Thomas T175 Repair Manual
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Thomas T175 Repair Manual

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REPAIR MANUAL
T175/1700
Publication No. 49012
THOMAS

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  • Page 1 REPAIR MANUAL T175/1700 Publication No. 49012 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 49012...
  • 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: Maintenance

    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 technicians as flame or acid resistant clothing.

  • Page 5: Safety Precautions

    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 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 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 Specifications ......... .5.1 Wiring Schematics .

  • Page 11: Hydraulic Circuit

    SECTION 1 HYDRAULIC SYSTEM Hydraulic Circuit Layout ..............pg.
  • Page 12 HYDRAULIC LAYOUT 1.1 C4165 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: Schematic

    HYDRAULIC SCHEMATIC 1.1 C4191...
  • Page 14 Tilt Cylinder Rods ..........1.5’’ Diameter Lift Cycle Cyl. + / - 1.5 seconds (Up / Down) T175 ......5.50 / 3.56 Lift Cycle Cyl.
  • Page 15 GENERAL INFORMATION 1.2 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 Gear pump location hydraulic pump. • 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

    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. WARNING To prevent personal injury do not work under the boom arms without the boom supports engaged.
  • Page 17 GEAR PUMP 1.2 Disassembly C3835 1. Screws 2. Rear Cover 3. Backing Strip 4. Moulded Seal 5. Drive Gear 6. O-Ring Seal 7. Body 8. Front Plate...

  • Page 18: Gear Pump Reassembly

    GEAR PUMP 1.2 Disassembly (continued) General The following is a detailed procedure for dissambly and assembly of the SP2.5 pumps. Prior to proceeding it may be necessary to prepare some subassemblies seperately. The details for preparing each subassembly are given in the following section, as well as some general recommendations.
  • Page 19 GEAR PUMP 1.2 Disassembly (continued) 6. Procedure 1. Clamp the unit in a vice from the flange side Vice (fig. C3973). Make sure the vice jaws are clean and have smooth surfaces to prevent damage to the pump. Clamping the pump body is not recommended because serious damage to the surfaces, on which the ports are located, may occur.
  • Page 20 GEAR PUMP 1.2 Disassembly (continued) Push 6. Procedure 4. Place the pump on it’s side. While disassembling the unit, you need to mark the relative positions of the gear mesh (drive gear tooth and idler gear tooth) and the bearing blocks to the body so they can be reassembled in the same position.
  • Page 21 GEAR PUMP 1.2 Assembly 1. Have the entire seal kit available and layed 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 sealsin their grooves.
  • Page 22 GEAR PUMP 1.2 Assembly Blocks 6. Prepare the bearing blocks by cleaning both blocks (fig. C3983). Inspect the flat surfaces of the bearing blocks for burrs or scratches on the edges. If necessary, remove burrs with very fine emery paper. Then rewash the bearings.
  • Page 23 GEAR PUMP 1.2 Assembly 10. Remove any axcess lubrication and grease from the mating surfaces of the front flange and rear cover. Ensure that these surfaces are dry and free of contamination before moving on to the next step. 11. Install the four bolts through the rear cover then slide the assembly onto the rear of the housing (fig.

  • Page 24: Control Valve 1.3

    CONTROL VALVE 1.3 Testing and Adjusting the Relief Valve Pressure Hoses and gauges required for this test must be capable of withstanding 5000 PSI (207 Bar) continuous pressure, Flow Meter/Pressure Tester and hydraulic flow meter capable of measuring 30 gallons per minute.

  • Page 25: Control Valve Replacement

    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. Jam nut Turn the flow control valve further to restrict the oil flow to no flow.
  • Page 26 CONTROL VALVE 1.3 Remove the 3 nuts holding the control valve to the mount and remove the control valve. Remove any fittings left in the control valve. Cap all Valve mount plate open ports to prevent contamination. Place these fittings in the new or repaired control valve.

  • Page 27: Control Valve Disassembly / Repair

    CONTROL VALVE 1.3 Control Valve Disassembly (175) C3240 Diagram Legend 1. Control Box 2. Set Screws 3. Dust Cap Ass’y Kit 4. Check Valve 5. Main relief Valve 6. Lock Solenoid Coil 7. Auxiliary Solenoid Coil 8. Auxiliary Control With Coils 9.
  • Page 28 CONTROL VALVE 1.3 Control Valve Disassembly (1700) C3303 Diagram Legend 1. Control Box 2. Set Screws 3. Port Relief Valve 4. Check Valve 5. Main Relief Valve 6. Lock Solenoid Coil 7. Bar 1-18...
  • Page 29 CONTROL VALVE 1.3 Disassembly / Repair (175) 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 C3696 dirt from contaminating the control valve assembly.
  • Page 30 CONTROL VALVE 1.3 Disassembly / Repair 175 (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 31 CONTROL VALVE 1.3 Disassembly Repair 175 Spool O-Ring (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. C3718). C3718 Fit the seal washer to the control valve with the beveled side of the washer facing the control valve.
  • Page 32 CONTROL VALVE 1.3 Disassembly / Repair 175 Spool spring and bushings Detent (cont’d) 11 Install the spring return / centering cover and tighten the mounting screws evenly to 6.6 Nm (4.9 lbs / ft). Install the end cap to the cover and tighten to 9.8 Nm (7.2 lbs / ft).
  • Page 33 CONTROL VALVE 1.3 Disassembly / Repair 175 (cont’d) Spool Remove the solenoid spool assembly from the control valve. (fig. C3723) Note the effort required to remove the spool from the spool bore. It should come out smoothly without binding or “snagging” throughout it’s travel.
  • Page 34 CONTROL VALVE 1.3 Disassembly / Repair 175 Spring (cont’d) Piston Pull the flange and O-ring seal back toward the spring to expose the machined hex of the piston. Hold the hex with a wrench while removing the spring and spring bushings from the piston assembly.
  • Page 35 CONTROL VALVE 1.3 Disassembly / Repair 1700 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. C3744 Ensure all openings are plugged to prevent solvents and dirt from contaminating the control valve assembly.
  • Page 36 CONTROL VALVE 1.3 Disassembly / Repair 1700 (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 37 CONTROL VALVE 1.3 Disassembly / Repair 1700 Spool O-Ring (con’t) When replacing the spool to the control valve, use new O-ring seals and apply system 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 38 CONTROL VALVE 1.3 Disassembly / Repair 1700 (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 24 Nm (17.7 lbs / ft). (fig. C2254) C2254 11 Install the spring return / centering cover and tighten the mounting screws evenly to 6.6 Nm (4.9 lbs / ft).

  • Page 39: Hydraulic Cylinders 1.4

    HYDRAULIC CYLINDERS 1.4 T175 Shown Lift cylinder 1. Cylinder 2. Seal Kit 3. Cap, Cylinder End 4. Piston, Part B 5. Piston, Part A 6. Nut, Cyl. Hex Shaft 7. Bushing, Hardened 8. Grease Fitting, Straight 9. Bushing, Hardened 10. Grease Fitting, 90°...

