the front end of the body.
  • Page 47 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 48: Cylinder Inspection

    HYDRAULIC CYLINDERS 1.4 Cylinder Inspection Inspect the cylinder rod for scratches, dents and other Smooth down edges that could damage seals and cause damage. Minor rod damage may be repaired using a fine leakage. abrasive. Major scratches or dents are not repairable and Inspect the gland nut threads for damage.
  • Page 49 HYDRAULIC CYLINDERS 1.4 Install a new o-ring seal on the cylinder rod if used. Some cylinder rod are fully threaded here to accommodate a threaded type rear piston part. (fig. C133) C133 Install new wear rings and piston seal to the the 2 piece piston assembly.

  • Page 50: Oil Filter

    The hydraulic oil filter is a spin on type with a 10 micron rating. The filter material is a resin impregnated cellulose which features an accordion pleated design to provide maximum filtration area. Only Thomas approved filters C2347 should be used.

  • Page 51: Oil Cooler

    HYDRAULIC OIL COOLER 1.6 General Information The hydraulic oil cooler is mounted to the inside of the rear door. (fig. C2932) Oil returning from the control valve is circulated through the oil cooler before being sent on to other parts of the hydraulic system. An engine driven cooling fan drives air through the oil cooler when the rear door is closed.

  • Page 52: Oil Reservoir

    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. C2934) The reservoir is completely separated from all chain and gear drives to eliminate contamination.

  • Page 53: Servicing The Reservoir

    HYDRAULIC OIL RESERVOIR 1.7 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 1.8

    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 55: Torque Chart 1.9

    TROUBLE SHOOTING 1.8 Problem Cause Corrective Action Section Hydraulic oil Reservoir low on oil. Check for leaks and replenish as required. overheating. Clean the cooling fins. Oil cooler plugged or dirty. (if applicable) Auxiliary hydraulics Disengage. engaged. Temperature sender Replace. defective.
  • Page 56 NOTES THOMAS 1-44...

  • Page 57: Hydrostatic Drive System

    SECTION 2 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Circuit ... 2.1 Schematic ......... . . pg. 2-2 Specifications .

  • Page 58: Hydrostatic Drive Circuit

    HYDROSTATIC CIRCUIT 2.1 C1007 Hydrostatic Circuit Schematic...

  • Page 59: Specifications 2.2

    Charge Pressure ......200 PSI Min. (13.8 Bar) Hydrostatic Repair Manual ......Thomas P / N 44232 .

  • Page 60: General Information 2.3

    GENERAL INFORMATION 2.3 Charge pressure inlet Counterclockwise swash plate rotation Clockwise input shaft rotation Variable displacement Fixed displacement piston pump drive motor High pressure Case drain High pressure Counterclockwise Case drain C1700 output shaft rotation The driveshaft of the piston pump is rotated by the When the swashplate begins to move the check valve on engine.

  • Page 61: Trouble Shooting 2.4

    TROUBLE SHOOTING 2.4 Symptom: Neutral Difficult Or Impossible To Find Inspect servo Inspect external control ( if used ) control linkage Defective Defective Repair or Repair or replace replace Symptom: System Operating Hot Inspect heat Check charge Check oil level exchanger pressure in reservoir...
  • Page 62 TROUBLE SHOOTING 2.4 Symptom: Operates In One Direction Only Inspect external Inspect servo Inspect system control linkage control ( if used ) relief valves Defective Defective Defective Repair or Repair or Repair or replace replace replace Symptom: System Response Sluggish Inspect servo Inspect Check 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 Inspect charge Inspect charge Inspect inlet pump relief valve screen or filter Defective...

  • Page 64: Special Tools

    Photographs in the right hand column show some of the special tools that may be required to diagnose and repair the hydrostatic system. A complete testing kit is available from Thomas, p/n 44365, that contains gauges, hoses and adapters for Sauer Sundstrand model pumps.

  • Page 65: Pressure Tests 2.5

    Example: Charge pressure = 220 PSI (15.2 Bar) Gauge A complete testing kit is available from Thomas, p/n pressure reading would need to be 2220 PSI (153 Bar). 44365, that contains gauges, hoses and adapters for Minimum flow reading should be 9.5gal / min.

