Thomas 135TA, 137, 153 Operator's Manual

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135TA/137/153

PUBLICATION NO. 52935

June 2005

Owner’s

and

Operator’s

Manual

Skid Steer Loader

THOMAS EQUIPMENT LIABILITY WARRANTY

THE WARRANTY IS THE ONLY OBLIGATION OF THOMAS OR A THOMAS

DEALER TO THE PURCHASER OR ANYONE ELSE CONCERNING A PRODUCT, IT’S

SERVICE, IT’S USE OR PERFORMANCE OR IT’S LOSS OF USE OR FAILURE TO

PERFORM. NEITHER

THOMAS NOR A THOMAS DEALER HAVE MADE AND

NEITHER

WILL MAKE ANY OTHER EXPRESSED OR IMPLIED REPRESENTATION,

WARRANTY OR AGREEMENT

CONCERNING

A PRODUCT, NEITHER THOMAS NOR

A THOMAS DEALER HAVE MADE OR WILL MAKE ANY REPRESENTATION,

ARRANTY OR AGREEMENT CONCERNING A PRODUCT’S MERCHANTABILITY

OR OTHER QUALITY, IT’S SUITABILITY FOR PURCHASER’S PURPOSE (EVEN IF A

PURCHASER HAS INFORMED THOMAS OR A THOMAS DEALER OF THAT

PURPOSE), IT’S DURABILITY, PERFORMANCE OR OTHER CONDITION.

EVEN IF THOMAS OR A THOMAS DEALER WAS ADVISED OF THE POSSIBILITY OF SUCH LOSS, NEITHER THOMAS NOR A THOMAS DEALER WILL BE LIABLE TO PURCHASER OR ANYONE ELSE FOR ANY INDIRECT, INCIDENTAL CONSEQUENTIAL, PUNITIVE, ECONOMIC, COMMERCIAL, OR SPECIAL LOSS WHICH IN ANY WAY ASSOCIATED WITH A PRODUCT. THIS INCLUDES ANY LOSS OF USE OR NON-PERFORMANCE OF A PRODUCT, ANY REPLACEMENT RENTAL OR ACQUISITION COST, ANY LOSS OF REVENUE OR PROFITS, ANY FAILURE TO REALIZE EXPECTED SAVINGS, ANY INTEREST COSTS, ANY IMPAIRMENT OF OTHER GOODS, ANY INCONVENIENCE OR ANY LIABILITY OF THE PURCHASER TO ANY OTHER PERSON.

PURCHASER MAY NOT ATTEMPT TO ENLARGE ITS RIGHTS UNDER THE WARRANTY BY MAKING CLAIM, FOR INDEMNITY, FOR BREACH OF CONTRACT, FOR BREACH OF COLLATERAL WARRANTY, FOR A TORT (INCLUDING NEGLIGENCE, MISREPRESENTATION OR STRICT LIABILITY) OR BY CLAIMING ANY OTHER CAUSE OF ACTION.

THE WARRANTY IS A CONDITION OF SALE OF THE PRODUCT TO THE PURCHASER AND WILL THEREFORE APPLY EVEN IF THE 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 the warranty.

PUBLICATION NUMBER 52473

Printed in Canada

INDEX

1. SAFETY PRECAUTIONS

2. CONTROLS

2. 1 Instrument Panel

2. 2 Seat and Seat Belt

2. 3 Seat Bar

2. 4 Parking Brake

2. 5 Throttle Controls

2. 6 Lift Arm Supports

2. 7 Steering Controls

2. 8 Foot Pedals

2. 9 Quick - Tach

2. 10 Electrical Panel

3. OPERATION

3. 1 Starting Instructions

3. 2 Operating Procedure

3. 3 Filling From a Pile

3. 4 Digging with a Bucket

3. 5 Leveling and Backfilling

3. 6 Auxiliary Hydraulics

3. 7 Lifting

3. 8 Towing

3. 9 Securing and Transporting

3. 10 Lowering Lift Arms

4. MAINTENANCE

4. 1 Preventive Maintenance Service Schedule

4. 2 Service Access

4. 3 Daily Service Checks

4. 4 50 Hour Service Check

4. 5 150 Hour Service Check

4. 6 Final Drive Maintenance

4. 7 Hydraulic / Hydrostatic System Maintenance

4. 8 Engine Maintenance

4. 9 Air Cleaner Maintenance

4. 10 Engine Cooling System

4. 11 Electrical System

4. 12 Tire Maintenance

4. 13 Trouble Shooting

4. 14 Hydraulic / Hydrostatic Circuit

4. 15 Special Tools

5. SPECIFICATIONS

5. 1 Loader Specifications

5. 2 Torque Specifications

5. 3 Decals

6. ATTACHMENTS AND BUCKETS

6. 1 Thomas Approved Buckets and Attachments

WARNING

This warning indicates

hazards or unsafe

practices which COULD

result in severe personal

injury or death.

This warning indicates an

immediate hazard which

WILL result in severe

personal injury or death.

DANGER

Instructions are necessary

before operating or

servicing this machine.

Read the operators manual

and service decals on the

loader. Follow warnings and

instructions in this manual

when making repairs,

adjustments or servicing.

Check for correct operation

after adjustments and

repairs.

IMPORTANT

This notice shows

important procedures

which must be followed

to prevent damage to the

loader or attachment.

IMPORTANT

This warning indicates

hazards or unsafe

practices which COULD

result in minor personal

injury or product or

property damage.

CAUTION

FOREWORD

This book has been written to give the Owner / Operator necessary operating, servicing and preventative maintenance instructions on the loader. Read this manual completely and know the loader before operating or servicing it. Do not do any service procedures that are not in the Operator’s manual. Only service personnel that have had training in the service of this loader can do these service procedures.

Reference Information

Write the correct information for your loaders in the spaces below. Always use these numbers when referring to your loader.

Model No. Serial No. Dealer Name Address Phone

Throughout this manual the terms DANGER, WARNING and CAUTION are used to indicate the degree of hazard in terms of personal safety. These words will be used in conjunction with the Safety - Alert symbol, a triangle with an exclamation mark. Throughout this manual, the term IMPORTANT is used * To indicate that instructions are necessary before operating or servicing the

loader.

* To show important procedures which must be followed to prevent damage to

the loader or attachment.

1. SAFETY PRECAUTIONS

The following precautions are suggested to help prevent accidents.

A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. Read and take the following precautions before operating this loader to help prevent accidents. Equipment should be operated only by those who are responsible and instructed to do so.

1. Read this manual carefully before using the loader.

Working with unfamiliar equipment can lead to accidents.

2. Do not allow anyone to ride on the loader with the

operator.

3. Make sure the seat bar is installed and functioning at all

times.

4. Never run the engine in a closed building without

adequate ventilation, as the exhaust fumes can cause death.

5. Always fasten the seat belt around your waist before

starting the engine. Never fasten the seat belt behind you.

6. Never attempt to start the engine while standing beside

the unit unless as specified in this manual or under specific service and backhoe operation procedures. Start the engine only while sitting in the operator’s seat with the seat belt fastened around you. Always check to make certain that the seat cushion is secured to the frame.

7 Keep the operator’s area free of debris.

8. Never enter or leave the loader while the engine is

running. Always lower the lift arms down against the frame, drop the attachment down to contact the ground, set the parking brake and shut off the engine prior to leaving the loader.

9. If the unit is equipped with a cab enclosure kit always

close the door prior to operating the loader lift arms.

10. Do not operate the loader unless all safety equipment,

shields, seat belt, seat bar, hydraulic controls, parking brake, operator guard, and lift arm supports are working properly, as well as all safety and instruction decals are in place.

OPERATING THE LOADER

1. Always drive the loader at speeds compatible with safety,

especially when operating over rough ground, crossing ditches or when turning.

2. Avoid jerky turns, starts, stops, or reverses.

3. Use care when operating on steep grades to maintain

proper stability.

4. Do not turn the loader while the lift arms are in the

raised position.

5. Be careful when driving through door openings or under

overhead objects. Always make sure there is sufficient clearance for the operator’s guard.

6. When travelling on public roads, know the local rules and

regulations and make sure your loader is equipped with the proper safety equipment.

7. Always be sure of water, gas, sewage and electrical line

locations before you start to dig.

8. Watch out for overhead and underground high-voltage

electrical lines when operating the loader.

9. Always park the loader on level ground where possible. If

the loader is to be parked on an incline, always lower the attachment so it contacts the ground, set the parking brake and block the wheels.

10. Do not leave the loader when it is in motion.

11. Do not dismount from the loader and leave the loader lift arms raised, unless following specific service procedures. Always lower the lift arms down against the frame and drop the attachment down to contact the ground.

12. Always be watchful of bystanders when operating the loader.

13. Always carry the attachment low for maximum stability and visibility.

14. Exercise extreme caution when operating the loader with a raised attachment.

15. Never attempt to lift loads in excess of loader capacity.

16. Check that the foot pedals are locked before getting out of the operator’s seat.

17. Keep both hands on the control levers while the loader is in motion.

MAINTENANCE

1. Stop the engine before performing any service on the loader.

2. Never refuel the loader while smoking or with the engine hot or running.

3. Replace all missing, illegible or damaged safety and warning decals. See Section 5.3 for list.

4. Do not modify or alter, or permit anyone to modify or alter this loader or any of its components or any loader function.

5. Do not bypass the safety system. Consult your Thomas Equipment Dealer if your safety controls are malfunctioning.

6. Do not make mechanical adjustments while the loader is in motion or when the engine is running. However, if minor engine adjustments must be made, securely block the loader with the wheels clear of the ground, and use extreme caution.

7. Do not attempt to repair or tighten hydraulic hoses when the system is under pressure, when the engine is running or when the lift arms are raised.

8. Do not get under the attachment or lift arms or reach through the lift arms when they are raised.

9. Never attach the chains or ropes to the operator’s guard for pulling purposes, as the loader can tip over.

10. Whenever servicing or replacing pins in cylinder ends, buckets,

etc., always use a brass drift and a hammer. Failure to do so could result in injury from flying metal fragments.

11. Cooling system operates under pressure which is controlled by the radiator cap. It is dangerous to remove the cap while system is hot. Always turn cap slowly to the first stop and allow the pressure to escape before removing the cap entirely.

12. Keep the operator and foot pedal areas free from debris.

13. For lifting and towing instructions, refer to Sections 3.7 and 3.8 of this manual.

To prevent personal

injury do not start the

engine unless you are in

the seat with the seat belt

fastened around you.

WARNING

To prevent personal

injury do not operate the

loader without lowering

the safety bar, fastening the seat belt and keeping feet on the control pedals

or cab floor.

WARNING

This engine is equipped

with glow plugs. Do not

use ether or any high

energy fuels to assist

starting.

IMPORTANT

C-359

1. SAFETY PRECAUTIONS

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then, unlatch the seat belt and exit the loader. Do not

enter or exit with the engine

running unless as specified

in this manual or under

specific service and backhoe

operating procedures.

WARNING

START SAFELY

1. Sit in the operator’s seat and adjust it so you can operate all of the controls properly.

2. Adjust the seat and fasten the seat belt. Cycle the controls to make sure they are in the locked or neutral position. Lower the seat bar.

3. Know the exact starting procedure for your machine. See Section 3 for the manufacturer’s instructions for starting.

PARK SAFELY

Select level ground whenever possible. If you must park on a slope or incline, position the machine at right angles to the slope. Lower the attachment to the ground, engage the parking brake and block the wheels (C359).

C - 360

2. CONTROLS

2. 1 Instrument Panel

2. 2 Control Lever Handles

2. 3 Seat and Seat Belt

2. 4 Seat Bar

2. 5 Parking Brake

2. 6 Throttle Control

2. 7 Lift Arm Supports

2. 8 Steering Controls

2. 9 Auxiliary Controls

2. 10 Foot Pedals

2. 11 Hand Controls

2. 12 Quick-Tach

2. 13 Electrical Panel

2. CONTROLS

1. Fuel Gauge: The fuel gauge indicates the quantity of fuel remaining in the fuel tank.

2. Ignition Switch: The ignition switch is a four (4) position switch: ‘OFF’, ‘PRE-HEAT’, ‘RUN’ and ‘START’. Turn the key counter clockwise to engage engine ‘PRE-HEAT’. Turn the key clockwise to the ‘START’ position, this engages the starter. The key will be in the ‘RUN’ position when released. Turn the key to ‘OFF’ to shut off the engine and remove the key.

3. Hour Meter: The hour meter records the number of engine operating hours and has a total of 9999.9 hours.

4. Left Signal Indicator Light: This light will illuminate when the operator uses the optional left signal (not

available on all models).

5. Auxiliary Front Indicator Light: This light will

illuminate when the loader auxiliary hydraulic front switch

(not available on all models) is turned on.

6. Hi-Flow Hydraulics Indicator: This light will illuminate when the loader hi-flow hydraulics (not available on all models) are in use.

7. Work Lights Indicator: This light will illuminate

when the loader work lights are turned on. This will serve as a reminder to turn them OFF when the loader is not in use.

8. Right Signal Indicator Light: This light will illuminate when the operator uses the optional right signal

(not available on all models).

9. Hydraulic Oil Temperature Indicator: This light will

illuminate when the oil temperature has exceeded recommended levels. Shut off the engine immediately and determine the cause.

10. Brake Indicator Light: The brake light will illuminate when the parking brake is engaged.

11. Seat Belt Indicator Light: This light will illuminate when the seat belt is unfastened.

12. Hydraulic Oil Pressure Indicator Light: This light will illuminate when there is low hydraulic oil pressure. If this light illuminates, shut off the engine and determine the cause (not available on all models).

13. Rotary Beacon Indicator: This light will illuminate when the optional rotary beacon (not available on all

models) is turned on.

14. Engine Oil Pressure Indicator: This light will

illuminate when the engine loses lubrication pressure. Shut off the engine immediately and determine the cause.

15. Coolant Temperature Indicator Light: This light will illuminate if there is a rise in engine temperature. If this occurs, shut off the engine immediately and determine the cause.

16. Alternator Indicator Light: This light will illuminate when the alternator is not producing sufficient current.

2. CONTROLS

2.1 INSTRUMENT PANEL

C3170

Fig. 2.1

To prevent personal

injury never add fuel to

the loader when the

engine is running or is

hot. NO SMOKING!