  • Page 40: 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 41: Lift Cylinder Replacement

    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: C3601 IMPORTANT Cap all open lines and ports to prevent...

  • Page 42: 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.(fig. C3649) Loosen or remove the hydraulic hoses from hydraulic tubing under the boom arm step if you are changing the hoses also.

  • Page 43: 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 or on a pin held in the vice and support the front end of the body.
  • Page 44 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 45: Cylinder Inspection

    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 46 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 47: Oil Filter

    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 C3442 used.

  • Page 48: Oil Cooler

    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. C3443) Oil returning from the control engine radiator.

  • Page 49: Oil Reservoir

    HYDRAULIC OIL RESERVOIR 1.7 General Information Hydraulic oil The hydraulic oil reservoir is located at the rear of the reservoir loader on the left hand side. (fig. C3445) The reservoir is completely separated from all chain and gear drives to eliminate contamination.

  • Page 50: Servicing The Reservoir

    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 51: 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 52: 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. Auxiliary hydraulics Disengage. engaged. Cooling fan damaged or Check fan and drive belt inoperative 7.11 Engine RPM too low.

  • Page 53: Conversion Chart 1.10

    CONVERSION CHART 1.10 CONVERSION FACTORS Metric To U.S. MULTIPLY TO OBTAIN Area: sq. meter 10.763 91 square foot hectare 2.471 05 acre Force: newton 3.596 942 ounce force newton 0.224 809 pound force Length: millimeter 0.039 370 inch meter 3.280 840 foot kilometer 0.621 371...
  • Page 54 CONVERSION CHART 1.10 CONVERSION FACTORS U.S. To Metric MULTIPLY TO OBTAIN Area: sq. foot square meter 0.092 903 acre hectare 0.404 686 Force: ounce force newton 0.278 014 pound force newton 4.448 222 Length: inch millimeter 25.4 foot meter 0.304 8 mile kilometer 1.609 344...
  • Page 55 NOTES 1-45...

  • Page 56: Hydrostatic Drive System

    SECTION 2 HYDROSTATIC DRIVE SYSTEM Specifications Chart ..........pg. 2-3 General Information Introduction .

  • Page 57: Hydrostatic Circuit

    HYDROSTATIC CIRCUIT 2.1 Hydrostatic Circuit and System Pressure Schematic High Pressure Relieved at 345 Bar (5000PSI) Aux. Press. Relief Set at 2400 PSI (207 Bar) System Charge Pressure 200 PSI Minimum (13.8 Bar) Return Pressure Suction Line (Vacuum) 4 - 6 Hg @ 160ºF (71ºC) C4165...

  • Page 58: Specifications 2.1

    Hydrostatic Repair Manual ........

  • Page 59: General Information 2.2

    GENERAL INFORMATION 2.2 Introduction: Counterclockwise Variable displacement Fixed displacement swash plate rotation piston pump drive motor Case drain Clockwise input shaft rotation High pressure Charge pressure inlet High pressure High pressure C3760 When the swashplate begins to move the check valve on the dis- The driveshaft of the piston pump is rotated by the engine.

  • Page 60: Trouble Shooting 2.3

    TROUBLE SHOOTING 2.3 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 61 TROUBLE SHOOTING 2.3 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 62 TROUBLE SHOOTING 2.3 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 63 TROUBLE SHOOTING 2.3 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 64: Pressure Tests 2.4

    PRESSURE TESTS 2.4 The following photos show the various port locations available on the hydrostatic tandem pump for checking system pressure. Completing these pressure test will diagnose any mechan- ical problem in the hydrostatic system. LH side and top view Guage port B High pressure relief valves D and B WARNING...

  • Page 65: 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 position. To release the brake, turn the release plunger counter clockwise.

  • Page 66: Flushing The Hydraulic System 2.6

    FLUSHING THE HYDRAULIC SYSTEM 2.6 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: flush and clean thoroughly.
  • Page 67 FLUSHING THE HYDRAULIC SYSTEM 2.6 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 68 FLUSHING THE HYDRAULIC SYSTEM 2.6 For flushing water from the hydraulic system, perform the following procedures: Remove any attachment. Make sure all cylinders are fully retracted. Reservoir drain plug IMPORTANT Be sure attachments are removed and liftarm are in the lowered position. Change the hydraulic fluid.

  • Page 69: Start-Up Procedure 2.7

    START-UP PROCEDURE 2.7 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. C3431) The inlet hose from the oil reservoir to the charge should be filled with oil prior to starting.

  • Page 70: Gear Pump Replacement 2.8

    GEAR PUMP REPLACEMENT 2.8 Start the gear pump removal procedure by removing any Reservoir filler spout attachment, raising the boom arms and engaging the Vacuum 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 71: Tandem Pump Replacement 2.9

    TANDEM PUMP REPLACEMENT 2.9 Begin the pump removal by removing any attachment, Tandem case drain hose 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. Shut off the engine.
  • Page 72 TANDEM PUMP REPLACEMENT 2.9 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 73 TANDEM PUMP REPLACEMENT 2.9 10 Connect the tandem pump case drain fitting and Case drain connection hose. Torque the fittings and hoses to the specifications listed in the Torque Chart in Section 2.13 page 2 - 43. IMPORTANT When making repairs to the hydraulic system, keep the work area and parts clean.
  • Page 74 TANDEM PUMP REPLACEMENT 2.9 14 Reinstall the steering control linkages and locks as outlined in Section 4. and install access cover with 2 bolts. ( fig. C3485 ) Replace control linkage IMPORTANT Follow the start up procedure outlined in section 2.8 upon restarting after pump repairs or replacement.

  • Page 75: Tandem Pump Parts Diagram 2.10

    TANDEM PUMP PARTS DIAGRAM 2.10 Danfoss Series 40 Rear Pump 25 26 C1881 2-20 2-20...
  • Page 76 TANDEM PUMP PARTS DIAGRAM 2.11 Rear Pump Diagram C1881 Index Retaining ring Seal support washer Input seal Retaining ring For further service instructions refer to a Sauer Bearing Danfoss Dealer and request a Service / Repair Manual Drive shaft #BLN 9992 Bolt Cover O-ring seal...
  • Page 77 TANDEM PUMP PARTS DIAGRAM 2.10 Danfoss Series 40/ M44 Front Pump C2007 2-22...
  • Page 78 TANDEM PUMP PARTS DIAGRAM 2.10 Front Pump Diagram C2007 Index Retaining ring Seal support washer For further service instructions refer to a Sauer Input seal Danfoss Dealer and request a Service / Repair Manual Retaining ring #9992 Bearing Drive shaft Bolt Cover O-ring seal...

