Trojan 240A Front End Loader Operators Manual
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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.<ii}1, Tr.?,nsmissioq, ' .................. 74,75 • Bucket and Toot!h Assemhly .... " ..... ,..................... 39 "~. ;. ,:.': ~~:.;:..v T ~:» '-/ Bucket Cylinder . .................................... 65 Instrument 'Panel ... • 54 Bucket Indicator and Leveler ..... 52, 53, 52A, 53A. , . ',.- oj j:-;L C 36,37' cah .......... .. ..................... 34;3:" . t~hel~:~l~:~~~.i:;!:~:~:': .......... 36,3.7 > 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:<tqhtt.9I~ '. (GM Diesel) '41 Pre~s.ure rt.elie'i' \l.:h:~t:, f ... 1~1rt 60,6f .i'·. Euier Starti9gKit (GM.' Diesd.) 43 Presw:-i! Relief Valve, Steerin~~~ ,... Gi' ··''''l!·iB;!;llitu.',::.Sy~~em.(IHC) .. ' ." •... ~ .. ,., '.. ~n,)~ ~I>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 Gear .......................................................... 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 Throttle Linkage ................................................. 41, 42 Wheels ................................................................... 94 Tires 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 tire. 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