WARNING

To prevent personal

injury do not start the

engine unless you are in

the seat with the seat belt

fastened around you.

WARNING

This engine is equipped with glow plugs. Do not

use ether or any high

energy fuels to assist

starting.

IMPORTANT

22 23

17. Air Cleaner Indicator Light: This light will illuminate when there is an obstruction in the intake or when the air filter needs servicing. If this light illuminates, stop the engine and service the cleaner (see section 4.9).

18. Pre-heat Indicator Light: This light will illuminate when the ignition key is turned counter clockwise to activate the engine glow plugs.

19. Dipped Beam Light Switch: This switch is a toggle switch. Push up to turn the dipped beam lights on. These lights are located on the front of the loader (not available

on all models).

20. Rotary Beacon Light Switch: This switch is a toggle

switch. Push up to turn the optional rotary beacon light on

(not available on all models).

21. Hazard Light Switch: This switch is a toggle switch. Push up to turn the optional hazard light on (not available on all models).

22. Work Light Switch: This switch is a toggle switch. Push up to turn the optional work light on (not available on all models). The light is located on the back of the

loader.

23. Auxiliary Hydraulics Front Switch: This switch is a toggle switch. Push up to provide a continuous flow

of hydraulic oil to the quick couplers when using an attachment (not available on all models).

24. Lift Arm Supports: For safety while performing service or maintenance, the loader is equipped with a lift arm support device. Refer to section 2.6 for details.

25. Hi-Flow Hydraulic Switch: This switch is a toggle switch. Push up to turn the hi-flow hydraulics on (not

available on all models).

2.2 CONTROL LEVER HANDLES

1. Two Speed Switch (not available on all models):

This switch provides alternate switching. Press to activate Hi-Speed function. Pressing and releasing the switch a second time will return the loader to the Low-Speed function. (Fig. 2.2A)

2. Horn Switch (not available on all models): This switch is a momentary switch. Pressing and holding the switch will activate the horn. Releasing the switch deactivates the horn. (Fig. 2.2A)

3 & 4. Electric Solenoid Auxilliary Switch: This switch is a momentary switch. Pressing and holding the switch in position 3 provides hydraulic flow to the female quick coupling. Pressing and holding the switch in position 4 provides hydraulic flow to the male quick coupling. Releasing the switch returns it to neutral, stopping the hydraulic flow. (Fig. 2.2A)

5. LH Directional Signal Switch (not available on all models): This switch is a momentary switch. Pressing

and holding this switch will activate the LH turn signal. Releasing the switch deactivates the LH turn signal. (Fig.

2.2B)

6. RH Directional Signal Switch (not available on all models): This switch is a momentary switch. Pressing

and holding the switch will activate the RH turn signal. (Fig. 2.2B)

7 & 8. Hi-Flow Hydraulic Switch (not available on all models): This switch is a momentary switch. Pressing and

holding the switch in position 7 activates the hi-flow hydraulics to the male quick coupling. Pressing and holding the switch in position 8 activates the hi-flow hydraulics to the female quick coupling. Releasing the switch returns it to neutral and stops the hi-flowhydraulic flow. (Fig. 2.2B)

Fully retract lift arm

support pins before

raising or lowering lift

arms.

IMPORTANT

2. CONTROLS

LH Control Handle

RH Control Handle

C3015

Fig. 2.2A

C3933

Fig. 2.2B

2. CONTROLS

2.3 SEAT AND SEAT BELT

The loader is equipped with a deluxe seat. The seat can be adjusted forward or back for operator comfort. (Fig. 2.2A).

For your safety the loader is equipped with a seat belt. Before starting the loader adjust and fasten the seat belt (Fig. 2.2B) around you. The seat and seat belt also have integrated safety lock switches whereby the operator must be seated in the seat with the seat belt securely fastened and seat bar lowered before the loader hydraulics can be operated.

To prevent personal

injury do not start the

engine unless you are in

the seat with the seat belt

fastened around you.

WARNING

Fig. 2.2B

C2698

Fig. 2. 2A

C2699

Release

2. 4 SEAT BAR

For operator protection the loader is equipped with a seat bar.

The loader must be started with the operator seated in the loader and the seat bar in the up position. To raise the seat bar, lift up on the bar (Fig. 2.3A). In the up position, the seat bar activates the parking brake.

When down (Fig. 2.3B), the seat bar releases the park brake and the hydraulic controls of the lift and tilt circuits.

Before exiting the loader always check the controls by cycling them to ensure that they are in the neutral position.

2. CONTROLS

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

C3775

Fig. 2. 3A

C3776

Fig. 2. 3B

Seat Bar Up

Seat Bar Down

2. 5 PARKING BRAKE

The loader is equipped with park brakes, located inside the torque motor. The brakes are activated and de-activated by the seat bar, via charge pressure. When the seat bar is in the up position, the brake is activated (Fig. 2.4A). When the seat bar is in the down position, the brake is off (Fig.

2.4B).

The loader has a parking brake indication light to warn that the brake is engaged.

2. 6 THROTTLE CONTROL

The diesel engine throttle control is the lever located on the left hand side of the loader next to the steering control lever (Fig. 2.5). Engine start and stop are controlled electrically by the ignition key.

Before shutting off the engine, return the throttle control to idle position and allow the engine to cool at least 2 minutes.

Pushing the lever all the way forward increases the engine speed to maximum high idle. Pulling the lever back decreases the engine RPM.

The engine should always be operated at full speed and the loader travel speed controlled with the steering control levers (See Section 2.7).

2. 7 LIFT ARM SUPPORTS

For safety while performing regular service or maintenance work the loader is equipped with lift arm supports.

The lift arm supports, when extended, prevent the lift arms from dropping if hydraulic pressure is relieved or the foot control pedals are accidentally cycled.

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then, unlatch the seat belt and exit the loader. Do not

enter or exit with the engine

running unless as specified

in this manual or under

specific service and backhoe

operating procedures.

WARNING

C870

Fig. 2.5

2. CONTROLS

C3775

Fig. 2.4A

C3776

Fig. 2.4B

Seat bar UP

(Parking Brake On)

Seat bar DOWN

(Parking Brake Off)

To operate the lift arm supports, first remove any bucket or attachment from the quick - tach; raise the lift arms to full height and shut OFF the engine. Push the two lift arm support pin handles located directly in front of the operator at the top of the operator compartment (Fig. 2.6A) outward extending the lift arm locking pins (Fig. 2.6B). Slowly lower the lift arms down onto the pins. To retract the support pins, first lift the lift arms off of the pins before retracting.

2. 8 STEERING CONTROLS

The two steering levers control speed, direction and turning of the loader. The R.H. lever controls the wheels on the R.H. side of the loader and the L.H. lever the L.H. wheels. Loader speed is controlled by the amount each lever is moved from centre or neutral position. (Fig. 2.7A) The further away from neutral the faster the travel speed. For maximum power and slow travel speed move the control levers only a small amount.

To drive the loader forward in a straight line, move both control levers forward the same amount (Fig. 2.7B).

To drive the loader in reverse in a straight line, move both control levers back the same amount (Fig. 2.7B).

The loader is turned by moving one lever further forward than the other. To turn right, move the left lever further than the right lever. To turn left, move the right lever further than the left lever (Fig. 2.7B).

For the loader to turn or “skid-steer” within its own length, one lever is moved forward and the other back. This causes the wheels on one side to turn forward and the wheels on the other side to reverse turning the loader (Fig. 2.7B).

Fully retract the lift arm

supports before raising

or lowering lift arms.

IMPORTANT

2. CONTROLS

C - 694

Fig. 2. 6B

C3135

Fig. 2. 6A

C3938

Fig. 2.7A

C - 696 - 9

Fig. 2.7B

FORWARD REVERSE

LEFT TURN RIGHT TURN

To avoid personal injury do

not start the engine unless

you are in the seat with the

seat belt fastened around

you, unless as specified in

this manual or under

specific service and backhoe

operating procedures.

WARNING

2. CONTROLS

C3793a

Fig. 2.8B

C3015

Fig. 2.8A

C4086

Fig. 2.8C

2.9 ELECTRIC SOLENOID AUXILIARY CONTROLS

Auxiliary hydraulics (solenoid operated - standard)

A switch located on the L.H. steering control lever (Fig. 2.8A) is used to engage the loader’s auxiliary hydraulic circuit to power attachments such as post hole augers, sweepers, etc. Pressing and holding the switch in position 1 (fig. 2.8A) provides hydraulic flow to the female quick connect coupling located at the front of the lift arms (fig. 2.9C). Releasing the switch returns the auxiliary hydraulic circuit to neutral, stopping the hydraulic flow.

Pressing and holding the switch in position 2 (fig. 2.8A) provides hydraulic flow to the male quick connect coupling located at the front of the lift arms (fig. 2.8C). releasing the switch returns the auxiliary hydraulic circuit to neutral, stopping hydraulic flow.

For continuous flow to the auxiliary hydraulic circuit, a toggle switch is located on the L.H. instrument panel (fig. 2.8B). Placing the switch in the “ON” position provides continuous hydraulic flow to the female quick connect coupling located at the front of the lift arms (fig. 2.8C). To stop hydraulic flow to the auxiliary hydraulic circuit, return the switch to the “OFF” position (fig. 2.8B). When the switch on the instrument panel is in the “ON” position, the switch located in the L.H. control lever is not operable.

NOTE: See Section 2.2 for information on the control handles.

AUXILIARY HYDRAULIC CONTROL

NEUTRAL

ROPS SIDE

SEAT SIDE

TOGGLE SWITCH

T avoid persinal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the controls to

ensure they are locked. Then, unlatch the seat belt and exit the loader. Do not

enter or exit with the engine

running unless as specified

in this manual or under

specific service and backhoe

operating procedures.

WARNING

Male Quick Coupling

Female Quick Coupling

2.10 FOOT CONTROLS

Operation of the lift cylinders and the bucket tilt cylinders are controlled by the foot pedals (fig. 2.10) connected to a hydraulic control valve. The hydraulic control valve is a series type valve which allows simultaneoous use of both the lift and bucket tilt circuits.

Lift –

The L.H. pedal is the lift control (Fig. 2.10). To raise the lift arms press on the heel (2) of the pedal. To lower the lift arms press on the toe (1) of the pedal. Firm pressure on the toe (1) of the pedal will lock the lift arms in float position. This allows the bucket to follow the ground as the loader moves backward.

Bucket Tilt –

The R.H. pedal is the bucket tilt (dump) control. Pressing on the toe (3) of the pedal will dump the bucket. Pressing on the heel (4) of the pedal will roll the bucket back.

2. 11 HAND CONTROLS

Hand controls to operate the loader’s lift arm and bucket hydraulic system as well as the loader’s travel speed and direction are available. Refer to previous section for instructions on steering controls.

LIFT ARM AND BUCKET CONTROLS

The right hand lever controls the bucket tilt cylinders (2.11). Moving the control lever to the right causes the bucket to dump. Moving the lever to the left rolls the bucket to the carry position.

Moving the left hand control lever (Fig. 2.11) to the left will cause the lift cylinders to extend, raising the loader’s lift arms. Moving the control lever to the right causes the lift cylinder to retract, lowering the lift arms. Moving the control lever to the extreme right will place the lift arms in the float position. This allows the bucket to follow the contour of the ground as the loader moves backward.

When the control levers are released they will automatically return to the neutral position, stopping all hydraulic movement and travel speed. Before exiting the loader, lower the lift arms completely down to the frame and ground the attachment. Then shut off the engine. Move both levers to the left and right to ensure the hydraulic controls are locked before you get out of the loader.

2. CONTROLS

To prevent personal

injury do not operate the

loader without lowering

the safety bar, fastening the seat belt and keeping feet on the control pedals

or the cab floor.

WARNING

To avoid personal injury,

lower the lift arms, shut

off the engine, raise the

seat bar and cycle the

hydraulics to ensure they

are locked. Then unlatch

the seat belt and exit the

loader. Do not enter or

exit with the engine

running unless as

specified in this manual

or under specific service

and backhoe operating

procedures.

WARNING

C - 669

Fig. 2.10

Return the auxiliary

hydraulic control to the

neutral position when not

in use.

IMPORTANT

Fig. 2.10

C3020

2.12 QUICK - TACH

The quick - tach, which is standard equipment, allows changing from one attachment to another quickly without having to remove bolt or pins.

To operate, (Fig. 2.11A), lift the locking lever (1) up to completely retract the locking pins (2). Tilt the quick - tach frame forward (Fig. 2.11B) with the bucket tilt cylinders and drive into the attachment. Retract the bucket tilt cylinders (Fig. 2.11C) which will line up the bottom of the attachment with the quick - tach lock pins. Shut off the engine.

Push the locking lever (1) fully down (Fig. 2.11D) extending the lock pins (Fig. 2.11E item 2) through the attachment and securing the attachment.

Before operating the attachment check that the locking pins are correctly engaged.

After hooking up the

attachment check to be

sure pins and locking

levers are correctly

engaged.

WARNING

C3967

C3964

Fig. 2.11B

Fig. 2.11A

C 3966

C 3968

Fig. 2.11E

Fig. 2.11D

C3965

Fig. 2.11C

2. CONTROLS

2.13 ELECTRICAL PANEL

The loader is equipped with a 12 volt, negative ground electrical system. The fuse and relay panel are located in the engine compartment on the engine cover. The panel consists of the following:

1. Engine Pre-Heater Relay.

2. Starter Relay.

3. Fuse Panel.

FUSE PANEL (3)

4. Electric Fuel Solenoid Shutoff (15A)

5. Alternator Light (10A)

6. Electric Auxiliary (10A)

7. Spare

8. Spare

9. Valve Locks (10A)

10. Horn (Optional) (10A)

11. Spare

2. CONTROLS

Fig 2.12

C672

STARTER RELAY

PRE-HEATER RELAY

3. OPERATION

3. 1 Starting Instructions

1. Pre-Starting Inspection

2. Starting Procedure

3. Shut-Off Procedure

3. 2 Operating Procedures

3. 3 Filling From a Pile

3. 4 Digging With a Bucket

3. 5 Leveling and Backfilling

3. 6 Auxiliary Hydraulics

3. 7 Lifting

3. 8 Towing

3. 9 Securing and Transporting

3. 10 Lowering Lift Arms

3.11 Accumulator

3. OPERATION

3.1 STARTING INSTRUCTIONS

1. Pre-Starting Inspection

Before starting the loader complete the following inspection:

(1) Check the hydraulic oil level, engine oil level, engine

coolant level and fuel supply.