  • Page 79: Drive Motor 2.11

    DRIVE MOTOR 2.11 General Information C3873 GEROTER ASSEMBLY 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 80 DRIVE MOTOR 2.11 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 81 DRIVE MOTOR 2.11 The geroter (fig. C3487), is both a fluid displacement Roller (9) 8 point star 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 82 DRIVE MOTOR 2.11 For smooth and continuous motor output rotation, the C3488 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 83 DRIVE MOTOR 2.11 Removal Remove any attachment, raise the boom arms and Upper fill check engage the boom support pins. Raise the loader securely off the ground. Remove the wheels on the side to be repaired. Oil drain plug Drain the oil from the final drive housing. Be pre- pared to contain approximately 17 litres (4.5 gal) of fluid.
  • Page 84 DRIVE MOTOR 2.11 Removal 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. C3491) Hold the head of the bolts from inside the final drive housing. (fig. C3492) 13 Remove the drive motor.
  • Page 85 DRIVE MOTOR 2.11 Replacement Clean sealing area Clean the mounting areas thoroughly that need to be sealed with silicone. (fig. C3494, C3495) C3494 Clean sealing area C3495 Apply a bead 1/4 of an inch thick around the drive Apply silicone motor bearing retainer and around each mounting hole.
  • Page 86 DRIVE MOTOR 2.11 IMPORTANT Clean sealing area Refer to the torque chart in Section 2.13 when tight- ening hydraulic hoses and fittings IMPORTANT Inspect fitting o-rings and flares for marks or dam- age. Replace if necessary. C3495 Install the adapter fittings to the drive motor. Install the brake lines to the drive motor.
  • Page 87 DRIVE MOTOR 2.12 Parts Illustration C4168 TMT 500 FLV 1. Bolts 2. End Cover 3. Flushing Spool 4. Name Plate 5. Spacer 6. Springs 7. Restrictor 8. Spring Washer 9. O Ring 10. O Ring 11. Ring 12. Balance Plate 13.
  • Page 88 DRIVE MOTOR 2.12 Parts Illustration C4169 TMT 500 FLV 1. Screws 2. O Ring 3. Bearing Housing 4. Spring Plate 5. Piston 6. O Ring 7. Spacer Disc 8. Shaft Bearing Retainer 9. Screws 10. Outer Brake Disc 11. Inner Brake Disc 12.
  • Page 89 DRIVE MOTOR 2.11 Disassembly Stand unit on end and use a collar or vice to support shaft. (fig. C3505) C3505 Alternate the removal of each bolt (9) as the balance Bolts (9) plate will un-spring when the final bolt is removed. (fig. C3506) C3506 Lift off the end cover and note that the spacer may...
  • Page 90 DRIVE MOTOR 2.11 Disassembly (cont’d) Disk Valve Guide Pins(3) Bolts(9) Springs(5) Balance Plate Shuttle Housing Spacer C3509 Use a 6mm Allen key to remove the flushing valve Shuttle valve plug plug. (fig. C3510) C3510 Below the plug, the spring guide and the spring are easily removed.
  • Page 91 DRIVE MOTOR 2.11 Disassembly (cont’d) Carefully remove spool from the housing to avoid Spool scoring. (fig. C3513) C3513 Remember that the spool is set at an angel within the housing. (fig. C3514) Spool C3514 10 The second spring is deep within the housing. It is not necessary to remove this spring unless it is suspected Second Spring of failure.
  • Page 92 DRIVE MOTOR 2.11 Disassembly (cont’d) Retaining Drive Shaft Ring Channel Plate C3517 12 Remove the retaining ring, then the channel plate, RetainingRing and then lift off the drive shaft which will then expose the gearwheel and the Cardon shaft. (fig. C3518) Channel Plate C3518 13 With the drive section removed, losen the eight (8)
  • Page 93 DRIVE MOTOR 2.11 Disassembly (cont’d) Brake Disks 14 With the piston removed, the unit can be turned upside-down to remove the excess oil and the brake disks (inner and outer). (fig. C3527) C3527 15 With the brake disks removed it exposes the shaft Screws bearing retainer.
  • Page 94 DRIVE MOTOR 2.11 Disassembly (cont’d) 18 Complete disassembled unit. (fig. C3531) Complete disassembled unit. C3531 2-39...
  • Page 95 DRIVE MOTOR 2.11 Assembly The re-assembly of the motor is done opposite of the dissassembly. Support the housing and install the output shaft and bearing assembly. (fig. C3532). C3532 Install bearing retaining ring and tighten with Torx drive to 7ft/lbs. (fig. C3533) Install bearing C3533 Alternate installation of brake disks, first putting in...
  • Page 96 DRIVE MOTOR 2.11 Install spring plate (fig. C3536) C3536 Install brake cover and cross tighten all screws to Screws final torque specification of 65ft/lbs. (fig. C3537) C3537 Install Cardon shaft and gearwheel. (fig. C3538) C3538 With the gearwheel mounted and the cardon shaft in place, place the drive gear valley to valley with the gear- wheel.
  • Page 97 DRIVE MOTOR 2.11 Assembly Gear-roller stage of motor. Timing is important to ensure oil pressure/flow enters the correct chamber for proper drive/rotation. (fig. C3540) C3540 10 When preparing for timing, marker valley to valley Front cover in any location on shaft as shown (fig. C3541). C3541 11 Install guide pins on gearwheel (3) and fix channel plate onto gearwheer (fig.
  • Page 98 DRIVE MOTOR 2.11 Marker Guide 13 The timing is critical as the gearwheel valley cannot be seen. Use a marker point as a guide to offest 1 tooth counter-clockwise to the disk valve (fig. C3544). C3544 14 In the valve housing, install the 6 springs in the drilled holes (fig.
  • Page 99 DRIVE MOTOR 2.11 17 With a balance plate incorrectly installed other prob- lems such as a break in the valve housing may occur and damage other hydraulic components (fig. C3548). C3548 18 With the balance plate in the proper position and tapped down to seat, apply some vaseline or grease to prevent the spacer from falling out when installed onto the motor (fig.
  • Page 100 TORQUE CHART 2.12 NOTE: all torque specifications are in ft / lbs. (Multiply by 1.36 = N.m.) Hydraulic Fittings HOSE SIZE 37º JIC FITTINGS HOSE SIZE ORB FITTINGS 9 to 10 14 to 16 5/16 15 to 16 5/16 18 to 20 20 to 22 24 to 26 30 to 33...
  • Page 101 CONVERSION CHART 2.13 CONVERSION FACTORS Metric To U.S. MULTIPLY TO OBTAIN Area: sq. meter 10.763 91 square foot hectare 2.471 05 acre Force: newton 3.596 942 ounce force newton 0.224 809 pound force Length: millimeter 0.039 370 inch meter 3.280 840 foot kilometer 0.621 371...
  • Page 102 CONVERSION CHART 2.13 CONVERSION FACTORS U.S. To Metric MULTIPLY TO OBTAIN sq. foot square meter Area: 0.092 903 acre hectare 0.404 686 ounce force newton Force: 0.278 014 pound force newton 4.448 222 inch millimeter Length: 25.4 foot meter 0.304 8 mile kilometer 1.609 344...
  • Page 103 SECTION 3 FINAL DRIVE Specifications & Maintenance Chart ............pg. 3-2 Lubrication Checking the Oil .