  • Page 66: 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 position. To release the brake, turn the release plunger counter clockwise.

  • 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 ic drive system is to disassemble each component and component failure. Contamination can enter the hydraulic flush and clean thoroughly.
  • Page 68 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 69 FLUSHING THE HYDRAULIC SYSTEM 2.7 For flushing water from the hydraulic system, perform Reservoir drain plug the following procedures: WARNING Be sure attachments are removed and liftarms 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. C2354) 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 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 Vacuum To prevent personal injury do not work under the boom arms without the boom supports engaged.

  • Page 72: Tandem Pump Replacement 2.10

    C2609) Remove the tandem pump from the loader. Refer to the Sauer Sundstrand Repair Manual, (Thomas p / n 44232 or Sauer Sundstrand p /n BLN - 9992), for complete pump servicing. Thomas does not cover or handle warranty processing or repair work performed on the Sauer Sundstrand product.

  • Page 73: Installation

    TANDEM PUMP REPLACEMENT 2.10 Installation 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. Apply lithium type grease to the tandem pump input shaft and the flywheel coupling splines.
  • Page 74 TANDEM PUMP REPLACEMENT 2.10 Installation (continued) Charge line connection Connect the tandem pump case drain fitting and hose. (fig. C2608) Torque the fittings and hose to the specifications listed in the Torque Chart in Section 8. IMPORTANT When making repairs to the hydraulic system, keep the work area and parts clean.
  • Page 75 TANDEM PUMP REPLACEMENT 2.10 Installation (continued) Replace control linkage Reinstall the steering control linkages as outlined in Section 4. (fig. C2443). 10 Fill the hydraulic oil reservoir to the proper level. 11 Follow the start up procedure outlined in section 2.8 before attempting to start the loader.

  • Page 76: Tandem Pump Parts Diagram 2.11

    TANDEM PUMP PARTS DIAGRAM 2.11 Sauer Sundstrand Series M25 PT Rear Pump (as located in machine) C2621 2-20...
  • Page 77 48. Cylinder block kit, items 37 ~ 45 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. 2-21...
  • Page 78 TANDEM PUMP PARTS DIAGRAM 2.11 Sauer Sundstrand Series M25 PT Front Pump (as located in machine) C2622 2-22...
  • Page 79 31. Cylinder block kit, items 20 ~ 28 16. Trunnion cover 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. 2-23...

  • Page 80: Drive Motor 2.12

    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 simi- lar to an internal gear that is held in a fixed position by securing it to the motor housing.
  • Page 81 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 82 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 83 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 84: Removal

    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. Oil drain plug Raise the loader securely off the ground.
  • Page 85 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 86: Final Drive

    DRIVE MOTOR 2.12 Replacement Clean sealing area Clean the mounting areas thoroughly that need to be sealed with silicone. (fig. C2078, C2424) C2078 Clean sealing area Apply a bead 1 / 4 of an inch thick around the drive motor bearing retainer and around each mounting hole. (fig.
  • Page 87 DRIVE MOTOR 2.12 IMPORTANT Refer to the torque chart in Section 8 when tighten- ing hydraulic hoses and fittings Brake hoses IMPORTANT Inspect fitting o-rings and flares for marks or dam- age. Replace if necessary. C2360a Install the adapter fittings to the drive motor. Install the brake lines to the drive motor.

  • Page 88: Parts Illustration

    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 89 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 90: Disassembly

    DRIVE MOTOR 2.12 Disassembly Mark sections Place the drive motor in a vise with the output shaft 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 91 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 92 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 93 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 94 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 95 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 96 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 97 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 98: Assembly

    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 12 Nm. (8.9 lbs / ft) (fig. C2322). Use new seals when assembling the motor.
  • Page 99 DRIVE MOTOR 2.12 Assembly 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 100 DRIVE MOTOR 2.12 Assembly (cont’d) Install the bearing housing bolts and torque to 46.5 lbs / ft. +/- 2 lbs / ft. (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 101 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 102 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 103 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 104 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 105 DRIVE MOTOR 2.12 Assembly (cont’d) Shuttle valve springs 25 Install the shuttle valve springs to either side of the piston. (fig. C2293). C2293 26 Install the shuttle valve plugs. (fig. C2292) Be sure to use new seals when assembling the motor. Seal Shuttle valve plug C2292...
  • Page 106 THOMAS 2-50...

