TTrroojjaann Service, Part, & Operator’s Manual 204A Front End Loader

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF Service, Part, & Operator’s Manual TROJAN OR IT’S SUCCESSORS. TROJAN AND IT’S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. TR-SOP-204A+ "': if!$ .\. -.~ ~ Main Hydra!l:lic System ' .. ~ .. . Ordering Parts ; ... Operating Controls Operating Instructions ...... Preparation for Operation .... ,.,.,.,. 'and Safety Precautions ...... , ...... Hydraulic Systems Start-Up Procedure ...... '.~;: .. . Instrriment Panel ..... ,...... 6,7 Steering Hydraulic System ''t',-,. .- J,uJbricationGharts . 28,29 Trapynl;issfon Hydraulic System ... Luhrication I~structions 30,31 .',... '. PARTS t)f~TtNG A Fuel Tank and: Lines' (IHC) ...... 42 . :, . Accelerator Pedal and Linkage (IHe) ..... 42 Fuel Tank and Lines (GM Diesel) " Al '." ~".~ .... ~, Accelerator.;Pedal and Linkage (OM Diesel) 41 ... Air Cleaner and Exhaus'i: $ystem (IHe) ...... 50,)1 g::Jt",rn',:um'ri' P",.1 G...... ~("f .' ,-0;'- _~. ~, .' . AirClea?er and Exhaust System (GM Diesel) .. 48,49 ;.,~;. Automatic Bucket Leveler ...... 52,53 ,;:, . Axle Assemhl y, Rigid ., ...... 82 .. Axle Assembly, Steer 83 '.-' i1~~~. Lights ...... :~:::·;~-.·:t::;~:::·::~t~~:~,:2~~,. B l-!ydraul~c ~(''''~)1 ~ .,lvekv~rs. ~ain .., .... /·'.. 6#·,::;: ·')~a,¢k-UpLights ...... 57 f:iydrauk '- ·_, .. ~tOl .Jalve, !MalJ1. . 60,61.:" .,,! Battery and Wiring (IHCL-...... ,...... 56 Hyd.... aulil: ,.~·_:l'm'ol Valve, S:ee;'j_.g' : ...... 7·f Battery and Wiring (GM Diesel) ...... (: 55 Hydrant<: r'!1np, M?ln ...... __ .... , .... , 62 ,l3ritke, Rigid Axle ...... ~4, 8:J Hydrauli'~ ~)u)n,::·. '::;:ceriI~g ...... "'" .. :;: .. c~~·· 68' Brake, Steer Axle ...... 88,89 Hydraulic.Systeir''1.Main ..... ~-• .-:."'!~~, 59 Brake System and Controls ...... 80,81, 80A, 8IB-CD Hydraul;c STst~!r" Steering ..... ,.: .... '66, 67 Brake Control, Parking ...... ,...... 33 .. _Hydravtl..!:.5,y;'l. Control Valve, Main Hydraulic .... . 60,61 Lift Arm Linkage ...... 36,3.7 Control Valve, Steering Hydraulic ...... 71 Lift Cylinder ..... : ...... ;~:":, ...... 64 Counterweight ...... 38 Lights and Moul:)-tfRgs ... 'Cylinder, Bucket ...... 65 M Cylinder, Lift ...... 64 Main .Frame ~omponents Cylinder, Steering ...... :70 . Main Hydraulic System D Hydraulic Pump. Decals ...... 43 Mounts (IHe) Differential Group .... . 92,93 !Mounts (GM Diesel) .... • Directional Lever, F-N-R ...... 76,77, (IHC) . "'y' Drag Link. iZ • (GM Diesel) Drive ShCl'ft 78,79 p Paint ...... 4} . "t' E, ... , Parking 'Brake Control 33 'Ii_ne and Related Parts(U-lC)·.. ":." 46,47 Planetarv Huh, Rigid A.xle 86.S7 Engine ancj.H.elated Part<; (GM Diesel) ... . "M,45 Planetary Huib, Steer 90,91 .f· 42 Axle En.;ine .(]?'il:trdl~.(lHq·:. '...... Propeller Shafts 78,]9 Eilg~ne:unlP,' Mai.,. ,!'iy,draulic . ,." .. ~:~.~·.. f',,;.J,""""" '62 r . '.~hil'~$i~)~lt~r,) (GM· Dle:}~l) 46,49, P~,mp, Steering, H"'!~:J.Jlic ...... ' .··':::.~}r·'~\· 68 l,' ' ",'__ , -: ,\~J :9.':;~""':..' .' . 't"", F; '. fi, F:j'o~rbo;-'~;d'S~ ., .. /.:~-r:;~:~:~~~:~~·;~:8~~iv.;-bl::o~e.~· •. " t;'" •• , Fr.Hr~·.. Y.·ja'H "':~:~}T::~~"-' ~.-~:' ... :'.-' -."...,-...,---,.--,,-.- . .... TB03~;-,'''' ~,,: ::~;, :l'~,:-~~:" »..?- .~ ,:>., TROJAN ,.. .;i .. ~ .'.;,. . (C"'- t· d)' .' -",",~~.,> o~ 'n~~ -.'" .. -'" -~. -~ . "'t-:' ~ c,~' s :};::: ~f~~,. .. .~!i::~!~~:~n Q>ntr,ols ...... ~~.: ...... , ...... : ...... 7~~~;' '~. }~\'-~-~,';,,;: . S~at" ...... :~~. 33 ··'FWnsmission HY4~a:4.ij,c System ...... ~...... 74,75 ii-' . . Sheetmetal ...... 40 'Transmission MQutttirfg Parts ...... _ ...... 74,75 Steering Axle ...... 83 :' Steering ...... 71 v Steering Linkage ...... 72 Valve Con·trols, ,Main ...... 63 Steering Hydraulic System ...... 66, 67 Valve,IMain Hydraulic Control ...... :· 60,61 Steering Pressure Relief Valve ...... •...... 69 Valve, Steering Hydraulic Con·trol ...... 71 Steering Pump ...... :...... 68 Valve, Steering ·PressureRelief ...... 69 T W Linkage ...... 41, 42 Wheels ...... 94 and Wheels ...... _.... ~ .... _ 9'1, \~:;·idng (IHC) ...... : 56 Tools ...... _...... _... _...... __ ...... 43 \r.r; d:n;?, (GM Diesel) ...... 55