  • Page 104: Torque Specifications

    SPECIFICATIONS & MAINTENANCE 3.1 Specifications Chain Size ..................... ANSI 100 Approved Chain Manufacturer..............Tsubaki Lubricating Oil............10W30 API Classification SJ Oil Capacity (each) ..............17 Liters. (4.5 gal) Torque Specifications: Motor Sprocket Bolt ..............25 lbs /ft (34 nm) Wheel Nuts............100 - 110 lbs /ft (135 - 149 nm) Tire Pressure................

  • Page 105: Final Drive

    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 the top (upper) check plug located between the 2 tires at the side of the loader. (fig. C3496) Lower drain plug The oil level should be at the top of the check hole with a little to trickle out.

  • Page 106: Drive Chain 3.3

    DRIVE CHAIN 3.3 Chain Inspection The drive chains should be inspected for wear or damage after the first 50 hours of operation and every 150 hours Sprocket thereafter, or at any time the final drive inspection cover Connection is removed. If the chain shows any sign of wear or dam- Link age replace it.
  • Page 107 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 108 DRIVE CHAIN 3.3 Chain Installation Install the wrapped chain into the final drive housing. (fig. C3812) Place one end of the front chain over the top of the C3812 front axle sprocket. Rotate the axle and bring the chain along the bottom of the final drive housing to approxi- mately the center.

  • Page 109: Drive Motor Sprocket 3.4

    DRIVE MOTOR SPROCKET 3.4 Remove inspection cover 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 110: Axle Assembly 3.5

    AXLE ASSEMBLY 3.5 C3235 Axle Assembly 1. Axle Puller 10. Wheel Stud 2. Seal Installation Tool (2) 11. Plate, Axle Washer 3. Axle Ass’y 12. Washer, Axle 4. Seal 13. Castle Nut 5. Bearing, Cup 14. Cotter Pin 6. Plate, Axle Spacer 15.
  • Page 111 AXLE ASSEMBLY 3.5 Axle Removal Axle Cover 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 AXLE ASSEMBLY 3.5 14 Attach a special axle puller tool, Thomas P/N 957372, to the axle flange wheel studs using the wheel nuts that are on the loader. (fig. C3807) 15 Using the slide hammer action of the special puller, remove the axle.
  • Page 113 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.(fig. C3799) Inspect the splined teeth for wear. Replace the axle if the splined teeth do not fit tightly into the sprocket spline.
  • Page 114 AXLE ASSEMBLY 3.5 10 Guide the axle into the final drive housing. 11 Place 2 seal installation tools, Thomas P/N 958674, equally spaced around the axle flange, behind the seal. (fig. C3671). This special tool must be used to properly locate the seal into the final drive housing.
  • Page 115 AXLE ASSEMBLY 3.5 14 Tighten the castle nut and guide the axle into the 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. As the castle nut is being tightened the rear (inside) bear- ing is being pressed into place and the axle oil seal is simultaneously pulled into the proper location into the...

  • Page 116: Stud Replacement

    AXLE ASSEMBLY 3.5 Axle Stud Replacement Remove any attachment, raise the boom arms and engage the boom locks. Raise and block. Clear the side of the loader the wheel studs are to be changed on. Remove the wheel the studs are to be replaced on. Strike the stud with a hammer to remove from the axle flange.

  • Page 117: 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. Axle has too much end Check and adjust the bearing pre-load on play. (Bearing pre-load) the axle bearings No drive on one side.
  • Page 118 SECTION 4 CONTROLS Steering Steering Control System Illustrations ....... . . pg. 4-2, 4-3 Neutral Adjustment .

  • Page 119: Steering 4.1

    STEERING 4.1 Control Levers 175 C3227 Handle, Ergonomic Plain Washer, Lock Rod End Ass’y, Female Handle, Ergonomic w/Rocker Switch Washer, Flat Rod End Ass’y, Female Lever Base Welded Ass’y Washer, Fender Nut, Nylok Bolt, Hex. Flange Bushing Bolt, Ergonomic Handle (w/Hole) Jam Nut, Locking Hydroback Ass’y Bolt, Ergonomic Handle (No Hole)
  • Page 120 STEERING 4.1 Control levers 1700 C3300 Handle, Control Washer, Lock Rod End Ass’y, Female Lever Base Welded Ass’y Washer, Flat Rod End Ass’y, Female Bolt, Hex. Washer, Fender Nut, Nylok Jam Nut, Locking Flange Bushing Bolt, Hex Clevis Hydroback Ass’y Washer Cotter Pin Bar, Pintle Linkage L.H.

  • Page 121: Neutral Adjustment

    STEERING 4.1 Neutral Adjustment Remove mounting bolt 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 122 STEERING 4.1 Neutral Adjustment (con’t.) Hydroback assembly Loosen the 2 jam nuts next to the main body. (fig. Rod ends C3555) Turn the 2 nuts away from the main body of the hydroback. Cycle the control lever several times. 2 jam nuts Push the control lever rearward until you feel resis - tance.
  • Page 123 STEERING 4.1 Neutral Adjustment Before performing the neutral adjustment make sure Control rod linkage the hydro back is functioning and adjusted properly. Refer to page 4-4. IMPORTANT If you are unfamiliar with the control operations of the loader, read the Owner’s / Operator’s Manual beforehand.

  • Page 124: Tracking Adjustment (Speed)

    Raise the loader securely off the ground before start- ing the engine. Using an RPM surface speed measuring tool (Thomas P/N 43981) check each wheel speed in the for- ward and reverse direction. Repeat for opposite side. (fig. C3560) Correct wheel speed is set evenly at 83 RPM forward and reverse for both sides.

  • Page 125: Control Lever Replacement

    STEERING 4.1 Control Lever Replacement Raise the boom arms, engage the boom supports and shut off the engine. Raise the loader securely off the Control lever cover 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 126: Foot Pedals 4.2

    FOOT PEDALS 4.2 C3228 1. Bar, Foot Pedal Shaft 13. Bolt, Hex 2. Screw, Cap, Hex Socket head, Stainless 14. Washer, Lock 3. Dampener, Self-Centering, 9 lbs. 15. Activator, R.H. Ass’y 4. Pedal, Lift Ass’y (L.H.) 16. Bearing 5. Pedal, Lift Ass’y (R.H.) 17.