(2) Check for fuel, oil and hydraulic leaks.

(3) Check lights, battery level and cables.

(4) Check tire pressure:

10.00 x 16.5 . . . . 40 - 45 PSI (276 - 310 kPa)

(5) Check wheel nut torque 100 - 110 ft. lbs. (136- 149

Nm).

(6) Lubricate all grease fittings.

(7) Check the condition and operation of all safety decals

and equipment – Ensure all shields and safety screens are in place. If necessary repair or replace before starting.

For complete daily servicing refer to section 4. 3.

2. Starting Procedure – Diesel

1. Ensure the seat bar is in the UP position and the steering controls are centered and the foot pedals locked.

2. Adjust and fasten the seat belt securely around you.

3. Place the throttle control in idle position.

4. Turn the ignition key counter clockwise to activate the glow plugs. Hold approximately 15 seconds. Both the alternator and engine oil pressure warning lights should be on.

5. Turn the key clockwise to start position to engage the starter. Do not crank the starter for more than 15 seconds. If the engine fails to start turn the key counter clockwise and pre-heat again.

6. When the engine has started the engine oil pressure and alternator warning lights should go out. If they don’t, shut - off the engine immediately and determine cause.

7. Allow the engine to warm up for five minutes before operating. When ready to operate, lower the seat bar and advance the throttle to full on position.

3. Shut-Off Procedure

(1) Park the loader on level ground. If it’s necessary to

park on a slope, position the machine at right angles to the slope.

(2) Lower the lift arms and ground the attachment.

(3) Return the throttle control to idle position. If the

engine is hot allow it to idle until normal. At least 2 minutes.

(4) When the engine is cool, turn the ignition key to the

OFF position and remove the key.

(5) Never enter or exit the loader when the engine is

running.

(6) Raise the seat bar to apply the park brake. Turn the

ignition switch to the OFF position, unfasten the seat belt, and ensure the hydraulic controls are locked by rocking them.

This engine is equipped

with glow plugs. Do not

use ether or any high

energy fuels to assist

starting.

IMPORTANT

3. OPERATION

To avoid personal injury

do not start the engine

unless you are in the seat

with the seat belt

fastened around you, unless as specified in this manual or under specific

service and backhoe

operating procedures.

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulic

controls to ensure they are

locked. Then, unlatch the seat

belt and exit the loader. Do

not enter or exit with the

engine running unless as specified in this manual or under specific service and

backhoe operating

procedures.

WARNING

To prevent personal

injury do not operate the

loader without lowering the safety bar, fastening

the seat belt and keeping

feet on the control pedals

or cab floor.

WARNING

3. 2 OPERATING PROCEDURES

1. When learning to use the loader operate at a slow rate.

2. Take advantage of the efficient operation of the loader. Keep the travel distance as short as possible. Keep the work area small so the cycle time is short.

3. Keep the work area as level as possible.

4. Decrease cycle time by “skid” turning (See Section

2.7) rather than a go backward-go forward turn.

5. Fill the bucket to rated capacity. Turning is easier with a full load than with a partial load. Keep the loaded bucket close to the ground when transporting.

6. Tilt the bucket as you raise the lift arms or drive up a slope. This will prevent material from falling off the back of the bucket.

7. Do not drive across a slope. Always go up or down a slope with the heavy end of the loader pointing up towards the top of the slope.

3. 3 FILLING FROM A PILE

Push down on the toe of the lift arm pedal and lower the lift arms completely down (Fig. 3.3A). Push the toe of the bucket pedal and place the cutting edge of the bucket on the ground. For hand control units, move the L.H. control lever towards you and lower the lift arms completely down. Move the R.H. control lever away from you (Fig. 3.3A) and place the cutting edge of the bucket on the ground.

Drive the loader forward slowly. As the bucket begins to fill push on the heel of the bucket pedal to raise the front of the bucket (Fig. 3.3B) and push on the heel of the lift arm pedal to raise the lift arms. When the bucket is full back away from the pile. For hand control units, move the R.H. control lever towards you to raise the front of the bucket, and move the L.H. control lever away from you to raise the lift arms (Fig.

3.3B). When the bucket is full back away from the pile.

To dump the bucket (Fig. 3.3C) push down on the heel of the lift arm pedal to raise the lift arms. Push down on the toe of the bucket pedal small amounts as the lift arms are raising to stop material from falling off the back of the bucket. When the bucket is at the correct height for dumping, push on the toe of the bucket pedal to empty the bucket.

For hand control units, move the L.H. control lever away from you (Fig. 3.3C) to raise the lift arms. Move the R.H. control lever away from you in small amounts as the lift arms are raising to stop material from falling from the back of the bucket. When the bucket is at the correct height for dumping, move the R.H. lever away from you to empty the bucket.

* Hand controls not available on all machines.

Always let the engine

warm completely before

you begin operation each

day.

IMPORTANT

3. OPERATION

Fig. 3.3A

Fig. 3.3B

C706

Fig. 3.3C

C709

C707

R H

C710

3. 4 DIGGING WITH A BUCKET

Push on the toe of the lift arm pedal and lower the lift arms completely down. Push on the toe of the bucket pedal and place the cutting edge of the bucket on the ground (Fig.

3.4D). Drive the loader forward at a slow rate and continue to tilt the bucket down until it enters the ground.

Push down on the heel of the bucket pedal (Fig. 3.4E) to increase traction and keep an even digging depth.

Continue to drive forward until the bucket is full. When digging in hard ground, it is easier to raise and lower the bucket cutting edge with the tilt pedal while slowly driving forward. When the bucket is full, push down on the heel of the bucket pedal (Fig. 3.4F) to raise the tip of the bucket.

For hand control units, move the L.H. control lever towards you to lower the lift arms completely down. Move the R.H. control lever away from you and place the cutting edge of the bucket on the ground (Fig. 3.4D). Drive the loader forward at a slow rate and continue to tilt the bucket down until it enters the ground. Move the R.H. control lever towards you (Fig.

3.4E) to increase traction and keep an even digging depth. Continue to drive forward until the bucket is full. When the bucket is full, move the R.H. control lever towards you (Fig.

3.4F) to raise the tip of the bucket.

* Hand controls not available on all machines.

To avoid personal injury:

When starting or

operating loader in an

enclosed area make sure

there is enough

ventilation. Exhaust

fumes can kill.

WARNING

3. OPERATION

Fig. 3.4D

To prevent personal

injury always carry the

load low.

WARNING

Fig. 3.4E

C711

C713

Fig. 3. 4F

C715

C712

C714

C718

To prevent personal

injury, ensure that the bucket with the proper rated capacity is being

used for the job you are

doing.

WARNING

3. 5 LEVELING AND BACKFILLING

Spread dirt on uneven ground by pushing on the heel of the lift arm pedal (Fig. 3.5G) to raise the lift arms and push on the toe of the bucket pedal to tilt the bucket down as you drive forward.

For hand control units, spread dirt on uneven ground by moving the L.H. control lever away from you (Fig. 3.5G). This will raise the lift arms. Move the R.H. control lever away from you to tilt the bucket down as you drive forward.

To level the ground; raise the lift arms and tilt the bucket down by pressing on the toe of the bucket pedal. (See Fig. 3.5H) Push firmly on the toe of the lift arm pedal to lock the lift arms in the float position. The weight of the lift arms and bucket will hold the bucket on the ground. Drive backward to level material.

To level the ground with a hand control unit, raise the lift arms and tilt the bucket down by moving the R.H. lever away from you. Move the L.H. control lever all of the way towards you (Fig. 3.5H) to place the lift arms in the float position. The weight of the lift arms and the bucket will hold the bucket on the ground. Drive backwards to level material.

To fill a hole (Fig. 3.5I) drive the loader slowly with the bucket low, up to the hole. As the bucket passes the edge of the hole, push on the toe of the bucket pedal to dump the bucket. When necessary raise the lift arms to empty the bucket.

On hand control units, as the bucket passes the edge of the hole, move the R.H. control lever away from you to dump the bucket. When necessary, raise the lift arms to empty the bucket.

* Hand controls not available on all machines.

3. OPERATION

Fig. 3.5H

C717

Fig. 3.5G

To prevent personal

injury always carry the

load low.

WARNING

C719

Fig. 3.5I

C721

C716

C720

C722

3. 6 AUXILIARY HYDRAULICS

To operate an attachment such as a grapple fork the Left Hand Control Lever will be used. Push right of neutral on the Auxiliary Hydraulic Control Switch to open the grapple (Fig. 3.6J).

To close the grapple (Fig. 3.6K), push left of neutral on the Auxiliary Hydraulic Control Switch, or push down on the toe of the auxiliary pedal if so equipped. The lift arm and bucket pedals can be used to raise and tilt the grapple as with a bucket.

To operate an attachment which requires a constant flow of oil, a toggle switch on the L.H. instrument panel (Fig.

3.6L) should be placed in the “ON” position.

When the auxiliary circuit is not in use switch to the “OFF” position. Otherwise starting the loader may be difficult or impossible and damage to the starter may occur.

Return the auxiliary

control to neutral when

not in use otherwise

starting may be

impossible and damage

to the starter may occur.

IMPORTANT

3. OPERATION

Fig. 3.6J

Fig. 3.6K

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

C723

C724

C3022

Fig. 3.6L

C3793

Toggle Switch

3. 7 LIFTING

The loader is equipped with features to use in lifting (for example by crane onto a flatbed trailer or a flat car), for securing, and for extraction (from mud or snow). To facilitate this requires the optional lifting lugs.

To lift using a crane, first follow the shut - off procedure in section 3.1-3.

Once this is done, attach properly rated cables, chains or straps to lift points provided (See Fig. 3.7). To prevent marking the operator guard or chafing of the lifting cable, a lifting frame should be used.

3. 8 TOWING

1. When winching or towing a stuck loader from the rear, always lower the lift arms until the attachment is resting on the ground and then follow the shut - off procedure (See Section 3.1-3).

2. When winching or towing a stuck loader from the front, lower the attachment so that the front attachment points are accessible and have an assistant block the attachment, then follow the shut-off procedure (See Section 3.1-3).

3. Attach a properly rated chain, cable or towing strap to the towing point provided (Fig. 3.8A).

4. Deactivate the brake system for towing. To release the park brake, turn the release button on the brake valve counter clockwise. Pressurize the brake release quick coupler to 200 PSI (15 Bar). This will release the motor brakes for towing. See maintenance section for details.

5. Open the tandum pump by-pass valve which are integral with the high pressure relief valves by turning four (4) revolutions. There are four of the high pressure relief valves. Two (2) on the top of the pump (fig. 3.8B), and two (2) on the bottom. Do not open the valves past four (4) turns. When open, the valve connects both sides of the pump/motor circuit and allows the motor to turn for towing short distances at low speeds without running the engine. The valve closing torque is 30 - 70 ft. lbs. (41 - 95 Nm.).

*Damage to the unit may result from over-torquing the bypass valve.

6. The attachment point on the towing or winching equipment should be kept as low as possible and in as direct a line as possible with the stuck loader. A steep tow line angle or side pull could result in upsetting the stuck loader.

3. OPERATION

C3939

Fig. 3.8A

Fig. 3.7

C3407

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this

manual or under specific

service and backhoe

operating procedures.

WARNING

IMPORTANT

Never install tie down

chains across the bucket

cylinders. Damage to the

cylinders may occur.

C1882

Fig. 3.8B

Bypass Valves (Top)

3. OPERATION

3.9 SECURING AND TRANSPORTING

There are three tie down points provided for securing the skid steer while transporting. One at the lower front and two at the rear (Fig. 3.9).

Be sure the trailer and/or truck is of adequate size and capacity to safely transport your skid steer.

Measure the clearance height of the machine and trailer or truck, and post it in the cab of the truck.

Before loading the skid steer make sure the ramps and parking surface are free of all oil, grease, ice, etc. and of sufficient strength to support the load.

Know the local rules and regulations, and make sure your truck and trailer is equipped with the correct safety equipment.

When loading a skid steer with an attachment, always load the heavy end first.

Once the skid steer has been loaded, lower the attachment to the floor, stop the engine and engage the park brake.

Install chains at the front and rear tie down locations, and securely attach to the transport vehicle.

NOTE: Minimum 3/8 in. grade 40 chain is required

C3408

Fig. 3.9

C362

SAFE SHUTDOWN PROCEDURES

- Stop machine

- Lower the bucket and other attachments flat on the ground

- Position controls in neutral

- Raise operator seat bar to engage parking brake

- Idle engine for short cool-down period

- Stop engine

- Cycle all controls to ensure they are locked in neutral

- Unbuckle seat belt

- Remove ignition key and lock covers and closures

C361

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then, unlatch the seat belt and exit the loader. Do not

enter or exit with the engine

running unless as specified

in this manual or under

specific service and backhoe

operating procedures.

WARNING

IMPORTANT

When moving your skid steer

on or off a transport vehicle,

drive slowly and keep the

machine centered.

WARNING

Ramps must be of sufficient

strength to support the

weight of your skid steer.

Wooden ramps can break

and cause personal injury.

3.10 LOWERING LIFT ARMS (ENGINE OFF)

In the event that you should have an electrical failure which renders your skid steer inoperable with the lift arms up, the following procedures would apply.

1. Lift Arm Height Is Sufficient To Engage

Lift Arm Support Pins

Engage lift arm support pins. (Fig. 3.10A) Raise seat bar and cycle all controls to ensure they are locked. Exit loader and open rear door. Locate the control valve on the left side of the machine. Unplug the electrical wire and remove the knurled nut holding the solenoid on the spool lock. Remove the solenoid, then remove the lock pin and spring assembly (Fig. 3.10C). Once the lock pin and spring are removed, the lift arm spool is free to travel. Enter the machine, being careful not to cycle the foot pedals or the control levers as the locking system has been disabled. Once in the operator seat dis-engage lift arm support pins. Move the lift arm pedal or control lever to lower the lift arms to the ground.

2. Lift Arm Height Is Not Sufficient To

Engage Lift Arm Support Pins

DO NOT EXIT FROM FRONT OF LOADER WITHOUT LIFT-ARMS ON GROUND OR SUPPORTED BY ACCEPTABLE MEANS!