Disassen~!qlya!l.4 AssemMy of Convert~i ...... 97, W; ~'ui:que.C~v\.cr~e:· P~rt~ Listing ...... 112,113 Disassemhlya-nd Assembly of Pl;,,:s~ure Transmlsslr.-tl c'.:. ri;.<; Listing ...... 115, 116 Regulating Valve ...... 99. Pressure Regulatir.,g Va'{,ve Parts Listing ...... 114 Disassemtbly & Asse1ll'bly of Transmission .. 100 thrv. ~ 11 Control Valve ...... 118 thru 121 -._. TR-QJAN STANDARD IPA'RTS SE'CTI'ON (See Index, Rear of Manual)

Vendors and Part Numbers (See Rear of Manual) SAFETY -PRECAUTIONS The Trojan Tractor Shovel has been designed to incorporate every safety device possible. The Trojan ((Safety Curve Lift Arms*" which has been widely imitated but never equalled completely eliminates the shear hazard present in many other tractor shovels. Your Trojan has large, well-positioned steps with adequate hand holds so the ~perator can easily climb to the seat without having to step on a slippery . However, with all these safety features which have been incorpora;ted in the design of the Trojan Tractor Shovel there are still the dange~sQf rt.Jnnmg overa)~an. '~. dropping the bucket on him, etc. And therefore, thi}perator·m'ust:be~1{tremelycarefulin the operation of a big tool such .~s this. In order to hei'p prevent accidents thefollowingsa:fd:y rules should be observed at ~lltimes: . !~{ . 1. Ne;er !,eave the'op~rators seif\vith the arms rai~~d~ _,', .. '2~ ,Never leave the seat':with the' engine nipnihg., . .. c~ :8~tih!! parking br~k~ bef9reJeaving the.se~~:' . '4YAlway~ J90k c.arefully b~fore starting the machine in motion., Have some- . oriebfl'thegroundg~\:,e ahand signal that all is dear. . ..' . ····:5. ; Never lift the bucket over a ~round crew or truck cab. .... 6. Never carry a rider in the bucket.

'7. Keep the brakes properly adjusted. . c. . '. 8. Always stop the engine"to'iriake adjustments or lubricate'the machine. * P;tented in the United ..'--