  • Page 127: Angle Adjustment

    FOOT PEDALS 4.2 Angle Adjustment The foot pedal angle can be verified and / or adjusted to Jam nut provide operator comfort and proper pedal travel clear- ance. Cable Rod End Note: If the operator feels discomfort due to current pedal angles, they may be adjusted to their preference.
  • Page 128 FOOT PEDALS 4.2 Foot Pedal Replacement If the foot pedals or shaft need replacement due to dam- age or wear. Each pedal has it’s own shaft. Raise the boom arms, engage the boom supports and shut off the engine. WARNING Never work under the boom arms without the boom Bolt supports engaged.

  • Page 129: Hand Controls 4.3

    HAND CONTROLS 4.3 175 Shown Ergonomic Handle 13. Hex Bolt 30. Lock Washer Lever Base 14. Bolt 31. Nylok Nut Hex Bolt 15. Lock Washer 32. Female Rod End Locking Jam Nut 16. Flat Washer 33. Female Rod End Clevis (Hand Control 17.

  • Page 130: Cable Replacement

    HAND CONTROLS 4.3 Cable Replacement Check cable ends, eyelets or rod ends, and mounting pins for wear before removing the cable. Replace worn parts when replacing new cables. Cable ends should be inspect- ed every 150 hours of operation. Raise the boom arms, engage the boom supports and shut off the engine.

  • Page 131: Angle Adjustment

    HAND CONTROLS 4.3 Angle Adjustment After changing the control cable the control lever angle will need to be verified and / or adjusted to provide oper- ator comfort and proper pedal travel clearance.Ensure the loader is parked on a level surface. Make sure the cable ends are screwed onto the cable threads a minimum of 3/8’’...
  • Page 132 HAND CONTROLS 4.3 Control Lever Replacement 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 and hydrostatic shield. Control Lever Cover Remove control lever plates and boots.

  • Page 133: Throttle

    THROTTLE 4.4 C3215 1. 56” Cable, Turn To Lock 2. Joint, Ball Socket 3. Nut, Hex 4. Pin, Spring 5. Washer, Flat 6. Linkage, Reverse Ass’y. 7. Joint, Ball Socket 8. Bar, Throttle Linkage 9. Bushing 10. Pivot, Throttle Ass’y 11.

  • Page 134: Throttle 4.4

    THROTTLE 4.4 Adjustments The throttle system can be adjusted for total travel (stroke). The throttle cable can be set and locked in the full throttle position. Bolt WARNING Never work under the boom arms without the boom supports engaged. Bolt C3568 C3569 TO CHECK THE THROTTLE TRAVEL:...
  • Page 135 THROTTLE 4.4 Throttle Cable Replacement Seat assembly Raise the boom arms, engage the boom supports and shut off the engine. Hydrostatic Shield WARNING Never work under the boom arms without the boom supports engaged. Remove the seat and hydrostatic shield.(fig. C3557) Remove the tee handle, nut and washer holding the C3557 assembly in place.

  • Page 136: Restraint Bar 4.5

    RESTRAINT BAR 4.5 1. Nut, Jam 2. Nut, Nylok 3. Stud. Ball 4. Gas Spring 5. Switch, Dual 6. Screw, Self Tapping 7. Washer, Lock 8. Restraint Bar Ass’y 9. Spacer 10. Lockwasher 4-19...
  • Page 137 RESTRAINT BAR 4.5 Gas Spring Replacement The restraint bar is held up, over head, by means of a gas Gas spring assist type strut. (gas spring) (fig. C3571) If the seal in the strut has deteriorated and failed, or the strut rod has been damaged, the restraint bar will not stay Mounting nut in the upright position due to gas pressure loss.

  • Page 138: Restraint Bar 4.5

    RESTRAINT BAR 4.5 Restraint Bar Replacement Lower the liftarms and park the loader on a level sur- Restraint bar mounts face. Shut off the engine. Remove the nut from the upper gas spring pivot ball. (fig. C1105, C3573) Remove the mount and gas spring together allowing the restraint bar to lower.

  • Page 139: Parking Brake

    PARKING BRAKE 4.6 General Information Seat pressure switch Each drive motor contains a set of clutch pack type fric- tion discs that are spring loaded in the engaged position. The parking brake is inter locked with various safety switches. (fig. C807, C3573, C3574, C3575) The parking brake will only release when the engine is operating, the operator is seated with the seat belt fastened and the restraint bar is in the lowered position.

  • Page 140: Trouble Shooting 4.7

    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...
  • Page 141 NOTES THOMAS...
  • Page 142 SECTION 5 ELECTRICAL Specifications General Information..............pg. 5-2 Wiring Schematic ROPS Harness ............... pg. 5-3, 5-5 Engine Harness..............pg. 5-6, 5-8 Instrumentation Left Hand Dash Panel..............pg. 5-9 Switch and Bulb Replacement............pg. 5-9 Right Hand Dash Panel ............... pg. 5-10 Fuel Gauge..................

  • Page 143: Specifications 5.1

    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 144: Wiring Schematics

    WIRING SCHEMATIC 5.2 ROPS Harness Connector Diagram C1741 Legend. Shown is the wire color and function of each pin terminal in the connector plug. WIRE COLOR FUNCTION Purple Eng. oil press. indicator White Ignition (30) Red / Wht Ignition (19) Blk / Wht Ignition (acc) Ignition (50)
  • Page 145 WIRING SCHEMATIC 5.2 C4187 ROPS Electrical Wiring 175 1. Electrical Harness, Rops 2. Light Kit Harness 3. LH Instrument Panel 4. RH Instrument Panel 5. Indicator Bulb panel 6. Hour Meter 7. Fuel Gauge 8. Ignition Switch 9. Switch, Headlights 10.
  • Page 146 WIRING SCHEMATIC 5.2 ROPS Electrical Wiring 1700 C3688 1. Electrical Harness, Rops 2. LH Instrument Panel 3. RH Instrument Panel 4. Indicator Bulb panel 5. Hour Meter 6. Fuel Gauge 7. Ignition Switch 8. Switch, Headlights...
  • Page 147 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 Blk / Wht Fuse block Red / Wht Glow plug relay White Circuit breaker Purple...
  • Page 148 WIRING SCHEMATIC 5.2 Engine Electrical Wiring 175 C4188 1. Engine Wire Harness 2. Light Kit Harness 3. Electrical Box Assy 4. Fuse Panel & Circuit Breaker 5. Relay 6. Black Knob w/Brass Insert...
  • Page 149 WIRING SCHEMATIC 5.2 C3690 Engine Electrical Wiring 175 1. Engine Wire Harness 2. Electrical Box Assy & Circuit Breaker 3. Fuse Panel 4. Relay 5. Black Knob w/Brass Insert...

