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Thomas 135 - User Manual

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

Table of Contents

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Summary

Thomas Equipment Liability Warranty

Foreword

Safety Precautions

Personal Safety Considerations

Personal protective measures for operator safety, covering clothing, skin, eye, breathing, hearing, hand, and foot protection.

Equipment Safety Considerations

Safety measures related to machine parts like guards, lifting appliances, and compressed air usage.

Hand Tools Safety

Guidelines for safe usage of hand tools to prevent injury and ensure proper job execution.

Electrical Safety

Precautions for handling electrical equipment and avoiding potential hazards like worn cables or plugs.

General Safety Considerations

General workplace safety practices including safe solvent use, housekeeping, fire prevention, and cleanliness.

Operational Safety

Critical safety procedures during loader operation, maintenance, and working with raised components.

Service Techniques Safety

Safe methods and procedures for performing service and repair work, emphasizing cleanliness and correct tools.

Component Safety

Specific safety measures for components like bearings and boom supports to prevent accidents.

Section 1 Hydraulic System

Hydraulic Circuit

Overview of the hydraulic system layout and schematic, detailing fluid flow and component connections.

Gear Pump

Detailed information on gear pump replacement, disassembly, and assembly procedures for different models.

Control Valve

Procedures for control valve testing, replacement, and disassembly, including spool and relief valve adjustments.

Hydraulic Cylinders

Information on hydraulic cylinder inspection, assembly, replacement, and testing of piston seals.

Hydraulic Oil Filter

Details on hydraulic oil filter general information and procedures for filter replacement.

Hydraulic Oil Cooler

Information regarding the hydraulic oil cooler, its function, and procedures for cooler replacement.

Hydraulic Oil Reservoir

Procedures for checking oil level, adding oil, and servicing the hydraulic oil reservoir.

Trouble Shooting

Troubleshooting guide for common hydraulic system problems, listing causes and corrective actions.

Torque Chart

Specifications for hydraulic system component torque settings, including hose fittings and pump mounting.

Conversion Chart

Factors for converting between US and Metric units for various measurements.

Notes

Section 2 Hydrostatic Drive System

Hydrostatic Drive Circuit

Schematic and pressure details of the hydrostatic system, including high pressure and charge pressure.

Specifications

Technical specifications for hydrostatic tandem pumps, drive motors, and the hydraulic reservoir.

General Information

Overview of the hydrostatic drive system operation, components, and principles of fluid power.

Trouble Shooting

Diagnostic steps and troubleshooting for hydrostatic system issues, presented as symptoms and causes.

Pressure Tests

Procedures for testing system pressure and diagnosing faults using pressure gauges and flow meters.

Towing Procedure

Safe procedure for towing the loader with a failed hydrostatic drive system, including brake release.

Flushing The Hydraulic System

Steps for cleaning and flushing the hydraulic system due to contamination, including oil and filter changes.

Start-up Procedure

Correct procedure for starting up the hydrostatic system after repairs or new installation.

Gear Pump Replacement

Step-by-step guide for removing and replacing the gear pump in the hydrostatic system.

Tandem Pump Replacement

Detailed instructions for removing and replacing the tandem pump assembly.

Tandem Pump Parts Diagram

Illustrated parts breakdown of the tandem pump assembly, including front and rear pump diagrams.

Drive Motor

Information on drive motor general info, removal, replacement, disassembly, assembly, and parts.

Torque Specifications

Torque values for hydrostatic system components, including pumps, motors, and fittings.

Section 3 Final Drive

Specifications & Maintenance

Specifications and maintenance schedule for the final drive, including chain size and lubrication oil.

Lubrication

Procedures for checking oil level, adding oil, and changing final drive lubrication oil.

Drive Chain

Steps for checking, adjusting, removing, and installing the drive chain, including tension specifications.

Chain Tightener

Procedures for removing, inspecting, and installing the chain tightener assembly.

Drive Motor Sprocket

Instructions for replacing the drive motor sprocket on the final drive assembly.

Axle Assembly

Comprehensive guide for axle assembly, covering removal, inspection, installation, and stud replacement.

Trouble Shooting

Troubleshooting common issues related to the final drive, such as noise, lack of drive, and lubrication leaks.