[4J TB035 , .... ~. .. TROJAN .. ~'(i?;t~· ·.,.n· '..," PREPARATI(''N FOR OPE~ATION, ','itl . ..<~:~-~.. "" ''Before starting' yOur Trojan Trutor Shovel, place it .~,: ~h~ to see ,that die cooling ,systel~\ ~sfilled. ,~;;~:~::, on level ground and make the fol,lowing checks: ~. Cheac the strength of tlhe; anti-freeze: l(freez- . " J 1 L k lIth . I 'b I d. '~';.Ii,,~g conditions prevail. .'. i'.' ,,~...... , .t,... " .....:.:..... • 00 at a e sena nu,m er pates an enter.. ~ ef th <'I" the numbers in the parts 'and operators manual. 7. Grooseall lwbrica.tion points, r erring to e • ~. '" : luhri~at1on section of this manual for location ..;;' 2. Check the entire machine for damage in transit. and type 0,£ lworicani required. ~ ....,.. a. See that all the holts and nuts are tight. 8. "Check the oil level of the follow:!~g, r~ferring ,. ~.?l".'; b. Pay paI'ticular a,ttention to the axle, trans­ to . the> Jtil'bri.cation dhart as a guide fOL 10ca- .'Ir' mission, ,wheel nuts, and engine bolts. See tion, quantity and type of luibricttion: torque chart. a. Engine crankcase. 3. Oheck all the drain p!·<.Igs, drain co-cks, filler h. Front drive axle. openings, fuel lines, cooling system; brake lines, <.. c.. Rear drive axle. and air cleaner ce{tnect~d)ns m .. ee -that they are "d. Main hydraulic SYfi,te:m. .. ' tight and do not leak.' '. e. . St~ering !hl'draulk sys'teni. .£.. 1'ra~ltimiss!on h;:4raulic ·~stem. 4. Fill tlhe fuel tank. ;\/:r . ~ '.': ,g.... S,*vice br,alsef}ciraulic syst.?:m. . ·dl 1,·J· . ,1, I d 5. Be sure .th~{we tr.{itt;n'platesarec~(~·r,rith ;:c:.~',:.'_-i·~ ,~' C'o 'f, ;':.'-" '('sections Of,' In<.trurnents, contro s, an

water. Add only<:l~ndistilIeJ wa~&. . . op~"f~:~;g ;rlst;:iJ.ctions ,befor.~ I)tacti"s the erugi!1e. . I ~" . INSTRUMENTS AND S,WilCH5· _. . . =:·">~.-'-'·~'4J·; .,J'::-'.\:.,:"" It is a ,good practice for the operatotto -Le c'_',npie;;dv,'"'; It¢ltl, No.8 familiar with all the instruments and tlheir function 6': IGNITION SW1T~H: Energizes all the gauges that he can glance '.. jc::.;, ... ing items as lis~ed: ", . '. -::$'; .'{:. ,,-> TORQUE CONVERTER TEMPERATURE GAUGE: .", Item No. I""" Indicates the temperature of the torque converter oil ENGINE OIL PRESSURE GAUGE: Indicafes pres- as it leaves the torque converter. It will normally reg- sure in the engine lubrication system. This gauge will,.. ister in the range of 200 to 220 F. When the temper- register between 30 and 70 pounds pressure under nor- ature approaches 250, shift to a lower gear. An ex- mal conditions. If the gauge fails to register pressure, ;'.,:~. cessive or climbing temperature might mean clogging stop the engine immediately and find out the cause. ;':.,<: on the radiator cooler or a lack of torque converter oil Item No.2. ': :'.' flows Investigate immediately if the torque converter ENGINE WATER TEMPERATURE:.l~AUGE: Jil- 1 temQtt. The tl!(l1 1.'10. 10· . gauge will register in tlhe vicinity d 180" for nC'r·nal LIGHT $ WITCH: . Opemtes :the dash Hght, head Operation. lights, and ;back-up lights in the first position. In the ~econd position, the dash lights and head lights remain on but the hack-up lights go off and the tail lights Indicates the amount of fuel in the C0!11e on. Pull the switch to operate it.. when the ignition is on. When the ignition is turned off the pointer drops hack to the empty Item No. 11 MAIN HYDRAULIC PRESSURE GAUGE: Indi- • . cates the pressure at the. hy;,iraulic valve for operating Item"No. 5 . " I the lift at'111oS and bucket. Gi6:'ge sihould read 1500 p.s.i. The HORN BUTTON ·locai:ed.in the center o.f~he maximum. (Pur Machines Having Serial No. 21443 .~;: steering wheel, operates the electric hon~. thru 64-1029). Item No.6 AIR PRESSURE GAUGE: (For Machines Having AMMETER: . Shows -the current' How