  • Page 150: Instrumentation 5.3

    INSTRUMENTATION 5.3 Legend for fig. C3577 Retaining Screw LH Turn Signal Aux. Hydraulic Indicator Hi-Flow Hydraulic Indicator Headlight Indicator RH Turn Signal Hyd. Oil Temperature Indicator Parking Brake Indicator Seat Belt Indicator Hyd. Charge Pressure Indicator 10 Strobe Light Indicator 11 Engine Oil Pressure 12 Engine Coolant Temperature 13 Alternator Indicator...
  • Page 151 INSTRUMENTATION 5.3 Replacement Fuel gauge Hour meter To replace a faulty gauge, meter or switch in the right hand dash panel: Disconnect the battery cable connection. Remove the 3 screws retaining the dash panel to the Screw dash pod. (fig. C3580) Access the rear of the dash panel.
  • Page 152 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 153: 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 154: Engine Glow Plugs 5.5

    ENGINE GLOW PLUGS 5.5 Testing the Glow Plugs Before performing any test on the glow plugs, disconnect Glow plug location the ground wire from the battery. 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.

  • Page 155: Battery 5.6

    BATTERY 5.6 Removal and Inspection Mounting bolt The batteries are located in the ROPS behind the opera- tors seat. To remove the battery: Remove the seat mount retaining bolts and discon- nect the seat switch wiring harness. (fig. C3557) Pull up and toward the front of the loader and remove the seat.
  • Page 156 BATTERY 5.6 Removal and Inspection Check and clean 10 Inspect the battery case for cracks that may allow electrolyte to leak into the environment. Inspect the batteries on a regular basis for damage such as cracks or a broken case. Inspect the battery cables for tightness and corrosion.

  • Page 157: 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 underneath of the engine cover. (fig. C3588) To access the electrical panel: Fuse panel access knob Open the rear door and raise the engine cover.
  • Page 158 STARTING CIRCUIT 5.8 C3852 5-17...

  • Page 159: Charging Circuit 5.9

    CHARGING CIRCUIT 5.9 C3853 5-18...

  • Page 160: Safety Circuit 5.10

    SAFETY CIRCUIT 5.10 1700 C3855 5-19...
  • Page 161 SAFETY CIRCUIT 5.10 General Information Seat switch The loader is equipped with 3 inter - connected safety switches. These 3 switches operate 2 electric solenoid controlled lock devices. One (1) solenoid coil on the hydraulic brake valve (fig. C3575), one (1) pair of sole- noid coils on the hydraulic control valve (fig.

  • Page 162: Auxiliary Circuit

    ELECTRIC AUXILIARY CIRCUIT 5.11 Auxiliary Switch Auxiliary Indicator Ignition Switch Battery Auxiliary Solenoid HITE Circuit Breaker Fuse Panel Auxiliary Solenoid Control Handle C2086 5-21...
  • Page 163 ELECTRIC AUXILIARY CIRCUIT 5.11 THE ERGONOMIC HANDLE CONTROL: Rocker Switch The Ergonomic Handle contains 3 switches: 1 rocker switch (fig. C3861) and 2 push button switches. (fig. 3860) The handle is normally installed only on the left hand control lever for the 175 loader. When installed on the L.H.
  • Page 164 ACCESSORIES CIRCUIT 5.12 C3859 5-23...

  • Page 165: Trouble Shooting 5.13

    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 166 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 167 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............... pg. 6-7 ROPS (Cab) Removal..................

  • Page 168: Quick - Tach 6.1

    QUICK - TACH 6.1 C2649...

  • Page 169: Preventative Maintenance

    QUICK - TACH 6.1 Preventative Maintenance To keep the quick - tach locking pins and mechanism Grease lock pin assembly (L & R) working freely, and to prevent pin and bushing wear, the quick tack must be lubricated every 8 hours of operations. More often in dirty applications.

  • Page 170: Removal

    QUICK - TACH 6.1 Removal Extend tilt cylinders Remove any attachment and lower the boom arms. Start the engine and extend the hydraulic tilt cylin- ders approximately 12 inches. (fig. C3880) Shut off the engine and engage the parking brake. Remove the bolts retaining the upper pivot pins to the quick - tach frame until the quick-tach is level and the pins removed.

  • Page 171: Disassembly

    QUICK - TACH 6.1 Disassembly Q / T handle bolts 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 172: Boom Arms 6.2

    BOOM ARMS 6.2 Removal Disconnect hoses, both sides 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 173: Boom Support

    BOOM ARMS 6.2 Boom Arm Supports Boom support pin For safety while performing regular service or mainte- nance work, the loader is equipped with boom supports. Boom arm (fig. C3597) The boom supports, when extended, prevent plate the boom arm from lowering when servicing the hydraulic system, controls or other repair work while the engine is not operating.

  • Page 174: Rops 6.4

    ROPS 6.4 Removal Lower the boom arms, shut off the engine and engage the parking brake. Remove the seat assembly and the hydrostatic shield and disconnect the battery terminals as outlined in Section 5. Disconnect the ground cable from the mainframe and engine.

  • Page 175: Rear Door 6.5

    REAR DOOR 6.5 Rear Door Assembly Bearing Set Collar Bolt Rear Door Lock Assembly Lock Nut Flat Washer Handle 10 Lever Grip 11 Bolt 12 Bearing 13 Pivot Pin 14 Split Spring Pin 15 Bolt 16 Door Guide Plate 17 Flat Washer 18 Lock Nut C3197 Removal...
  • Page 176 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 177: Engine Maintenance

    ENGINE MAINTENANCE 7.1 Lubrication System Access the engine compartment Engine Oil and Filter: Engine oil and filter changes should be made with the engine warm. Change the engine oil every 75 hours and the oil filter every 150 hours of operation. Park the loader on a level surface, lower the boom arms, engage the parking brake and shut off the engine.
  • Page 178 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. C3613) Add 7.5 liters (8qts) of 10W30 API classification SE / CD engine oil. Replace the fill cap in the rocker arm cover.

  • Page 179: Fuel System

    ENGINE MAINTENANCE 7.1 Fuel System Fuel Filter: The fuel filter is a spin on type on the inner side of the oil tank attached to a bracket and is located in the engine compartment on the engine mounting bracket. Change the fuel filter every 400 operating hours.
  • Page 180 ENGINE MAINTENANCE 7.1 Fuel System (cont’d) Fuel line shut off petcock 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 £) of fuel.

  • Page 181: Daily Checks

    ENGINE MAINTENANCE 7.1 Air Filter Inlet Cover The loader is equipped with dual dry cartridge, radial seal type filter elements. The larger outside element is called a Vacuator primary and the one inside of the primary is referred to as valve a safety element.
  • Page 182 ENGINE MAINTENANCE 7.1 Air Filter (cont’d) Safety air filter element If required, remove the safety air filter element by pulling straight out of the air cleaner housing. (fig. C3621) After removing the air filter elements, carefully wipe out any excess dirt from the air cleaner housing. (fig. C3622) Check the air filter element seal before installing to the air cleaner housing.