Raise seat bar and cycle all controls to ensure they are locked. If help is readily available, have some one place a suitable support under the lift arms (e.g. 4” x 4” Lumber) or a piece of angle iron between lift cylinder end cap and lift cylinder rod mount.

Then exit loader using extreme caution. If help is not available, the operator must exit the loader from the rear window and perform the proper lift arm supporting (as described previously). Once this is completed, open rear door. Locate the control valve on the left side of the machine (Fig. 3.10B). Unplug the electrical wire and remove the knurled nut holding the solenoid on the spool lock. Remove the solenoid, then remove the lock pin and spring assembly (Fig. 3.10C). Once the lock pin and spring are removed, the lift arm spool is free to travel.

Ensure assistance is available, then the operator can enter the machine, being careful not to cycle the foot pedals or the control levers as the locking system has been disabled. Once in the operator seat, lower the safety bar. Have the assistant remove the lift arm support devices. The operator can then move the lift arm pedal or control lever to lower the lift arms to the ground.

To avoid personal injury:

Do not leave lift arms up

unless the lift arm

supports are engaged.

WARNING

3. OPERATION

C-694

Fig. 3.10A

Fig. 3.10C

C805

Knurled Nut

Lock Pin

Solenoid

C3413

Fig. 3.10B

Lift Arm Lock

Solenoid

C3949

Lift Arm Support

Spring

O-Ring (underneith)

O-Ring

3. OPERATION

3.11 ACCUMULATOR

The accumulator (fig. 3.11A) stores system pressure until it is required to activate the electric auxiliary. The key must be placed in the “On” position to operate the electric auxiliary (engine not running).

The electric auxiliary and stored system pressure can be used to activate the spools. This decreases the hydraulic pressure from the male/female couplers located on the lift arms. This is accomplished by cycling the momentary switch on the L.H. control a couple of times (fig. 3.11B).

Once this pressure is decreased the operator can remove/replace the quick attach accessories easily.

C3901

Fig. 3.11A

Accumulator

C3915

Fig. 3.11B

Momentary

Switch

ROPS SIDE

SEAT SIDE

4. 1

Preventative Maintenance Service Schedule

4. 2 Service Access

1. Lift Arm Support

2. Seat Removal

3. Battery Access

4. Engine Compartment

4. 3 Daily Service Check

1. Hydraulic Oil Level

2. Air Cleaner

3. Tires and Wheel Nuts

4. Safety Equipment

5. Decals

6. Lubrication

7. Engine Oil Level

8. Radiator / Oil Cooler Service

4. 4 50 Hour Service Check

1. Engine

2. Hydraulic / Hydrostatic

3. Final Drive

4. Controls and Safety Equipment

5. Electrical

6. Grease / Lubrication

7. General

4. 5 150 Hour Service Check

4. 6 Final Drive Maintenance

1. Oil Level Check

2. Adding Oil

3. Drive Chain, Axle and Sprocket Inspection

4. Chain Drive Adjustment

4. 7 Hydraulic / Hydrostatic System Maintenance

1. Oil Level Check

2. Adding Oil

3. Hydraulic Filter Replacement

4. Draining System Fluid

5. Oil Cooler and Cooling Fan

6. Brake Service Override

4. 8 Engine Maintenance

1. Engine Maintenance

2. Oil Level Check

3. Engine Oil and Filter Replacement

4. Cooling System Fluid

5. V-Belt Tension

6. Adding Fuel

7. Fuel Filter Replacement

8. Bleeding the Fuel System

4. 9 Air Cleaner Maintenance

1. Daily Maintenance

2. Servicing Cleaner Element

4. 10 Engine Cooling System

4. 11 Electrical System

1. Battery Maintenance and Boosting

2. Electrical Schematic - ROPS

3. Electrical Schematic - Engine

4. 12 Tire Maintenance

1. Tire Inflation and Service

2. Tire Rotation

4. 13 Troubleshooting

1. Hydraulic System

2. Hydrostatic Drive

3. Final Drive Transmission

4. Control Levers

5. Electrical

6. Engine

4. 14 Hydraulic / Hydrostatic Cicuit

4.15 Special Tools

4. MAINTENANCE

ITEM SERVICE REQUIRED

8 HOURS

50 HOURS

150 HOURS

300 HOURS

1000 HOURS

Engine Oil

Hydraulic Oil

Radiator & Oil Cooler

Air Cleaner

Tires and Wheel Nuts

Safety Equipment

Decals

Lubrication

Hydraulic Oil Filter

Safety System Linkages and Springs

50 Hour Service

Engine Oil

Engine Oil Filter

Final Drive

Hydraulic Oil Filter(s)

Preventative Maintenance Service Check

Engine Oil

Engine Oil Filter

Check level and add if necessary. Use 10W30 API Classification CF oil.

Check level and add if necessary. Use10W30 API Classification SJ or 20W50 API Classification SJ oil.

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.

Empty dust cap. Check condition indicator and service or replace element as required.

Check for low pressure or tire damage, refer to Section 5.1 for more information. Check wheel nut torque 100-110 ft. lbs. (136-149 Nm).

Check all safety equipment for proper operation and condition. Seat belt, lift arm supports, quick-tach locks, parking brake, safety treads, front shield and cab side screens. If necessary lubricate foot pedal and steering control linkages, springs and shafts with a silicone based lubricant. If necessary repair or replace.

Check for damaged safety or instruction decals (See Section 5.3). If necessary replace.

Grease all hinge pin fittings and pivot bearings until excess shows.

Replace hydraulic oil filter element. Initial change only.

Check and if necessary adjust. Lubricate lock springs, shaft and linkage with a silicone based lubricant.

Perform complete 50 hour service (See Section 4.4).

Replace engine oil. Use API Classification CF oil. (See Section 4.8-3). Initial change only.

Replace engine oil filter. Initial change only.

Check chain and sprocket condition. Check every 150 hours.

Replace hydraulic oil filter element (See 4.7-3).

It is recommended as a preventative maintenance procedure that the 50 hour service be repeated every 150 hours. (See Section 4.5)

Replace engine oil. Use API Classification CF oil. See 4.8-3. Replace every 150 hours.

Replace engine oil filter. See 4.8-3. Replace every 300 hours.

4.1 PREVENTIVE MAINTENANCE SERVICE SCHEDULE

4. MAINTENANCE

WARNING

ITEM SERVICE REQUIRED

50 HOURS

150 HOURS

300 HOURS

800 HOURS

1000 HOURS

Engine Fuel Filter

Engine Valve Clearance

Final Drive

Hydraulic reservoir

Engine Cooling System

Replace engine fuel filter. (See Section 4.8-6).

Adjust (See Thomas Dealer).

Change final drive lubricating oil. Use 10W30 API Classification SJ oil.

Remove and replace the 100 micron suction element in the oil reservoir. Change hydraulic oil. Replace with 10W30 API Classification SJ oil or 20W50 API Classification SJ.

Drain, flush and refill. Use 50% mixture of ethylene glycol and water.

To avoid personal injury

service repairs must be

performed by an

authorized Thomas

dealer.

4. MAINTENANCE

WARNING

WARNING: Escaping hydraulic

fluid under pressure can

penetrate the skin causing

serious injury.

• DO NOT use your hand to check

for leaks. Use a piece of cardboard

or paper to search for leaks.

• Stop engine and relieve pressure

before connecting or disconnecting

lines.

• Tighten all connections before starting engine or pressurizing

lines.

If any fluid is injected into the skin

obtain medical attention

immediately of gangrene may

result.

4. 2 SERVICE ACCESS

1. Lift Arm Support

For safety while performing regular service or maintenance work, the loader is equipped with lift arm support pins. The lift arm support pins when extended prevent the lift arms from dropping if hydraulic pressure is relieved or the hydraulic controls are accidentally cycled.

To operate the lift arm support, first remove any bucket or attachment from the quick-tach; raise the lift arms to full height. Raise the lift arm support handle (Fig. 4.2A) up and push out toward lift arms to extend the lift arm supports. (Fig. 4.2B) Slowly lower the lift arms down on to the pins. To retract the lift arm supports, lift the lift arms off of the pins before retracting pins.

2. Seat Removal

The seat assembly can be removed to provide access to the controls, hydraulic and hydrostatic components. To remove the seat assembly, remove the fasteners located at the front of the seat. DISCONNECT ELECTRICAL PLUG! Lift the seat assembly out of the machine. When installing the seat, be sure the seat plate is locked in place at the rear (Fig. 4.2C).

3. Battery Access

The battery is located in a compartment found behind the operators seat (Fig. 4.2D). Remove the seat and remove the bolt holding the battery cover in place. The battery compartment is hinged with a prop rod to hold open.

Fully retract lift support

pins before raising or

lowering lift arms.

IMPORTANT

To avoid personal injury:

Do not leave lift arms up

unless the lift arm

supports are engaged.

WARNING

4. MAINTENANCE

Fig. 4.2C

Fig. 4.2B

C1132

C694

Electrical Plug

C3135

Fig. 4.2A

Fig. 4.2D

C4417

4. Engine Compartment

The engine compartment is completely enclosed for component protection and lockable to discourage vandalism. For servicing the rear door swings open and the engine cover hinges up.

To open; raise the door lock handle up over the lock plate; pull outward releasing the door catch and swing the door open (Fig. 4.2E). Lower the engine cover before closing the rear door. Figure 4.2F shows the engine compartment.

4. 3 DAILY SERVICE CHECK

1. Hydraulic Oil Level

Check the oil level with the machine on a level surface with the lift arms down and the attachment grounded. Open the rear door and check the oil level sight glass (Fig.

4.3A). If oil is apparent the oil level is satisfactory.

If necessary to add oil, remove the reservoir cap located at the top of the oil reservoir and add oil until oil appears in the oil level sight glass.

Use a good quality 10W30 oil which meets the API classification SH only.

2. Air Cleaner

The loader is equipped with an air cleaner restriction warning lamp. Should this lamp illuminate, shut off the engine and determine cause. Possibly a plugged air filter. Figure 4.3B shows the air cleaner.

Check that all hose clamps are tight and the hose is undamaged. Check the vacuator valve for damage (Fig

4.3B).

See Section 4.9 for Air Cleaner Maintenance.

Fig. 4.2F

C1866

Keep the rear door

closed except for

servicing. Make sure the

door is closed and

latched before operating

the loader.

IMPORTANT

4. MAINTENANCE

C644

Fig. 4.3A

C674

Fig. 4.2E

WARNING

To avoid personal injury:

Stop, Cool and Clean the

engine of flammable

materials before

servicing. Never service

or adjust machine with

engine running.

Fig. 4.3B

C1237

Air Cleaner

Vacuator Valve

3. Tires and Wheel Nuts

Inspect tires for wear or damage. Check and inflate tires to correct pressure:

10.00 x 16.5 ...........40 - 45 PSI (276 - 310 kPa)

Tires can be inflated to 50 PSI (345 kPa) when operating on hard, flat surfaces.

To prevent shearing of the wheel studs and rim damage check wheel nuts for proper torque 100 -110 lbs. ft. (136 149 Nm) daily (Fig. 4.3C). After changing a rim, Check wheel nuts hourly, until the reading stabilizes.

4. Safety Equipment

Check all safety equipment for proper operation and condition - seat belt, lift arm supports, seat bar, steering neutral lock, parking brake, quick tach lock, shields, safety treads and lift arm lock down. Lubricate all linkages, springs and pivot points with a silicone based lubricant. Repair or replace if necessary.

5. Decals

Check the condition of all safety and instruction decals. Replace any damaged or missing decals. Refer to Section

5.3 for decal description and locations.

6. Lubrication

There are sixteen (16) grease fittings located in the loader that require lubrication every eight hours. Lubricate with a good quality multi-purpose lithium based grease. Apply grease until excess shows. Refer to the service schedule for complete service details. (See Fig. 4.3D). The sixteen (16) lubrication points are:

Rear Lift Arm Pivots (2) Lift Cylinder Bushings (4) Bucket Cylinder Bushings (4) Lift Arm Supports (2) Quick Tach Pivot and Lock Pins (4)

7. Engine Oil Level

Check the oil before engine start up. If the engine has been running let it cool for at least 5 minutes to allow the oil to drain back to the oil pan.

To check the oil level, check with the loader on level ground, open the rear door and remove the dipstick (Fig.

4.3E).

Keep the oil level between the full and low mark on the dipstick (Fig. 4.3F). Do not fill above the full mark. Use API Classification CF oil.

4. MAINTENANCE

C3956

Fig. 4.3D

Torque Wheel Nuts 100 - 110 lbs. ft. (136 - 149 Nm)

Fig. 4.3C

C3415

Fig. 4.3E

Dipstick

Location

C3414

Fig. 4.3F

FULL

LOW

8. Radiator / Oil Cooler Service

With the engine cool, check the coolant level in the overflow reservoir (fig. 4.3G). Ensure the coolant level is at the Full-Cold mark on the reservoir by adding 50% mixture of ethylene glycol and water if required.

The radiator and oil cooler fins must be kept free of debris otherwise overheating of the engine will occur. Inspect the radiator cooling fins for damage or buildup of debris. Repair any damage and if necessary flush the radiator with compressed air to remove debris.

4. 4 50 HOUR SERVICE CHECK

The following service check is to be performed by your dealer after the first 50 hours of operation.

1 Engine

1.1 Oil and Filter:

Change the engine oil and filter. Use only original replacement parts. Change the oil every 150 hours thereafter. Change the filter every 300 hours thereafter.

1.2 Radiator: Check the coolant level. If necessary flush the radiator

with compressed air. A dirt buildup on the radiator cooling fins can cause both engine and hydraulic system overheating. Check the foam sealing ring on the fan drive.

1.3 V-Belt Tension and Condition: Check v-belt for cuts or wear, if necessary replace.

Check tension and adjust as shown in Section 4.8.4.

1.4 Fuel System for Leaks: Make a visual inspection of fuel system for leaks and

potential hazards such as fuel line(s) touching exhaust manifold, flywheel, etc. Replace fuel filter every 300 hours.

1.5 Air Intake and Cleaner System: Visually inspect the air cleaner system and be sure all

hose clamps are secure and no hoses are damaged.