6] THE YALE 8< TOWNE MFG. CO.' T£:I035 S'". .. '1.,' TROJAN

• i 1 2 3 4 5' 6:\78'ij,9 10 11 ~ ":.-

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',. 21 20 19 18 1'7

1. Engine Oil Press1.{~~:,Ga~ge' ift~}7. Emergency Stop Knob (G.M. Diesel Only) 2. "\7ater Tempera,t-ure Gaug~,\ ." .. _ -~'S.;'Foct Brake (For Machine Having Serial No. 3. Fuel Gauge' . thru 64-102:9. 4. Steering Wheel Spinner 19. Foot Brake (with Clutch Cutout) 5 .. Horn Button 20. Seat Adjustment Knob r, ,A,mmeter 2 i. Engine Shut Dciwn Knoh (G.M. Diesel Only) 7. Cknch. Pre-~sure. Gauge. . Choke Knob (IH. Gas Only) 8. Ignition Switoh 22. Hand Brake Lever 9. ~r~r'lu~ (:o~vertt.r Temperature Gauge 23. Starter Hutton 10. L1·~ht Sw!tch 23A. Gutch Cut Out Selector Valve (For Machines 11. M~in Hydra'llic Pressure Gauge Having Serial No. 64-1030 & Higher, 12. Buckel Conu'ol Lever .:. ' Not Illustrated)'- 13. 1,ift Control Lr.:ver Sf 24. EngineHourmeter 14. Accelerator Pedal 25. Speed Range Control Lever '1"5 ~ Hi-Lo gange Lever 26. Direction Control Lever -->1 16. Fou;:\'(lhee1 Drive Lever 1__ .• __ ··...... _. ___ • _____.____ • ______(Start in Neutral).,-- ______,

Fig. No.3. Operator's Compartment

------~---~~~~------~------~------THE YALE 8< TQWNE MFG. CO. [7] OJA i'·t.. '. .. '~ .~ ,,*.., h ~ T R "'. NP ". .<' ;""~~'!

Main Hydraulic ...... 1500 psi. *Bucket Circuit Relief Valve ...... 1100 psi .... ;. Steering Hydraulic ...... 1500 psi. Tires: 14.00-24 ..... 45 psi. Transmission Clutch 16.00-24 ...... 45 psi. (at Engine Idle) ..... 240 p.s.i. Min.-270 p.s.i. Max. * :POl' Machines Having Serial No. 64-1051 &

Sistem Voltage ...... 12v. Tail Lamps .. Ground ...... P-ositive Lamp Circuit Fuse 30 amp. Head lamps ...... ,~{,-~'.:. 12v. . Gauge Circuit Fuse 2 amp. Back-up Lamps ...... 12v. :<::;ircuit Breaker 12v . -: '" START·UP - SHUT-'[)OWN"PROCEDURE . Before avtempting to start the engine, the operator 2. Turn swit",h key to on position . should read carefully engine starting instruction,~ in the engine >n'lanu-factur·ers .operator's Imanual. Attempting 3, Set accelerator pedal at full fuel positiclll;. (Item 14, to run the engine 'hefore studyi!lg those instructions may Fig. 3). result in permanent damage to it. \XTith the machine fully serviced and -the operator com­ 4. Press ,;~arte, button firmly :to start engine. Crank pletely familiar 'with the location and function of the , engine fot· no mort' than 30 sec·onds in oneperi6d, OPERATING CONTROLS, INSTRUMENTS AND to 'avoid overheating starting m.otor. SWrJ1GHES, the Tractor Shovel is then'started accord­ ing1:o the -following instructions: CAUTION: ,If the el~gine fails to start DO NOT \ repress ,button· u'!'ltil startingmbtor IN WARM WEATHER: .<,topsrotating. Failure to'do·this may 1. Place d}rectional control lever In neutral position. .. '. (cslfh ill serious damage to engine. ""!Ml! Indicates Revision