  • Page 183: Maintenance

    ENGINE MAINTENANCE 7.1 Cooling System Radiator cap 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.

  • Page 184: Cylinder Head

    ENGINE MAINTENANCE 7.1 Cooling System (cont’d) Pressurizing the Attach a radiator tester and increase the pressure to cooling system 0.9 kg / cm (12.8 psi).(fig. C172) Inspect the radiator, hoses and engine block for external leaks. Repair as required. Attach a radiator tester to the radiator cap. (fig. C173) Apply 0.9 kg / cm (12.8 psi ) pressure to the radia- tor cap.

  • Page 185: Maintenance 7.7

    MAINTENANCE 7.7 Fan Belt Adjustment 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 rubber are observed. Failure to replace the drive belt could lead to slippage or complete failure, causing the engine to over heat and lead to extensive repairs.
  • Page 186 ENGINE MAINTENANCE 7.1 Universal Joint U-Joint service access panel bolts 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 with a standard grade of muti purpose grease.

  • Page 187: Cylinder Head 7.2

    CYLINDER HEAD 7.2 Valve Adjustment Rotate the engine after checking / setting cylinder The engine used in this application uses a solid lifter (tap- number 4 valves, until cylinder number 4 intake valve pet) design that requires periodic maintenance of the start to open.

  • Page 188: Specifications

    CYLINDER HEAD 7.2 Compression Testing Testing the engine for compression is not a normal part of a scheduled maintenance procedure, but is important when trying to diagnose engine power or unusual perfor- mance related problems with the engine. Before performing a compression test, be sure the bat- Injector pipe tery is fully charged and valve clearances are correctly adjusted.
  • Page 189 The cylinder head should be removed for further inspection. See the Kubota Service / Repair Manual P / N 97897-109-5 or Thomas P / N 40916. C179 Cylinder Head After replacement of the engine cylinder head, the proper Cylinder head bolt torque sequence bolt torquing sequence must be followed.
  • Page 190 ENGINE REPLACEMENT 7.3 Removal Access panel mounts 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, hydrostatic shield and U- Joint ser- vice access panel.
  • Page 191 ENGINE REPLACEMENT 7.3 Removal (cont’d) Disconnect the air filter restrictor sensor wires locat- ed at the rear of the air cleaner canister. Remove the exhaust system from the loader. Cover or plug any open exhaust ports to the engine. Air Cleaner Canister 10 Remove the air cleaner canister assembly.
  • Page 192 ENGINE REPLACEMENT 7.3 Removal (cont’d) 13 Disconnect the ground straps (cables) mounted from the engine to the loader frame. Starter terminals 14 Disconnect the engine starter cable coming from the positive terminal of the battery. (fig. C3634) C3634 15 Disconnect the electrical cable from the boosting lug terminal.
  • Page 193 ENGINE REPLACEMENT 7.3 Removal (cont’d) Hydraulic temperature sender 17 Disconnect the hydraulic oil temperature sender located on the left hand oil tank, inside the engine com- partment. (fig. C3636) C3636 18 Disconnect the throttle linkage. (fig. C3637) Disconnect throttle linkage C3637 Engine mounting bolt 19 Remove the 4 bolts retaining the engine to it’s rub-...
  • Page 194 ENGINE REPLACEMENT 7.3 Installation Remove protective coating 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. (fig. C3641) Use a solvent to remove. The flywheel must be cleaned to the surface metal. Install the engine U- Joint adapter.
  • Page 195 ENGINE REPLACEMENT 7.3 Installation 14 Install the engine to the loader. (fig. C3639) Have a helper inside the cab to line up the engine U- Joint to the hydrostatic pump input shaft. (fig. C3644) Align the engine U-Joint in a straight line with the hydrostatic pump.
  • Page 196 ENGINE REPLACEMENT 7.3 Stop Solenoid Stop lever cover bolts The engine stop solenoid requires special attention when replacing. If not properly adjusted, the stop sole- noid will fail prematurely. Remove the 4 bolts retaining the engine stop cover and lever assembly. (fig. C2225) Remove the cover. Knock out the roll pin retaining the stop lever to the stop cover.
  • Page 197 ENGINE REPLACEMENT 7.3 Stop Solenoid (cont’d) Install stop cover and mounting bracket Attach the stop solenoid to the shut off lever making Spacer washers sure the cable tie around the solenoid dust boot is facing down , away from the mounting bracket. (fig. C2277) Failure to do so may cause the solenoid to bind and fail prematurely.
  • Page 198 ENGINE SPECIFICATIONS T175 7.3 Make and model ........................Kubota V2003-T-B Type..........................Vertical , In Line, 4 Cycle Number of cylinders............................4 Displacement ........................19.99 cu. in.(122.12cc) Cylinder bore........................83 mm (3.27 inches) Allowable limit: 80 ~ 80.034mm. ( 3.1496 ~ 3.1563 inches) Stroke..........................92.4 mm (3.64 inches) Bearing clearance..Main journals: 0.04 ~ 0.118mm (0.0006 ~ 0.0015 in) <...
  • Page 199 ENGINE SPECIFICATIONS PT1700 7.4 Make and model ..........................Kubota V2203 Type ..........................Vertical , In Line, 4 Cycle Number of cylinders............................4 Displacement ........................134.08 cu. in.(2197cc) Cylinder bore........................87 mm (3.43 inches) Allowable limit: 80 ~ 80.034mm. ( 3.1496 ~ 3.1563 inches) Stroke..........................92.4 mm (3.64 inches) Maximum engine speed (no load) ......................2950 RPM Low idle setting...........................1000 RPM Cooling system ............................Liquid...

  • Page 200: Trouble Shooting

    ENGINE TROUBLE SHOOTING 7.5 Remedy Symptom Cause Replenish fuel Engine does not start No fuel Vent air Air in the fuel Change fuel and repair or replace Water in the fuel fuel system Clean Fuel pipe clogged Clean or change Fuel filter clogged Use the specified fuel or engine oil Excessively high viscosity of fuel or engine oil at...
  • Page 201 ENGINE TROUBLE SHOOTING 7.5 SYMPTOM PROBABLE CAUSE SOLUTION Excessive lubricant oil consumption Piston rings gap facing the same direction Shift gap direction 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 Fuel mixed into lubricant oil Injection pump’s plunger worn...

  • Page 202: Maintenance & Specifications

    SECTION 8 MAINTENANCE & SPECIFICATIONS Maintenance Preventative Maintenance Schedule..........pg. 8-2 Service Access................pg. 8-3 ~ 4 Daily Service ..................pg. 8-5 50 Hour Service ................pg. 8-6 ~ 7 Trouble Shooting Hydrostatic Drive ................pg. 8-8 Final Drive..................pg. 8-8 Parking Brake ..................