1.6 Exhaust System: Visually inspect the exhaust system and ensure all

clamps are secure and the manifold bolts/nuts are tight.

1.7 Engine Speed: Check engine speed and if adjustment is necessary,

contact a Thomas Equipment dealer.

4. MAINTENANCE

Keep the rear door

closed except for

servicing. Make sure the

door is closed and

latched before operating

the loader.

IMPORTANT

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

Coolant Overflow

Reservoir

C1663

Fig. 4.3G

2 Hydraulic/Hydrostatic

2.1 Hydraulic Oil Filter: Change the hydraulic filter now and every 150 hours

after the initial change. Lubricate the filter cartridge seal with system fluid.

2. 2 Hydraulic Oil Level: If oil is visible in the oil level sight glass the level

satisfactory. If additional oil is required use only 10W30 API

classification SJ oil. Fill to the top or maximum check point.

2.3 Hoses and Pipes: Make a visual inspection of all hydraulic lines and

fittings for leaks. Check that steel lines do not touch one another.

2.4 Cylinders:

Inspect cylinders for leaks. Extend cylinders and check for rod damage.

2.5 Hydraulic Functions: Check that the following operate properly: control

valve float position, auxiliary hydraulics, pedals and hydraulic cylinders.

2.6 Pumps & Motors, Leakage: Inspect pumps and motors for leaks.

2.7 Oil Cooler: Inspect the oil cooler for leaks, fin damage or clogged

with dirt. If necessary flush fins with compressed air.

2.8 Fan Drive:

Inspect fan, bolts, v-belt and guard to ensure there is no buildup of dirt, trash, or wear. Use compressed air to clean the area.

3 Final Drive

3.1 Oil Level: Check lubricating oil level. If necessary add 10W30

API classification SJ oil.

3.2 Drive Chain Condition: Check drive chains for any sign of wear or damage.

Check lubrication oil in housing for signs of contamination.

3.3 Hydrostatic Motor Mounting Bolts:

Check torque 85 - 90 ft. lbs. (115 - 122 Nm)

3.4 Bearing End Play:

Check both the idler sprocket and axle bearings for loss of bearing pre-load. If necessary, adjust the bearings for zero end play.

3.5 Axle Seal:

Inspect axle seal area. Clean area of debris build up and visually check for seal damage, replace as required.

4 Controls and Safety Equipment

4.1 Control Levers, Operation and Linkage: Check that the steering levers operate freely without

binding, they return to neutral when released and the machine travels in a straight line with both levers in forward position. Ensure control levers lock in neutral with seat bar up. Lubricate linkage with a silicone based lubricant.

4.2 Hydraulic Controls, Operation and Linkage: Check that the hydraulic controls, foot pedals or hand

controls operate freely without binding. Before leaving the operator seat, ensure the controls are locked.

Seat Bar Switch Check: Raise the seat bar and check that the

hydraulic controls are locked in neutral.

Seat Belt Switch Check:

Unbuckle the seat belt and check

that the hydraulic controls are locked in neutral.

Seat Switch Check: With the seat bar down and the seat belt

connected loosely around you, raise your weight off the seat and check that the controls are locked in neutral.

4.3 Engine Throttle Control: Check that the throttle control operates freely without

binding or slackening off due to vibration.

4. 4 Parking Brake: Check that the parking brake engages and completely

disengages. The park brake automatically engages with seat bar up.

4. 5 Lift Arm Supports: Check that the lift arm supports operate without

binding.

NOTE: Ensure the lift arm supports are fully retracted

before raising or lowering the lift arms.

4. MAINTENANCE

WARNING

To avoid personal injury:

never repair or tighten

hydraulic hoses or

fittings with the engine

running or the system

under pressure.

4.6 Quick-Tach, Operation & Linkage: Ensure the quick-tach linkage operates smoothly

without binding and engage completely.

4.7 Seat Belt: Check seat belt condition. If necessary replace.

5 Electrical

5.1 Battery (s): Maintenance Free.

5.2 Battery Terminals: Check battery terminals for corrosion. If necessary,

clean.

5.3 Starter Operation:

Engage and disengage the starter a few times to ensure it’s working properly. To prevent starter damage do not engage for more than 15 seconds. Allow 1 minute between starting attempts for cooling the starter and stop solenoid.

5.4 Operation of Electrical Equipment: Make a complete check of all electrical equipment,

gauges, warning devices, pre- heater indicator, work lights, seat and seat belt switch, seat bar switch and all optional equipment to ensure they are operating correctly.

6 Grease/Lubrication

Lubricate the following points with a good quality grease. Numbers marked ( ) indicate the number of fittings at each location.

Rear Lift Arm Pivots (2) Lift Arm Cylinder Bushings (4) Bucket Cylinder Bushings (4) Engine Universal Joint (2) Lift Arm Supports (2) Quick - Tach Pivot (4)

7 General

7. 1 Tire Pressure: Check tire pressure and if necessary inflate to the

following pressures:

10.00 x 16.5 . . . . . . . 40 - 45 PSI (207 - 241 kPa)

7. 2 Wheel Nut Torque: Check and torque wheel nuts to 100 - 110 ft. lbs. (136

- 149 Nm).

7.3 Condition of Cab: Inspect both the seat and seat belt. Ensure all safety and

instruction decals are in place. Inspect sound insulation, side windows and door operation for machines equipped with cab enclosure kits. Inspect for structural damage and alterations to R.O.P.S.

7. 4 Condition of Shields and Safety Equipment: Inspect and ensure all shields are in place and

securely fastened. Inspect and ensure all safety equipment is working properly. Ensure owners and operators manual,

safety manual and all safety and instruction decals are in place. If necessary, replace. If the safety controls are malfunctioning or require adjustment, consult a Thomas Equipment Dealer for service.

7. 5 General Condition: Make a general inspection of the machine looking for

loose or missing parts, oil leaks, etc.

4. 5 150 HOUR SERVICE CHECK

The following service check is to be performed by your dealer after the first 150 hours of operation.

1. It is recommended that the 50 hour check (see Section 4.4) be repeated at 150 hours.

4. MAINTENANCE

4. 6 FINAL DRIVE MAINTENANCE

1. Oil Level Check

The loader has two independent final drive housings. Check the lubricating oil level with the loader on a level surface. Remove the check plug (Fig. 4.6A) located on the front of the loader to determine the oil level. The oil level should be checked after 50 operating hours and every 150 hours thereafter. It is recommended the oil be changed after 1000 operating hours or if it shows signs of contamination.

2. Adding Oil

Add oil with the loader on level ground. Remove the oil level check plug (Fig. 4.6A) on the final drive housing. Remove the seat and hydrostatic shield. Remove the filler cap (Fig. 4.6B). Fill with 10W30 API Classification SJ to the level of the check plug.

3. Drive Chain, Axle and Sprocket Inspection

The condition of the drive chains should be checked after the first 50 hours of operation and every 150 hours thereafter.

To inspect, block the loader securely with all four wheels off the ground. Remove both the front and rear wheels. On reassembly torque the wheel nuts to 100-110 ft. lbs. (136149 N m). Remove the inspection cover on the side of the chain drive housing.

Inspect the chain for any sign of wear, damage or excessive looseness. Inspect the sprockets for any sign of damage or excessive wear. Inspect the lubricating oil for signs of contamination. Check both the idler sprocket and axle bearings for loss of bearing preload. If necessary adjust the bearings for zero end play.

Check the axle seals for leaking oil or damage. Replace seals at first sign of problem.

4. MAINTENANCE

Check Plug

Fig. 4.6A

C1033

Filler Cap

Fig. 4.6B

C1662

4. Chain Drive Adjustment

The drive chain must be checked for excessive slack after the first 50 hours of operation and every 150 hours thereafter.

To adjust, remove the inspection cover on the seat support.

With the parking brake engaged, remove the filler cap and measure the amount of free play in the chain with the chain tension gauge (Fig. 4.6C). The chain must be adjusted so there is between 1/4 - 3/8 inch (6.4 - 9.5 mm) free play.

Remove the shield protecting the chain tightener.

Loosen the 3 chain tightener nuts (Fig. 4.6D), until the spring washers just begin to open. do not over-loosen or over tightening of the chain can occur.

Back off the rear adjuster nut (Fig. 4.6D) and tighten the front adjustment nut until free play measured on the chain is between 1/ 4 - 3/8” (6. 4 - 9.5 mm).

Tighten the rear adjuster nut and torque the 3 chain tightener nuts to 150 ft. lbs. (203 Nm) (Fig. 4.6D).

Repeat on opposite side of machine.

4. 7 HYDRAULIC/ HYDROSTATIC SYSTEM MAINTENANCE

1. Oil Level Check

Check the oil level of the hydraulic reservoir with the machine on a level surface with the lift arms down and the attachment grounded. Shut off the engine. Open the rear door and check the oil level sight glass (Fig. 4.7A). If oil is apparent the level is satisfactory.

WARNING

WARNING: Escaping hydraulic

fluid under pressure can

penetrate the skin causing

serious injury.

• DO NOT use your hand to check

for leaks. Use a piece of cardboard

or paper to search for leaks.

• Stop engine and relieve pressure

before connecting or disconnecting

lines.

• Tighten all connections before starting engine or pressurizing

lines.

If any fluid is injected into the skin

obtain medical attention

immediately of gangrene may

result.

Front

Axle

Rear

Axle

4. MAINTENANCE

C644

Fig. 4.7A

Fig. 4.6D

C-1037

Fig. 4.6C

C372

Chain Tension Guage

Oil Level Sight Glass

Adjustment Nuts

Chain Tightener Nuts

2. Adding Oil

To add oil, remove the oil filler cap located at the top of the oil reservoir (Fig. 4.7B). Check and ensure the filter screen in the filler neck is undamaged. Add 10W30 or 20W50API Classification SJ oil until oil is visible in the oil level sight glass (Fig. 4.7A).

3. Hydraulic Filter Replacement

The hydraulic oil filter (Fig. 4.7C) must be changed after the first 50 hours of operation and every 150 hours thereafter.

To change the filter; shut off the engine, lower the lift arms, ground any attachment and set the parking brake. Open the rear door and using an oil filter wrench remove the filter element. Lubricate the new filter seal with system fluid and reinstall hand tight. Note: The loader only has one filter.

4. Draining System Fluid

Change the hydraulic oil:

1. After 1000 operating hours.

2. If the oil has become contaminated.

3. After any major hydrostatic repair.

To drain the oil: remove the drain plug located at the bottom of the reservoir (Fig. 4.7D). Have a container(s) ready to hold approximately 15 gallons (58 liters) of fluid. Remove any metal particles stuck to the magnet. Seal the plug with teflon tape when replacing.

4. MAINTENANCE

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

OIL RESERVOIR

DRAIN

Fig. 4.7B

Fig. 4.7D

C1034

C-1108

Thomas recommends

that you abide by all

applicable enviromental

regulations when

disposing of oil.

IMPORTANT

OIL FILLER CAP

C3364

Fig. 4.7C

Hydraulic

Filter

5. Oil Cooler and Cooling Fan

Oil returning from the control valve is circulated through the oil cooler before being sent to other parts of the hydraulic system.

An engine cooling fan drives air through the oil cooler when the rear door is closed. Refer to Figure 4.7E.

The oil cooler should be checked daily for dirt buildup on the cooling fins. If the air flow is restricted through the cooling fins, overheating of the hydraulic system may occur. Clean any dirt buildup with compressed air. Flush with water if necessary. Figure 4.7E shows the radiator/oil cooler setup for the loader.

6. Brake Service Override

A service override has been incorporated for use by Thomas Dealers. The normal position of the plunger is down and turned into the locked position (Fig. 4.7F).

To release the park brake, turn the release button counter clockwise. Go to the rear of the machine and pressurize the small quick coupler to 200 psi to release the park brake (Fig. 4.7G).

4. MAINTENANCE

Fig. 4.7E

C3416

Oil Cooler

Fan

To avoid eye injury

always use safety goggles

when cleaning with

compressed air.

WARNING

Fig. 4.7F

C1255

C1663

Fig. 4.7G

Brake Quick Coupler

Plunger

2. Oil Level Check

Check the oil before engine start up. If the engine has been running let it cool for at least 5 minutes.

To check the oil level, stop the engine with the loader on level ground, open the rear door and remove the dipstick (Fig. 4.8A).

Keep the oil level between the full and low mark on the dipstick. Do not fill above the full mark.

3. Engine Oil and Filter Replacement

Operate the engine until warm, approximately 5 minutes. Stop the engine. Remove the oil drain plug located at the bottom of the oil pan. Remove the oil filter (Fig. 4.8B). Clean the filter housing surface. Put clean oil on the seal of the new filter and install the filter hand tight.

Replace the oil drain plug. Remove the filler cap and add 10W30 API classification CF engine oil. Start the engine and run for 5 minutes. Stop the engine and check for leaks at the filter. Recheck the oil level and add oil until the level is at the top mark on the dipstick.

WARNING

To avoid personal injury:

Stop, Cool and Clean the

engine of flammable

materials before

servicing. Never service

or adjust machine with

engine running.

4. MAINTENANCE

C3415

Fig. 4.8A

Dipstick

Location

C828

Fig. 4.8B

Engine Oil

Filter

Thomas recommends

that you abide by all

applicable enviromental

regulations when

disposing of oil.

IMPORTANT

4. 8 ENGINE MAINTENANCE

1. Engine Specifications 153 135TA/137

Make............................................................................................Kubota............................................Kubota

Model...........................................................................................V2203E..........................................V1903E

No. of Cyls ..................................................................................4......................................................4

Horsepower (Gross) ....................................................................49....................................................42

Power (ISO9249 Net Power) ......................................................34.3 kW...........................................29kW

Power CE (ISO9249 Net Power) ................................................33.8 kW...........................................28.9kW

High Idle............................................................................. ........2800................................................2800

High Idle CE ...............................................................................2600................................................2600

Max. Torque.................................................................115 ft.lbs. (15.9kg/m@1600)............89.1 ft.lbs. (12.3 kg/m @ 1600)

Displacement ...................................................................... 134 in.

(2197 c.c.)..........................113.5 in.3(1861 c.c.)