TB035 YALE & TOWNE, INC. TROJAN

. ;:~ OPE D G THE TRACTOR SHOVEL ..'I':*"if) ' '. .Ir ,; I '<': ~~.," -.' ,- ' ~ATI~: "" '; " ~4..~ ", . ':b%~, ,~" .' , ' ~Qt~~NG_E B~J?T: Plac;;espeed:range lev~ off the I~round. Nev~ trans~ t'lie load wLth~~,.,~,_ IX In li:rst,gear an~,th.e dlrect1onallevet'~elie fSiw POSI- hucket raised more than half. ~ , the_::";:,, .tion. When loading ,f,ro.m a stock plle/dq,ye 'iJ;i.t" . pil.., ground that .the· huoke:t is held, the :, .':"\IJ~ with the cutting edge parallel to the ground. Push ~U;,. of tthe machme; espeCially on slopes or . , ting edge into the pile untiltthe buclcetis nearly filled.. Pull the Hft arm control lever back and alternately pull DUMPING THE BUCKET: Raise the the !bucket control lever back, so that tthe lift arm raises that it dears the top edge of th,e truck side Qr the and the buoket tips :b3!ck a little hit at a time. Continue Keepvhe machine perpendiou1ar to the truck side or to raise until the !bucket is full. Push the lift arm con­ bin so. the lQ3!d can he dumped ,evenly inside the dump­ trollever to neutral. Back away f,rom the pile keeping ing area. With the Hft arm ,contrQl lever in the neu- , the load low" and carry the 103!d to where it is, to. be tral Qr hold PQsition, push .forward Qn the hucket con" .r. . dumped. " tro1 lever to. dump the' l.oad. Do. nQt push the lever all the 'Way fDrward immediately-the lQad may dump When grading or excavating, the hucket should :be ad­ tQQ quickly and damage tthe truck -body. ,Pull back­ justed so. that the PQinter Qn the ,right hand cylinder ward o.n the 'bucket cDntrol lever to' return the huoket indicates ,the hucket· is in a level PQ~ition. The hucket to. a level pDsitipn and back the machine· away fr.om is then tipped slightly fQrwal'd, toward the dump posi­ the truck o.r hin. Put the lift arm oQntrQl lever in tiQn;tCi get 'some penetratiQn., \~hen the cutting edge flQat PQ.sitiQn toO lower the bucket and proceed 'back to. penetrates, use the bucket ,cQntrQl lever to. adjust the the pile toO get another lQad. , bucket to. the right angle to. prevent excessive penetra. tiQn. The bucketcQntrQI lever can be worked sHghtly TRAVELING WITHOUT A LOAD IN Tr.,IB fQrward and 'back to. maintain agra:de as the machine BUCKET: When the machine is takenfrQm ~tQ mQves forward. To hQld a, gr3!de properly, the fOQt job the ;'bucket -shQuld be Taised abQut 14 inc;ktes throttle shQuld be rheldat 'ah'o.ut halfthrQttle in low off the -ground. The machine can he driven in gear. When the 'bucket is [ulland the' e~d of cut is' one o.f the higher to the new job site. SQme reached, pull iba,ckward' on 'the bucket cQntrQl lever to. .operators prefer to. drive the machin¢4n reverse to. get tiptthe hucket back against 'the stops, and, raise the lift higher speed, witih more steering contrQl. This pro­ arms slightly Qff the ground-for carrying the l()ad. ,cedure is, not recommended hecause Qf tqe re~art:ively TRANSPORTING THE LOAD: When transport­ .. pOQr visrbility o.f the; operator Qver the r~aT, hood of ing tthe lQad, travel speed OIf the machine will depend the machine and:al-scl ibecauseof the danger of over on the length of the haul and the kind of ~urface over heating the engine. The impact air coming through which the machine must pass. RQugh terrain'calls fo.r the radiato.r .fwm traveling baokward'S neutralizes tthe fairly slQW speed as do sharp CQrner.s. When the bucket air flo.W from the pusher fan. Engine Qver heating may is full, it should he carried ,approximately 14 inches result. :~ "--~ HYDRAUUC SY;ST'EMS L, . There ate 'four separate hydra~lic lSystems Qn this machine. Each i.s serviced differently. A. Main Hydraulic System, ., In, additiQn to. an Oil D. ReservQir, Main Pump, tw~ DQuble Acting Uft and Bucket Cylinders, CQnnecting Hoses and Fit­ tings, there is a two. Spool CQntrol Valve with three Sa:fety Check Valves and a Pressure Relief Valve huilt as an integral unit lQcated 'behind the reser- . voir. Installed in the reservoir is a full flow MONEi.filter to. protect the sy.stem against dirt and .fQreign material. Use SAE-IOW Hydraulic Oil. D. B. Steering Iiydraulic System cQnsists of an Oil Reser­ voir, Steering Pump attached to the TQrque CQn­ verter, CQntJ;'Ol Valve .located at the base of the Steering CQl~~, Prdsure Relief Valve, Qne Steer- "i,'; ing Cylinder, Qriefull flQW MONEL filter mQunt­ ed in the re~eryQit,; one Replacei,'ll.i'~d the re...,ervQir, and. CQnnect­ ,ff' ing Hoses and Fittitlgs:UEI! SAE;.. lOW Hydraulic Oil. Cir.;; c. TransmissiQn H;d~~uli~';Sy;+~m 'consists' o.f an Oil Supply'in thl!- ;rransmissionSump, Charging Pump, CQntrol Vahre and Pressure Relief;'Vah,e huilt in­ tegraUy"~Ith,the 'to'qi'.l.e (;Dnvertet, ,'TransmissiQn, and CDnnecting Hos~s ancl"'Flttings'-~UseType A Suffix A, Automatic Transmission Fluid•

.r--:· TB035 THE YALE Be',TOWNE MFG. CO.

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