  • Page 107: Trouble Shooting

    SECTION 3 FINAL DRIVE Specifications & Maintenance ....3.1 Chart ............pg. 3-2 Lubrication .
  • Page 108 SPECIFICATIONS & MAINTENANCE 3.1 Specifications Chain Size ............. ANSI 60HT Approved Chain Manufacturer ........Tsubaki Lubricating Oil ....10W30 API Classification SE/CD Oil Capacity (each)........7 Liters. (1.9 gal) Torque Specifications: Motor Sprocket Bolt........25 lbs /ft (34 nm) Wheel Nuts......100 - 110 lbs /ft (135 - 149 nm) Inspection Cover Nuts........12 lbs /ft (16.5 nm) Tire Pressure..........

  • Page 109: Lubrication 3.2

    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 110: 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 is measured at 1/4 ~ 2 inches (6 to 50 mm) free play.

  • Page 111: 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 112: Installation

    DRIVE CHAIN 3.3 Chain Installation Chain wrap Wrap the chain in a “Z” pattern (fig. C2273). Install the wrapped chain into the final drive housing. Place one end of the chain over the top of the axle sprocket. Rotate the axle by hand and bring the chain along the bottom of the final drive housing to approxi- C2273 mately the center.

  • Page 113: Drive Motor Sprocket 3.4

    DRIVE MOTOR SPROCKET 3.4 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 114 THOMAS...

  • Page 115: Axle Assembly 3.5

    AXLE ASSEMBLY 3.5 C1027 Axle Assembly Axle Wheel Stud Wheel Nut Seal Axle Sprocket (frt / rr) Bearing 10 Washer Race 11 Castle Nut Axle “Tower” 12 Cotter Pin...

  • Page 116: Removal

    AXLE ASSEMBLY 3.5 Axle Removal Remove control pedals and axle covers 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 axle is to be removed.

  • Page 117: Inspection

    AXLE ASSEMBLY 3.5 Axle Removal 14 Retrieve the inside bearing, sprocket and axle sprock- Rear sprocket et keys from inside the final drive housing. Please note the orientation of the axle sprocket on the Front sprocket axle and in the housing. Front and rear sprockets have a different offset.

  • Page 118: Installation

    AXLE ASSEMBLY 3.5 Axle Installation Check the axle seal surface area for damage. Minor scratches may be repaired using fine emery cloth. Inspect the axle threads for damage. Replace axle if the threads are non serviceable. Inspect the key way slots for wear. Replace the axle and keys if the keys do not fit tightly into the key ways.
  • Page 119 AXLE ASSEMBLY 3.5 Axle Installation (cont’d) Place the axle sprocket into the final drive housing, make sure the hub offset is facing the proper way to align the chain with the drive motor sprocket. 10 Apply gasket sealant to the outer edge of the axle oil seal.
  • Page 120 AXLE ASSEMBLY 3.5 Axle Installation (cont’d) Place washer on axle and start castle nut 14 Place the axle washer and castle nut onto the threaded end of the axle. (fig. C2434) Lightly tap the face of the axle flange, while holding the sprocket in position, if nec- essary to get the axle washer on and the castle nut started.

  • Page 121: 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 C209...

  • Page 122: Trouble Shooting 3.6

    TROUBLE SHOOTING 3.6 Problem Cause Corrective Action Section Final drive noisy. No lubricating oil. Check oil level. Add 10W30 SE/CD oil to correct level. Chain is loose. Adjust the chain tension. Check chain ten- sion every 150 hours. Axle has too much end Check and adjust the bearing pe-load on the play.

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