Engine Oil ...................................................................................8.5 qts. (8 L)...................................8.5 qts. (8 L)

Firing Order.................................................................................1 - 3 - 4 - 2......................................1 - 3 - 4 - 2

Alternator.....................................................................................40 A.................................................40 A

Oil Check.....................................................................................Daily................................................Daily

Oil Change...................................................................................150 hrs............................................150 hrs.

Filter Change ...............................................................................150 hrs............................................150 hrs.

4. V-Belt Tension

Check the V-belt tension midway between the crankshaft pulley and alternator pulley (Fig. 4.8C). Deflection should be between 1/4 to 3/8 in. (7-9 mm).

5. Adding Fuel

Use No. 2 diesel fuel only. Total tank capacity 18 gal. (68 L). Before adding fuel to the loader the key switch must be off and the engine must be cool. Remove the fuel cap (Fig. 4.8D). Use a clean approved safety container to add fuel. Add fuel only in an area that is well ventilated and away from open flames or sparks - NO SMOKING!

6. Fuel Filter Replacement

The fuel filter is located in the engine compartment on the left hand side (Fig. 4.8E). The fuel filter should be removed every 100 hours and any water or dirt found in the element drained off. Change the filter every 300 hours.

To replace the filter; close the fuel inlet line shut - off located on the side of the fuel tank (Fig. 4.8E). Remove the filter element (Fig. 4.8E). Lubricate the seal on the new filter and install the filter hand tight. Open the fuel inlet shut - off. It may be necessary to remove air from the fuel system after changing the filter element. (Refer to Section

4.8-8).

7. Bleeding the Fuel System

Air must be removed from the fuel, after replacement of the fuel filter element, or when the tank has been run out of fuel, before starting the engine.

To remove air, ensure the fuel inlet shut-off located on the side of the fuel tank is open (fig. 4.8E). Open the bleed valve by turning it counter clockwise (fig. 4.8F) on top of the injector pump. Place the throttle at idle, then turn the engine over with the starter. After the engine starts and runs smoothly, shut off the engine and close the bleed valve by turning it clockwise.

Fuel Filter

Fig 4.8E

Fuel Inlet Shut - off

C-831P C-1238

Fig. 4.8F

C-833

Fuel Air

Bleed Valve

4. MAINTENANCE

Alternator

Pulley

Fan Pulley

Crankshaft Pulley

Fig. 4.8C

C-834

Fuel Tank

C1254

Fig.4.8D

WARNING

To avoid personal injury

never add fuel to the

loader when the engine is

running or is hot. NO

SMOKING.

4. 9 AIR CLEANER MAINTENANCE

1. Daily Maintenance

Inspect the air cleaner canister for holes, dents, missing or mis-aligned gaskets. Check all hose clamps for tightness and inspect the hose and vacuator valve for damage (Fig. 4.9A).

2. Servicing Cleaner Element (Fig. 4.9B)

DO NOT open unless the indicator indicates a blocked filter or under normal scheduled servicing. To check the indicator, with the engine running, block half of the intake inlet and check the indicator on the dash panel. It should illuminate to simulate a blocked filter.

2.1 Unlatch and remove the cover assembly

2.2 Release The Seal Gently - The filter should be

removed gently to reduce the amount of dust dislodged. Move the end of the filter up and down and side to side or twist to break the seal.

2.3 Avoid Dislodging Dust from the Filter - Gently pull

the filter off the outlet tube. Avoid knocking the filter against the housing.

2.4 Always clean the sealing surface of the outlet tube

- Dust on the outside diameter of the housing could hinder an effective seal.

2.5 Always clean the inside of the outlet tube. Dirt

inside of the outlet tube will reach the engine : it only takes 9 grams of dirt to dust an engine.

2.6 Check your old filter. Inspecting your old filter will

detect foreign material on the sealing surface that may causing leakage.

2.7 Inspect the new filter for seal or pleat damage.

2.8 Insert the new filter properly - The seal area is on

the inside of the open end of the primary filter. A new filter has a dry lubricant to aid installation. The critical sealing area will stretch slightly, adjust itself and distribute the sealing pressure evenly. To complete a tight seal, apply pressure at the outer rim of the filter, not the flexible centre. No cover pressure is required to hold the seal.

2.9 Check connections and ducts for air tight fit - Make

sure all clamps, bolts and connections are tight. Check for holes in piping. Leaks here send dust directly to the engine.

2.10 DO NOT reuse filters by cleaning and reinserting.

4. MAINTENANCE

To avoid personal injury,

lower the lift arms, shut off

the engine, raise the seat bar

and cycle the hydraulics to

ensure they are locked. Then,

unlatch the seat belt and exit

the loader. Do not enter or

exit with the engine running

unless as specified in this manual or under specific

service and backhoe

operating procedures.

WARNING

To avoid personal injury: DO NOT charge a frozen battery because it can explode and cause

personal injury. Let the

battery warm to 60°F.(15.5°C.) before putting on a charger.

WARNING

Inlet

Outlet

Cover Assembly

Vacuator Valve

Latch

Safety Filter (Optional)

Primary

Filter

C-653

Fig. 4.9B

Fig 4.9A

C3417

Air Cleaner

Hose

Vacuator Valve

4. 10 ENGINE COOLING SYSTEM

The engine cooling system fluid is a 50-50 mixture of ethylene glycol and water for cold-weather protection.

To drain the cooling system; attach a hose to the drain valve located at the engine block (Fig. 4.10A). Remove the radiator cap. Turn the drain valve handle so that it’s toward the valve outlet. To completely drain the radiator remove the rubber drain plug located at the bottom of the radiator (Fig. 4.10B). To fill the cooling system; close the drain valve on the engine block (Fig. 4.10A) and refit the radiator drain plug. Fill the radiator with a 50-50 mixture of ethylene glycol and water. Refit the radiator cap.

C3418

Fig. 4.10A

WARNING

To avoid personal injury:

DO NOT remove the

radiator cap when the

engine is hot.

4. MAINTENANCE

Engine Coolant

Drain

Drain Valve

Handle

C3419

Fig. 4.10B

Rubber Drain

Plug

WARNING

To avoid personal injury

never add coolant when the engine is running or

is hot.

4. 11 ELECTRICAL SYSTEM

1. Battery Maintenance and Boosting

Inspect the batteries on a regular basis for damage such as a cracked or broken case or cover which would allow electrolyte loss.

Check the battery cables for tightness and corrosion. Remove any acid corrosion from the battery and cables with a baking soda and water solution. Coat the terminal connections with di-electric grease.

If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operators seat and one person to connect and disconnect the battery cables.

BOOSTING PROCEDURES

The ignition must be in the OFF position. The booster battery to be used must be 12 volt. Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the loader battery positive (+) terminal. Connect the end of the second cable to the negative (–) terminal of the booster battery (fig. 4.11A). Connect the other end of the same cable to a ground. Keep cables away from moving parts. Start the engine. After the engine has started, disconnect the end of the second cable from the negative (–) terminal of the booster battery. Disconnect the other end of the same cable from the ground. Disconnect the end of the first cable from the positive (+) terminal of the booster battery. Disconnect the other end of the same cable from the loader battery positive (+) terminal.

4. MAINTENANCE

WARNING

To prevent personal injury

DO NOT charge a frozen

battery because it can

explode and cause

personal injury. Let the

battery warm to 60°F.

(15.5°C.) before putting on

a charger.

Lead-acid batteries contain

sulfuric acid which will

damage the eyes or skin on

contact. Always wear goggles

to avoid acid in the eyes. If

acid contacts the eyes, wash

immediately with LARGE

QUANTITIES of clean water

and get medical attention.

Wear rubber gloves and

protective clothing to keep

acid off the skin. If acid

contacts the skin, wash off

immediately with clean water.

WARNING

C3419

Fig. 4.11A

Boosting Lug

2. ELECTRICAL SCHEMATIC – ROPS

4. MAINTENANCE

C3361

3. ELECTRICAL SCHEMATIC – ENGINE

4. MAINTENANCE

C3690

4. 12 TIRE MAINTENANCE

1. Tire Inflation and Service

1.1 Upon receiving your loader, check the air pressure in the tires as indicated in the tables.

1.2 Check tire pressure every 8 hours.

1.3 Tire inflation pressure affects the amount of weight which a tire may carry. Do not over-orunder inflate the tires.

1.4 Do not inflate a tire above the manufacturer’s maximum pressure shown on the tire or the maximum pressure shown in the table.

1.5 Do not re-inflate a tire that has been run flat or seriously under-inflated until the tire has been inspected for damage by a qualified person.

1.6 When checking tire pressure, inspect the tire for damaged side walls and tread cuts. Neglected damage will lead to early tire failure.

1.7 Be sure the rim is clean and free of rust.

1.8 Lubricate both tire beads and rim flanges with soap solution. Do not use oil or grease.

1.9 Use a clip-on tire chuck with a remote hose and gauge which allows the operator to stand clear of the tire while inflating it.

1.10 After seating the beads, adjust inflation pressure to recommended operating pressure.

1.11 Do not inflate a tire unless the rim is mounted on the loader or is secured so that it will not move if the tire or rim should suddenly fail.

1.12 Do not weld, braze, or otherwise repair a rim, Do not use a damaged rim.

1.13 Never attempt tire repairs on a public road or highway.

1.14 Use jack stands or other suitable blocking to support the loader while repairing tires

1.15 Insure jack has adequate capacity to lift your loader.

1.16 Insure jack is placed on a firm level surface.

1.17 Do not put any part of your body under the loader or start the engine while the loader is on the jack.

1.18 Torque lug nuts to specification after reinstalling wheel. Check lug nut torque hourly until torque stabilizes.

Tire Inflation Pressure

12.00 x 16.5 40-45 PSI (276 - 310 kPa)

2. Tire Rotation

The front and rear tires will wear at different rates. For even wear move the front tires to the rear and the rear tires to the front when wear is first noticed.

If two tires become worn more than the other two put the two worn tires on the same side.

When new tires are installed, always keep tires the same size on the same side of the loader. Two different size tires on the same side of the loader will cause drive chain wear, tire wear and a loss of power

WARNING

To avoid personal injury:

Inflating or servicing

tires can be dangerous.

Trained personnel should

be called to service

and/or mount tires when

possible. In any event to avoid possible serious or

fatal injury, follow the

safety precautions below.

4. MAINTENANCE

WARNING

NEVER INFLATE

TIRES TO OVER 240

kPa (35 PSI) TO SEAT

BEADS. If beads have not

seated by the time

pressure reaches 240 kPa

(35 PSI), deflate the

assembly, reposition the

tire on the rim,

relubricate both tire

beads, rim flanges and re-

inflate. INFLATION Beyond 240 kPa (35 PSI) with unseated beads may

break the bead or rim

with EXPLOSIVE force,

sufficient to cause serious

injury.

4. MAINTENANCE

4. 13 TROUBLESHOOTING

Contact Thomas Equipment for all major fixes under the remedy column except for regular service (ie. Replenish fluids, tightening etc.)

1. Hydraulic System

Problem Cause Remedy

Loss of hydraulic power (no flow from gear pump)

Loss of hydraulic power (flow from gear pump)

Hydraulic action jerky

Hydraulic Overheat

Lift arms raise slowly at full engine RPM

Lift or tilt cylinders will not support a load

Hydraulic fluid overheating

Reservoir low on fluid

Coupling between engine and pump failure

Spline coupling failure between front and rear hydrostatic pump Hydraulic gear pump not functioning Reservoir low on fluid Foot pedal linkage disconnected or binding Auxiliary hydraulics engaged Relief valve failure in control valve Reservoir low on oil Air in hydraulic system

Anticavitation check valve not functioning Engine fan not turning

Broken hydraulic fluid line

Reservoir low on oil Foot pedal linkage binding Auxiliary engaged Engine RPM too slow Anticavitation check valve spring broken Main relief or port relief valve in control valve faulty Internal leakage in pump due to wear

Oil bypassing one or both lift cylinder piston seals External leak between or at control valve and cylinders Control valve spool not centering

Oil leaking by one or both cylinder piston seals Reservoir low on fluid Oil cooler plugged or dirty (also check engine radiator) Auxiliary engaged

Replenish with 10W30 API SJ oil. Check for hose or fitting leaking. Inspect and replace damaged parts. Check for misalignment between engine and pumps. Inspect coupling for sheared splines. Also check pump shaft bearings. Inspect and repair. Replenish with 10W30 API SJ oil. Inspect and adjust.

Disengage. Check pressure and adjust. Replenish with 10W30 API SJ oil. Check for leak between reservoir and pump. Bleed system by extending and retracting lift cylinders several times. Inspect and repair or replace.

Clean fan area or repair or replace faulty drive system components. Repair or replace defective line. Replenish with 10W30 API SJ oil. Replenish with 10W30 API SJ oil. Inspect and adjust. Disengage. Check RPM and reset. Replace.

Check pressure, if necessary - adjust.

Check pump flow and repair or replace as necessary. Install new piston seal kits.

Check for leaks and correct.

Check for sticking foot pedal linkages. Check for broken or stuck return spring on valve spool. Install new piston seal kits.

Replenish with 10W30 API SJ oil. Clean cooling fins.

Disengage.

4. MAINTENANCE

1. Hydraulic System (Continued)

Problem Cause Remedy

Hydraulic fluid overheating (continued) Foot pedals do not operate smoothly

Engine RPM too slow Incorrect temperature sensor Foot pedal linkages out of adjustment Foot pedal linkages need lubrication

Cable binding

Check RPM and adjust. Replace. Adjust foot pedal linkages.

Lubricate with a silicone based lubricant. Check routings for kinks etc.

2. Hydrostatic Drive

Problem Cause Remedy

No power on one side (both directions)

No power on one side (one direction only) No power on both sides (also loss of hydraulic power)

Gradual loss of power as machine warms up System erratic and/or noisy

Machine will not travel in a straight line

Reservoir low on fluid

Disconnected control linkage Bolt sheared on pump pintle lever

High pressure line failure

Drive chain failure

Motor shaft or key failure

Excessive internal leakage in motor and/or pump

Defective relief valve

Reservoir low on oil

Coupling failure between engine and pump

Drive coupling between front and rear pump failure

Check system pressure

Excessive internal leakage in pump and/or motor Air in system due to low oil level in reservoir Air in system due to leak at suction fitting Internal pump or motor wear caused by overspeeding Excessive play in linkage or pintle lever Control levers binding

Replenish with 10W30 API SJ oil. Check for hose or fitting leak. Reconnect and adjust linkage. Replace. Check pintle lever for loose bolt or excessive play. Replace line. Ensure new line fits without being forced. If necessary stress relieve. Replace chain or connection link. Adjust tightener tension. Inspect and repair defective parts. Check motor mounting bolts. Inspect and repair defective unit. Flush all lines and tank. Replace filter. Check on type of fluid used and engine RPM. Replace defective valve.