Summary

Thomas Equipment Liability Warranty

Foreword

Safety Precautions

Personal Safety Considerations

Personal protective measures for operator safety, covering clothing, skin, eye, breathing, hearing, hand, and foot protection.

Equipment Safety Considerations

Safety measures related to machine parts like guards, lifting appliances, and compressed air usage.

Hand Tools Safety

Guidelines for safe usage of hand tools to prevent injury and ensure proper job execution.

Electrical Safety

Precautions for handling electrical equipment and avoiding potential hazards like worn cables or plugs.

General Safety Considerations

General workplace safety practices including safe solvent use, housekeeping, fire prevention, and cleanliness.

Operational Safety

Critical safety procedures during loader operation, maintenance, and working with raised components.

Service Techniques Safety

Safe methods and procedures for performing service and repair work, emphasizing cleanliness and correct tools.

Component Safety

Specific safety measures for components like bearings and boom supports to prevent accidents.

Section 1 Hydraulic System

Hydraulic Circuit

Overview of the hydraulic system layout and schematic, detailing fluid flow and component connections.

Gear Pump

Detailed information on gear pump replacement, disassembly, and assembly procedures for different models.

Control Valve

Procedures for control valve testing, replacement, and disassembly, including spool and relief valve adjustments.

Hydraulic Cylinders

Information on hydraulic cylinder inspection, assembly, replacement, and testing of piston seals.

Hydraulic Oil Filter

Details on hydraulic oil filter general information and procedures for filter replacement.

Hydraulic Oil Cooler

Information regarding the hydraulic oil cooler, its function, and procedures for cooler replacement.

Hydraulic Oil Reservoir

Procedures for checking oil level, adding oil, and servicing the hydraulic oil reservoir.

Trouble Shooting

Troubleshooting guide for common hydraulic system problems, listing causes and corrective actions.

Torque Chart

Specifications for hydraulic system component torque settings, including hose fittings and pump mounting.

Conversion Chart

Factors for converting between US and Metric units for various measurements.

Notes

Section 2 Hydrostatic Drive System

Hydrostatic Drive Circuit

Schematic and pressure details of the hydrostatic system, including high pressure and charge pressure.

Specifications

Technical specifications for hydrostatic tandem pumps, drive motors, and the hydraulic reservoir.

General Information

Overview of the hydrostatic drive system operation, components, and principles of fluid power.

Trouble Shooting

Diagnostic steps and troubleshooting for hydrostatic system issues, presented as symptoms and causes.

Pressure Tests

Procedures for testing system pressure and diagnosing faults using pressure gauges and flow meters.

Towing Procedure

Safe procedure for towing the loader with a failed hydrostatic drive system, including brake release.

Flushing The Hydraulic System

Steps for cleaning and flushing the hydraulic system due to contamination, including oil and filter changes.

Start-up Procedure

Correct procedure for starting up the hydrostatic system after repairs or new installation.

Gear Pump Replacement

Step-by-step guide for removing and replacing the gear pump in the hydrostatic system.

Tandem Pump Replacement

Detailed instructions for removing and replacing the tandem pump assembly.

Tandem Pump Parts Diagram

Illustrated parts breakdown of the tandem pump assembly, including front and rear pump diagrams.

Drive Motor

Information on drive motor general info, removal, replacement, disassembly, assembly, and parts.

Torque Specifications

Torque values for hydrostatic system components, including pumps, motors, and fittings.

Section 3 Final Drive

Specifications & Maintenance

Specifications and maintenance schedule for the final drive, including chain size and lubrication oil.

Lubrication

Procedures for checking oil level, adding oil, and changing final drive lubrication oil.

Drive Chain

Steps for checking, adjusting, removing, and installing the drive chain, including tension specifications.

Chain Tightener

Procedures for removing, inspecting, and installing the chain tightener assembly.

Drive Motor Sprocket

Instructions for replacing the drive motor sprocket on the final drive assembly.

Axle Assembly

Comprehensive guide for axle assembly, covering removal, inspection, installation, and stud replacement.

Trouble Shooting

Troubleshooting common issues related to the final drive, such as noise, lack of drive, and lubrication leaks.

Thomas 135 Specifications

General IconGeneral
BrandThomas
Model135
CategoryCompact Loader
LanguageEnglish

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