  • Page 203: Maintenance 8.1

    MAINTENANCE 8.1 8.1 Preventative Maintenance Service Schedule ITEM SERVICE REQUIRED Engine Oil Check level. If necessary add 10W30 API Classification CF oil. Radiator Check level and add if necessary. Fill with 50% mixture of ethylene glycol and water. Check cooling fins for dirt. If necessary blow out with compressed air. Check rubber seal around radiator baffle.
  • Page 204 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 C693 pins.
  • Page 205 MAINTENANCE 8.1 IMPORTANT Keep the rear door closed except for servicing. Make sure the door is closed and latched before operating the loader. C3427 Door Handle Locked Unlocked C3427 1.2D Universal Joint Access After removal of the operators seat, the U-joint service / U-joint access panel retaining nuts inspection panel can be accessed.

  • Page 206: Daily Service

    MAINTENANCE 8.1 8.1.3 DAILY SERVICE CHECK 1.3E Safety Equipment Check all safety equipment for proper operation and con- dition - seat belt, boom support, seat bar, foot pedal lock, 1.3A Radiator Service parking brake, quick tach lock, shields and safety treads. Lubricate all linkages, springs and pivot points with a sili- With the engine cool remove the radiator cap and check the cone based lubricant.
  • Page 207 MAINTENANCE 8.1 8.1.4 50 HOUR SERVICE CHECK The following service check is to be performed by your dealer after the first 50 hours of operation. Engine Hydraulic/Hydrostatic 1.1 Oil Filter: 2.1 Hydraulic Oil Filter: Change the engine oil filter. Use only original replace- Change the hydraulic oil filter.

  • Page 208: 4.4 Parking Brake

    If necessary, replace. If the safety con- For your safety, the loader is equipped with electrically trols are malfunctioning or require adjustment consult activated safety devices through the seat and seat belt. your Thomas Equipment Dealer for service. See Section 5. 7.5 General Condition: Electrical Make a general inspection of the machine looking for 5.1 Battery:...

  • Page 209: Troubleshooting 8.2

    No power to brake Check fuse, If fine, con- Gradual loss Excessive Consult dealer or Brake will not valve solenoid sult Dealer or Thomas of power as internal Thomas Service release machine Service Dept. machine leakage in Dept.

  • Page 210: Hydraulic System

    TROUBLESHOOTING 8.2 8.2D Hydraulic System 8.2D Hydraulic System Symptom Cause Remedy Symptom Cause Remedy Hydraulic Reservoir low on Replenish with 10W30 Loss of Reservoir low on Replenish with 10W30 action jerky API or 20W50 SF oil. hydraulic fluid. Hose or fitting or 20W50 API SJ oil.

  • Page 211: 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 212: 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 213 TROUBLESHOOTING 8.2 8.2G Diesel Engine Symptom Cause Remedy 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 plunger worn Replace pump element or pump...

  • Page 214: Special Tools 8.3

    Quantity - 3 required T103 AXLE EXTRACTOR TOOLS - To remove axle 955283 T135 from final drive housing. T173HLS’ T173HL’S’II Quantity - 2 T175/1700 T203HD T233HD T243HDS SEAL INSTALLATION TOOL - To install axle 955287 T173 seal in final drive housing. T233...
  • Page 215 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 216 SPECIAL TOOLS 8.3 P / N Illustration Description Model 42530 DEUTZ TOOTHED BELT TENSION GAUGE T243HDS For adjusting the timing belt to proper T245HDS tension. C754 42531 DEUTZ LOCATING PINS T243HDS For locating crankshaft and camshaft T245HDS when changing / adjusting timing belt. C816 42535 DEUTZ...
  • Page 217 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 FORCE GAUGE, PUSH PULL T173HLS For measuring restraint bar brake cable T173HLS II adjustment.
  • Page 218 NOTES THOMAS 8-17...

  • Page 219: Specifications 8.4

    SPECIFICATIONS 8.4 LOADER SPECIFICATIONS -175 Dimensions A. Overall operating height ........... . 168”...

  • Page 220: Loader Specifications

    SPECIFICATIONS 8.4 LOADER SPECIFICATIONS -1700 1700 Dimensions A. Overall operating height ........... . 168”...
  • Page 221 SPECIFICATIONS 8.4 Engine Make and model............................Kubota V2003T-B Type...............................Verticle , In Line, 4 Cycle Number of cylinders ................................4 Cylinder bore ............................83 mm (3.27 inches) Stroke..............................92.4 mm (3.64 inches) Displacement .............................122.12 cu. in.(1999cc) Maximum engine speed (no load) ........................2950 RPM Low idle setting..............................1000 RPM Cooling system ................................Liquid Horsepower (Gross) ...........................58 @ 2800 RPM Power (ISO 9249 Net Power)....................41.8Kw (56 hp) @ 2800 RPM...
  • Page 222 SPECIFICATIONS 8.4 1700 Engine Make and model..............................Kubota V2203 Type...............................Verticle , In Line, 4 Cycle Number of cylinders ................................4 Cylinder bore ............................87 mm (3.43 inches) Stroke..............................92.4 mm (3.64 inches) Displacement ............................134 cu. in.(2197cc) Maximum engine speed (no load) ........................2950 RPM Low idle setting..............................1000 RPM Cooling system ................................Liquid Horsepower (Gross) ..........................49.5 @ 2800 RPM Power (ISO 9249 Net Power)....................34.3 Kw (46 hp) @ 2800 RPM...
  • Page 223 SPECIFICATIONS 8.4 Hydrostatic Transmission & Final Drive Pump type ...........................Two in line, axial piston pumps Pump displacement ..........................2.65 cu. in. (44 cm Motor type .................................Geroter Motor displacement .........................31.9 cu. in. (523.6 cm System relief setting ..........................5000 PSI (345 bar) Final drive ...................(2 of) Single roller chain running in oil bath to each axle Drive chain size ..............................ASA 100 Electrical Alternator..................................40 amp...
  • Page 224 SPECIFICATIONS 8.4 Torque Specifications Loader Wheel nuts (24) ............100 - 110 ft lbs. (136 - 139 Nm) Motor mount isolators (4) .

  • Page 225: Decals 8.5

    DECALS 8.5 175 DECAL CHART 8-24...
  • Page 226 DECALS 8.5 175 DECAL CHART 8-25...
  • Page 227 DECALS 8.5 175 DECAL CHART 8-26...
  • Page 228 DECALS 8.5 1700 DECAL CHART 8-27...
  • Page 229 DECALS 8.5 1700 DECAL CHART 8-28...
  • Page 230 DECALS 8.5 1700 DECAL CHART 8-29...
  • Page 231 NOTES THOMAS 8-30...

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