Replenish with 10W30 API SJ oil. Check for hose or fitting leaks. Inspect and replace damaged parts. Check for misalignment between engine and pumps. Inspect couplings for sheared splines, replace. Also check support bearings in pumps. If low, consult dealer or Thomas Service Dept. Consult dealer or Thomas Service Dept. Replenish with 10W30 API SJ oil.

Check fittings and tighten.

Consult your dealer or Thomas Service Dept. Adjust linkage and tighten or replace pintle lever. Check that shields are not stopping lever from full travel. Adjust tracking.

4. MAINTENANCE

4. Control Levers

Problem Cause Remedy

Control levers will not center

Machine operates erratically

Machine will not travel in a straight line

Control levers do not operate smoothly

Linkage out of adjustment

Linkage disconnected

Centering spring broken Linkage binding

Control lever linkage loose

Bolt in pintle lever worn or broken

Linkage binding Control lever travel out of adjustment Internal pump and/or motor linkage

Control lever linkages out of adjustment. Control lever linkages need lubrication.

Adjust, check for wear at rod ends, loose counter nuts. Reconnect, check for wear at rod ends, loose counter nuts. Replace Binding of spring bushing in spring box. Align spring box with linkage. Control levers binding with safety shields or sound insulation. Adjust. Control lever bearings binding in lever assembly. Inspect, replace or clean as required. Inspect linkage for wear at rod ends, loose counter nuts. Replace bolt. Inspect pintle lever for wear at bolt hole. Ensure bolt clamping lever to pump shaft is tight. See also troubleshooting guide for hydrostatic system. Adjust. Adjust.

See troubleshooting hydrostatic system. Adjust control lever linkages.

Lubricate with a silicone based lubricant.

3. Final Drive Transmission

Problem Cause Remedy

Final drive transmission noisy

No lubricating oil

Axles have too much end play

Parking brake damaged or out af adjustment Chain loose

Check and bring oil to the proper level. Use 10W30 API SH engine oil. Preload axle bearings removing all end play. Inspect and adjust or replace damaged parts. Replace the chain.

5. Electrical

Problem Cause Remedy

Engine will not crank over

Battery failure Battery cable failure

Starter failure

Check battery - charge or replace. Check for loose or corroded connectors. Tighten and clean as required. Use di-electric grease to prevent corrosion. Check continuity of cables and replace. Repair or replace.

5. Electrical (Continued)

Problem Cause Remedy

Engine will not crank over (continued)

Engine cranks over, but will not start

Loader starts, but hydraulic controls will not release.

Fuse burnt Defective relay

Ignition switch failure Auxiliary hydraulics engaged

Defective glow plug relay

Defective glow plug

Broken connection or defective wire

No fuel Electric solenoids not releasing valve spools

Check and replace. Check relay continuity. If defective, replace. Check continuity, repair or replace. Engine will smoke, but not run unassisted by starter. Disengage auxiliary hydraulics. Check continuity and if defective, replace. Check continuity and if defective, replace. Disconnect the ROPS harness from the engine harness. Open the dash panel and check continuity of the circuit not functioning properly in both engine and ROPS harness. Check fuel levels and system. Defective solenoid or binding solenoid locks. Loosen screws and re-adjust. Check continuity of connectors and wire.

4. MAINTENANCE

6. Engine

Problem Cause Remedy

Engine does not start

No fuel Air in the fuel Water in the fuel

Fuel pipe clogged Fuel filter clogged Excessively high viscosity of fuel or engine oil at low temperature Fuel with low cetane number Fuel leak due to loose injection pipe retaining nut Incorrect injection timing Fuel cam shaft worn Injection nozzle clogged Injection pump malfunctioning Seizure of crankshaft, camshaft, piston, cylinder liner or bearing Compression leak from cylinder

Improper valve timing Piston ring and liner worn Excessive valve clearance

Replenish fuel. Vent air. Change fuel and repair or replace fuel system. Clean. Clean or change. Use the specified fuel or engine oil.

Use the specified fuel. Tighten nut.

Adjust. Replace. Clean. Repair or replace. Repair or replace.

Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder. Correct or replace timing gear. Replace. Adjust.

4. MAINTENANCE

6. Engine (Continued)

Problem Cause Remedy

Starter does not run

Engine revolution is not smooth

Either white or blue exhaust gas is observed

Either black or dark gray exhaust gas is observed

Excessive lubricant oil consumption

Fuel mixed into lubricant oil

Water mixed into lubricant oil

Low oil pressure

High oil pressure

Battery discharged Starter malfunctioning Key switch malfunctioning Wiring disconnected Fuel filter clogged or dirty Air cleaner clogged Fuel leak due to loose injection pipe retaining nut Injection pump malfunctioning Incorrect nozzle opening pressure Injection nozzle stuck or clogged Fuel overflow pipe clogged Governor malfunctioning Excessive engine oil Low grade fuel used Fuel filter clogged Air cleaner clogged Overload Low grade fuel used Fuel filter clogged Air cleaner clogged Piston rings gap facing the same direction Oil ring worn or stuck Piston ring groove worn Valve stem and guide worn Crankshaft bearing and crank pin bearing worn Injection pump’s plunger worn Injection pump broken Head gasket defective Cylinder block or cylinder head flawed Engine oil insufficient Oil strainer clogged Relief valve stuck with dirt Relief valve spring weakened or broken Excessive oil clearance of crankshaft bearing Excessive oil clearance of crank pin bearing Excessive oil clearance of rocker arm bearing Oil passage clogged Oil pump defective Different type of oil Relief valve defective

Charge. Repair or replace. Repair or replace. Connect. Clean or change. Clean or change. Tighten nut.

Repair or replace. Adjust. Repair or replace. Clean. Repair. Reduce to the specified level. Repair or replace. Adjust. Adjust top clearance. Lessen the load. Use the specified fuel. Clean or change. Clean or change. Shift gap direction.

Replace. Replace. Replace. Replace.

Replace pump element or pump. Replace. Replace. Replace.

Replenish. Clean. Clean. Replace.

Replace.

Clean. Use the specified oil type. Use the specified oil type. Replace.

6. Engine (Continued)

Problem Cause Remedy

Engine overheated

Deficient output

Battery quickly discharges

Engine oil insufficient Fan belt broken or elongated Cooling water insufficient Radiator net and radiator fin clogged with dust Inside of radiator corroded Cooling water flow route corroded Radiator cap defective Overload running Head gasket defective Incorrect injection timing Unsuitable fuel used Incorrect injection timing Engine’s moving parts seem to be seizing Uneven fuel injection Deficient nozzle injection Compression leak

Battery electrolyte insufficient Fan belt slips Wiring disconnected Rectifier defective Alternator defective Battery defective

Replenish. Change or adjust. Replenish. Clean.

Clean or replace. Clean or replace. Replace. Loosen the load. Replace. Adjust. Use the specified fuel. Adjust. Repair or replace.

Repair or replace injection pump. Repair or replace nozzle. Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder. Replenish distilled water recharge. Adjust belt tension or charge. Connect. Replace. Replace. Change.

4. MAINTENANCE

4.14 HYDRAULIC / HYDROSTATIC CIRCUIT

4. MAINTENANCE

C4218

Fig. 4. 12

Oil Tank

Control Valve

Torque Motor w/ Brakes

Oil Filter

Brake Release Coupler

Oil Cooler

Hydraulic Gear Pump

Brake Valve

Tandem Pump

Torque Motor w/ Brakes

100 Micron Filter

4. MAINTENANCE

4.14 HYDRAULIC CIRCUIT

Tilt Cylinders

Lift Cylinders

Auxiliary Hydraulics

C4217

Control Valve

A. Lift Cylinder Circuit B. Aux. Hydraulics Circuit C. Tilt Cylinder Circuit

To Oil Cooler

From

Gear

Pump

4. MAINTENANCE

4.15 SPECIAL TOOLS

T95S, T103S, T105S,

T115S

T103, T133, T133S,

T135, 137, T153,

1300

Part #

ILLUSTRATION

DESCRIPTION

MODEL

962201

955281

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 3 required

T103, T103S,

T105, T115, T135,

137, 150, T153, 1300

955283

(6 Bolt)

AXLE EXTRACTOR TOOL:

To remove axle from final drive housing.

Qty. 1

T173HL, T173HLS,

T173HLSII,

T203HD, T233HD,

T243HDS, T245HDS,

T175, 1700

960475

(8 Bolt)

AXLE EXTRACTOR TOOL:

To remove axle from final drive housing.

Qty. 1

T83S, T85, T95

960986

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 1

T173, T233

955287

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 1

T233HD

(up to

S/N LH000338)

957189

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 2 required

T173HL, T173HLS,

T173HLSII, T203HD,

T233HD (S/N

LH000339 onward),

T243HDS,

T245HDS, T175,

T225, 1700, 2200

958674

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 2 required

T103, T133, T133S,

T135, 137, 150, T153,

1300

960997

CHAIN TENSION TOOL:

To test chain tension.

C3651

C3652

C3653

C3654

C3655

C3656

C3657

C3658

T173HL, T173HLS,

T173HLSII, T203HD,

T233HD (S/N

LH000339 onward),

T243HDS,

T245HDS, T175,

T225, 1700, 2200

964613

SEAL INSTALLATION TOOL:

To install axle seal in final drive housing.

Qty. 2 required

C3657

4. MAINTENANCE

KUBOTA

ALL

MODELS

U-1288

916-30042 - 01

25197

07909-30202 - 01

25198

07916-30820 - 01

25199

07916-30840 - 01

25200

70090-01125 - 01

25201

960456

UNIVERSAL TOOL KIT:

1 each. Combination wrench 7/16”, 1/2”, 9/16”, 11/16”, 3/4”, 1 1/16”, 1 1/4”. Sockets, 1”, 1/2” drive, 7/8”, 1/2” drive, tool pouch, allen wrench 5/32” and 1/8”.

DRY LINER PULLER:

Used for removing and installing the dry liner of the engine.

Consists of: 304742 (64mm); 304743 (68mm); 30744 (75mm); 304745 (76mm); 304746 (82mm); 304747 (105mm); Removing Plates; 304748 Installing Plate

DIESEL ENGINE COMPRESSION TESTER: Used to measure diesel engine

compression and diagnosis of need for major overhaul.

CRANKSHAFT NUT SOCKET:

Used to take off and fix the crankshaft nut. (46 mm).

NOZZLE REMOVER SOCKET:

Used to unfasten the screw type nozzle holders.

NOZZLE DISASSEMBLY SOCKET:

Used in place of a vice for disassembly and repair of nozzles.

HYDRAULIC FLOW AND PRESSURE

GAUGE ASSEMBLY

4.15 SPECIAL TOOLS (Cont’d)

Part #

ILLUSTRATION DESCRIPTION MODEL

Universal

Tool Kit

ALL

MODELS

4. MAINTENANCE

ALL

MODELS

ALL

MODELS

C1840

C1841

CHAIN PULLER

SPANNER WRENCH 2’’ - 4 3/4’’:

To Repair Hydraulic Cylinders

PHOTO SENSOR / WHEEL SPEED TACHOMETER (Dual Function)

ALL

MODELS

FORCE GAUGE, PUSH PULL:

For Measuring Restraint Bar Brake Cable Adjustment. Special Order Only

T173HLS

T173HLS II

T243HDS T245HDS

T245HDK

C1839

C1837

43979

43980

43981

4.15 SPECIAL TOOLS (Cont’d)

Part #

ILLUSTRATION DESCRIPTION MODEL

MULTI METER:

For measuring continuity, voltage, etc.

ALL

MODELS

C2342

ANGLE FINDER:

For measuring control angles, U-joint and chassis angles etc.

ALL

MODELS

C2343

5. SPECIFICATIONS

5. 1 Loader Specifications

5. 2 Torque Specifications

5. 3 Decals

5. SPECIFICATIONS

Dimensions: (With Std. Tires & Dirt Bucket) 153 135TA/137

A. Overall operating height .................................................................................... 138” (3505.2 ) 137 3/4” (3498.9)

B. Height to hinge pin .................................................................................................110” (2794) 110” (2794)

C. Overall vehicle height .......................................................................................... 73.5” (1867) 73.5” (1867)

D. Overall length with bucket............................................................................... 127.8” (3246.1) 127.8” (3246.1)

E. Dump angle ..........................................................................................................................35° 35°

F. Dump height .....................................................................................................89.8” ( 2280.9) 89.8” (2280.9)

G. Reach — fully raised ...........................................................................................23.8” (604.5) 23.8” (604.5)

H. Height at 45° dump angle ..................................................................................73.5” (1866.9) 73.5”(1866.9)

I. Reach at 45° dump angle ........................................................................................28” (711.2) 28” (711.2)

J. Maximum roll back at ground ..............................................................................................27° 27°

K. Maximum roll back fully raised ...........................................................................................96° 97°

M. Wheel base ..................................................................................................................35” (889) 35” (889)

N. Overall length less bucket...............................................................................104.4” (2651.8) 104.4” (2651.8)

O. Ground clearance ....................................................................................................7.5” (190.5) 7.5” (190.5)

P. Maximum grading angle – bucket .........................................................................................90° 90°

Q. Angle of departure ................................................................................................................23° 28°

R. Bucket width ............................................................................................................60” (1524) 60” (1524)

S. Clearance circle – front – less bucket ...................................................................48” (1219.2) 48” (1219.2)

T. Clearance circle – front – with bucket ..................................................................72.6” (1844) 72.6” (1844)

U. Clearance circle – rear ........................................................................................61.9” (1572.3) 61.9” (1572.3)

V. Overall width – less bucket ................................................................................57.5” (1460.5) 57.5” (1460.5)

W. Tread ....................................................................................................................46.6”(1183.64) 46.6”(1183.64)

Operational:

Tipping Load SAE ....................................................................................3000 lbs. (1360.7 kg) 2600 lbs. (1180 kg)

Rated Operating Capacity ..............................................................................1500 lbs. (682 kg) 1300 lbs. (590 kg)

Operating Weight .........................................................................................5700 lbs. (2585 kg) 5350 lbs. (2477 kg)

Shipping Weight............................................................................................5350 lbs. (2427 kg) 4830 lbs. (2191 kg)

Travel Speed............................................................................................0-6.2 mph (0-9.9 km/h) 0-6.2 mph (0-9.9 km/h)

5.1 LOADER SPECIFICATIONS

5. SPECIFICATIONS

Controls

VEHICLE: Steering direction and speed controlled by two hand operated control levers.

HYDRAULICS: Lift and bucket tilt are controlled by seperate foot pedals or hand controls. Auxiliary hydraulics

controlled by foot pedal.

ENGINE: Hand throttle, key type ignition switch and shutoff.

Engine 153 135TA/137

Make and model...............................................................................Kubota V2203E....................................Kubota V1903E

Cylinders .....................................................................................................4.........................................................................4

Cooling system .......................................................................................Liquid............................................................Liquid

Displacement ................................................................................134 cu.in. (2197 cc).......................113.3 cu. in. (1857 cc)

Horsepower (Gross) ...................................................................................50......................................................................42

Power (ISO 9249 Net Power) ..........................................................34.3 kW (46 Hp)....................................29 kW (39 Hp)

Power (ISO 9249 Net Power) CE..................................................33.8 kW (45.3 Hp).............................28.9 kW (38.8 Hp)

Max Torque.................................................................................115 ft. lbs. (15.9 kg/m)...................96 ft. lbs. (13.25 kg/m)

Fuel Type.......................................................................................................................Diesel No.2

Air Cleaner................................................................................................Replaceable Dry Cartridge w/Indicator

High Idle RPM..........................................................................................2800 ...............................................................2800

High Idle RPM, CE...................................................................................2600...............................................................2600

Hydraulic System

Pump type .......................................................................................................................Gear

Pump Capacity (theoretical) .........................................@ 2800 16.6 GPM (75.5 L/min).....@ 2600 15.4 GPM (70 L/min)

Control Valve.............................................................................Series type with float on lift and detent on auxiliary

Filtration..........................................................................................................................5 Micron

Hydraulic Fluid...................................................................................................10W30 API Class, SG

Oil Cooler.................................................................................................................674 BTU (711 kCal)

Cylinders. ................................................Lift (153)..........................Lift (135TA/137)..................Tilt (153/135TA/137)

Type..................................................Double acting.......................Double acting..........................Double acting

Qty- per mach .............................................2...........................................2 .............................................2

Bore dia ..................................................2.5 in......................................2 in.........................................2.5 in.

Rod dia ...................................................1.5 in....................................1.25 in....................................1.125 in.

Stroke .................................................27.125 in................................27.125 in.................................13.375 in.

Hydrostatic Transmission & Final Drive:

Pump type .................................................................................................Two in line, axial piston pumps

Pump displacement ..........................................................................................2.65 cu. in. (43.5 cm3)

Motor type ..................................................................................................................Geroler

Motor displacement .......................................................................................31.9 cu. in. (523.6 cm3)

System relief setting .........................................................................................5000 PSI (345 bar)

Final drive .......................................................................................Single roller chain running in oil bath to each axle

Drive chain size ..........................................................................................................ASA 100

Electrical 153/135TA/137

Alternator ........................................................................................................................40 A

Battery ..........................................................................................................................1 x 12V

Type (BCI GROUP).......................................................................................................34/78

Cranking Amps................................................................................................................730

Starter.......................................................................................................................12 V (1.4 kW)

Circuit breaker setting ....................................................................................................40 A

5. SPECIFICATIONS

153/135TA/137

Tires

Standard............................................................................................10.00 x 16.5, 6 ply rating, 40 - 45 PSI (276 - 310 kPa)

Fluid Capacities

Fuel tank ............................................................................................................16. 8 Gal. (64 L) ......................Diesel No. 2

Final drive transmissions (each) ..........................................................................1.5 gal. (5.7 L) ..................10W30 API SJ

Hydraulic reservoir ...............................................................................................8 gal. (30.3 L) ..................10W30 API SJ

Engine oil ...............................................................................................................8. 5 qts. (8 L) .................10W30 API CF

Engine cooling system ........................................................................................3. 2 gal. (12 L) ....50/50 water & ethylene

5.2 TORQUE SPECIFICATIONS

Loader

Wheel nuts (24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 - 110 ft lbs. (136 - 139 Nm)

Chain tightener adjuster nuts (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 ft. lbs. (203 Nm)

Torque motor drive sprocket (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 ft. lbs.(475 Nm)

Hydraulic / Hydrostatic

Gear pump section bolts (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 28 ft. lbs. (34 - 38 Nm)

Piston pump section bolts (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 31 ft. lbs. (37 - 42 Nm)

Torque motor section bolts (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ft. lbs. (68 Nm)

Hydraulic filter, case (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 ft. lbs. (41 Nm)

FOR NON-CRITICAL AND NOT OTHERWISE MENTIONED APPLICATIONS. THE FOLLOWING GENERAL ASSEMBLY TORQUES WILL APPLY:

Bolts & Nuts Torque

Lbs. ft. (Nm)

1/4 - 20 5 - 7 (6. 7 - 9. 5) 5/16 - 18 12 - 15 (16 - 20) 5/16 - 24 12 - 15 (16 - 20) 3/8 - 16 17 - 22 (23 - 30) 3/8 - 24 22 - 27 (30 - 37) 7/16 - 14 30 - 35 (41 - 47) 7/16 - 20 40 - 45 (54 - 61) 1/2 - 13 45 - 50 (61 - 68) 1/2 - 20 50 - 60 (68 - 81) 9/16 - 12 60 - 70 (81 - 95) 9/16 - 18 65 - 75 (88 - 102) 5/8 - 11 75 - 85 (102 - 115) 5/8 - 18 100 - 110 (136 - 139)

5. SPECIFICATIONS

5.3 DECALS

1. 37060

2. 42107

3. 39196

4. 23324

5. 32275

6. 39191

7. 39192

8. 23326

9. 41066

10. 23301

11. 37059

12. 31291

13. 23325

14. 25460

15. 36598

16. 39197

17. 23307

18. 38043

19. 41064

20. 23308

21. 23312

22. 23310

23. 23321

24. 37010

25. 23309

26. 41065

27. 44615

28. 48087 (135TA) ( S/N LE011400)

52868 (135TA) (S/N LE011400 )

49716 (137) ( S/N LE011400)

52769 (137) (S/N LE011400 )

47263 (153) ( S/N LN004400)

52770 (153) (S/N LN004400 )

6. ATTACHMENTS AND BUCKETS

6. 1 Thomas Approved Buckets and Attachments

6. ATTACHMENTS AND BUCKETS

7070

Cat. # Description Approx. Weight

941 9” X 48” (228.6 mm x 1219 mm) Auger Bits 75 lbs ( 34 kg ) 943 12” X 48” (304.8 mm x 1219 mm) Auger Bit w/Serrated Edges 100 lbs ( 45.4 kg ) 119 14” X 52” (355.6 mm x 1320.8 mm)Auger Bit w/Serrated Edges 105 lbs ( 47.6 kg ) 120 16” X 52” (406.4 mm x 1320.8 mm) Auger Bit w/Serrated Edges 118 lbs ( 53.5 kg )

Post Hole Auger Bits

6. 1 THOMAS APPROVED BUCKETS AND ATTACHMENTS

Cat. # Description SAE Heaped Cap. (cu. ft.) Approx. Weight

1882 54” (1372 mm) Dirt Bucket 10.5 330 lb.(149.7 kg) 1881 60” (1524 mm) Dirt Bucket 10.5 354 lb. (160.6 kg) 2667 66” (1676 mm) Dirt Bucket 12.85 425 lb. (192.8 kg) 1880 60” (1524 mm) Low Profile Dirt Bucket 11.6 402 lb. (182.3 kg) 1955 66” (1676 mm) Snow and Light Material Bucket 23.7 468 lb. (212.3 kg) 2001 60” (1524 mm) Fertilizer Bucket 14.3 330 lb. (149.7 kg) 2002 68” (1727 mm) Fertilizer Bucket 20.6 396 lb. (179.6 kg) 1935 60” (1524 mm) Flat Bottom Utility Bucket 13.6 386 lb. (175.1 kg) 2007 66” (1676 mm) High Capacity Bucket 28.7 495 lb. (224.6 kg)

Buckets

Cat. # Description Approx. Weight 2032 70” (1778 mm) Dozer Blade, Hydraulic Swing (1) 710 lbs. (322 kg)

Dozer Blade

6. ATTACHMENTS AND BUCKETS

Cat. # Description Approx. Weight 1930 60” (1524 mm) Industrial Grapple (1) 875 lb. (396.9 kg)

Industrial Grapple Bucket

Cat. # Description Approx. Weight 1943 Hydraulic Salt/Sand Spreader (1) 394 lb. (178. 7 kg)

Hydraulic Spreader

Cat. # Description Approx. Weight

2569 Model PA40 Auger Drive (Requires Mount and Bit) (1) 160 lb. (72.6 kg) 1891 Auger Mount 126 lb. (57.2 kg)

Post Hole Auger

Cat. # Description Approx. Weight

2441 Toothbar Complete for 60” Dirt Bucket 85 lb. (38.6 kg) 2670 Toothbar Complete for 66” Dirt Bucket 95 lb. (43.1 kg) 2451 8 Tooth Kit, Painted for 60” Bucket 18 lb. (8.2 kg) 2452 9 Tooth Kit, Painted for 66” Bucket 20 lb. (9.1 kg) 2455 Kit, Bolt-On Edge for 60” Bucket 84 lb. (38.1 kg) 2668 Kit, Bolt-On Edge for 66” Bucket 90 lb. (40.8 kg)

Bucket Options

(1) Require Quick Coupling Kit

Cat. # Description Approx. Weight

1694 Model HH300/500 Side Plates 200 lb. (91 kg) 1929 HH300/500 Breaker Mount 192 lb. (87.1 kg)

Breaker Side Plates and Mount

Cat. # Description Approx. Weight 1541 HH 300-300 lb. Class Hydraulic Breaker (1) (2) 300 lb. (136 kg)

Hydraulic Breaker (REQUIRES SIDE PLATES, MOUNT & TOOL)

Cat. # Description Approx. Weight

1545 Moil Point - HH300 25 lb. (11.3 kg) 1546 Chisel Point - HH300 35 lb. (16 kg) 1547 Blunt Point - HH300 35 lb. (16 kg) 1576 Asphalt Cutter - HH300 41 lb. (18.6 kg) 1577 Tamping Pad 12 x 12 - HH300 105 lb. (47.6 kg) 1549 Gas Charger 2 lb. (0.9 kg)

Breaker Tools

Cat. # Description Approx. Weight

2330 Pallet Fork Frame (Requires Tines) 226 lb. (102.5 kg) 99 30” Tines (Set of Two) 110 lb. (49.9 kg) 98 36” Tines (Set of Two) 138 lb. (62.6 kg) 437 42” Tines (Set of Two) 149 lb. (67.6 kg) 2564 48” Tines (Set of Two) 160 lb. (72.6 kg)

Pallet Fork

6. ATTACHMENTS AND BUCKETS

6. 1 THOMAS APPROVED BUCKETS AND ATTACHMENTS (Continued)

Cat. # Description Approx. Weight

2213 BH 108 Backhoe Base Unit (1) (2) 780 lb. (353.8 kg) 2211 External Controls (1) 470 lb. (213.2 kg) 2222 Internal Controls (1) 470 lb. (213.2 kg) 2234 Mounting Kit (1) 2235 English Manuals and Decals (1) 1 lb. (0.5 kg) 1483 12” Bucket w/Teeth (1) 120 lb. (54.4 kg) 1482 18” Bucket w/Teeth (1) 140 lb. (63.5 kg) 1481 22” Bucket w/Teeth (1) 160 lb. (72.6 kg)

BH 108 Backhoe

Cat. # Description Approx. Weight

1821 Quick-Tachs Complete 94 lb. (42.6 kg) 2031 Quick-Tachs Adapter Plate 69 lb. (31.3 kg)

Quick-Tachs

(1) Use Of A Cab Door Recommended With This Attachment (2) Prices Are FOB Glendale Hts., IL.

(1) Order one each base unit, controls, mount, manual & bucket. (2) Includes flat face quick coupling kit.

6. ATTACHMENTS AND BUCKETS

6. 1 THOMAS APPROVED BUCKETS AND ATTACHMENTS (Continued)

Cat. # Description Approx. Weight

2189 72” Angle Broom (Requires Quick Coupler Kit) 500 lb. (226.8 kg) 2708 Quick Coupler Kit, Poppet Style 5 lb. (2.3 kg) 2873 Quick Coupler Kit, Flat Face Style

Angle Broom

Cat. # Description Approx. Weight

1392 60” Bucket Sweeper Drive (Requires Quick Coupler, Plate, Bucket) 564 lb. (255.9 kg) 1428 72” Bucket Sweeper Drive (Req. CPLR, Plate, Bucket) (1) 660lb. (299 kg) 2708 Quick Coupler Kit. Poppet Style 5 lb. (2.3 kg) 2873 Quick Coupler Kit, Flat Face Style 1427 Backing Plate 5 lb. (2.3 kg) 1935 60” Flat Bottom Utility Bucket 386 lb. (175 kg) 1936 73” Utility Bucket 480 lb. (218 kg)

Bucket Sweeper

Cat. # Description Approx. Weight

1834 Gutter Brush (1) 80 lb. (36.3 kg) 1298 Water Sprinkler System (1) 50 lb. (22.7 kg)

Bucket Sweeper Options

Cat. # Description Approx. Weight

2570 Tracks, Metal, for 10.00 x 16.5 Tire (1) 819 lb. (371.5 kg) 2571 Tracks, Soft w/Replaceable Pads, for 10.00 x 16.5 Tire (1) 872 lb. (395.6 kg) 2572 Tracks, Hard w/Replaceable Pads, for 10.00 x 16.5 Tire (1) 981 lb. (445 kg)

Tracks

(1) Dealer Assembly Required

(1) Includes Axle Spacer Kit

Thomas 135TA, 137, 153 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual