Thomas PROTOUGH 900 Owner/Operator And Parts Manual Download

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Summary of Contents for PROTOUGH 900

Page 1: ...Owner s Operator s and Parts Manual Publication No 50008 November 2004 S N T9000101 onward 900...

Page 2: ...NYONE ELSE FOR ANY INDI RECT INCIDENTAL CONSEQUENTIAL PUNITIVE ECONOMIC COMMER CIAL OR SPECIAL LOSS WHICH IN ANY WAYASSOCIATED WITH A PROD UCT THIS INCLUDES ANY LOSS OF USE OR NON PERFORMANCE OF A PRO...

Page 3: ...Service Access 4 1 Preventative Maintenance Schedule 4 2 Daily Service 4 3 50 Hour Service 4 4 300 Hour Service 4 5 900 Hour Service 4 6 As Required Service 4 7 Battery Maintenance and Boosting 4 8 El...

Page 4: ...ility 3 Be careful when towing through door openings or under overhead objects Always make sure there is sufficient clearance 4 When travelling on public roads know the local rules and regulations and...

Page 5: ...d by the radiator cap It is dangerous to remove the cap while the system is hot Allow the engine to cool before removing the radiator cap 10 Wear protective clothing such as safety eye wear hearing pr...

Page 6: ...ocated on fan inside engine compartment Red White Reflective Tape 46152 25 45748 Amber Reflective Tape 46155 Red White Reflective Tape 46152 31 Amber Reflective Tape 46155 50259 Red Reflective Tape 46...

Page 7: ...White Reflective Tape 46152 162 Amber Reflective Tape 46155 50149 Red White Reflective Tape 46152 56 18 31 18 Red White Reflective Tape 46152 T90109 Red Reflective Tape 46154 Amber Reflective Tape 46...

Page 8: ...3 45413 WARNING STAND BACK 10 Feet 3Meters ROCKS BOUNCE OFFTHIS MACHINE TH45414 45414 46164 Red White Reflective Tape 46152 31 46152 white 6 46152 56 39192 HYDRAULIC HYDRAULISCH HYRAULICO HYDRAULIQUE...

Page 9: ...ments can be located using the pictures provided Details of control operations and functions are explained in the Operations Section 3 7 Hydraulic fill Top screen plate Bottom screen Hopper Hitch Shak...

Page 10: ...ontinued 8 Shaker deck head Front cylinder jack Rear suspension stop lock Counterweight Shaker motor Trailer Elecrical Gladhand service brake connector Gladhand emergency brake connector T90009 T90114...

Page 11: ...2 CONTROLS 2 CONTROLS Engine Controls 2 1 Hydraulic Controls 2 2 Pneumatic Controls 2 3 Axle Stop Controls 2 4 9...

Page 12: ...off the alternator is charging D Glow plugs This indicator will illu minate whenever the engine plow plug pre heaters are engaged If it is flashing the preheating is done and the engine is ready to st...

Page 13: ...on or CCW counter clock wise 1 4 of a turn to release the air from the suspension and lower the unit This must be done prior to engaging the Shakerhead T90017 If Toggle switch is used on unit switch s...

Page 14: ...12...

Page 15: ...ction 3 1 Starting Instructions 3 2 Shut Down Procedure 3 3 Set up 3 4 Operating Procedures 3 5 General 3 5A Loading Procedure 3 5B Removing Finished Material 3 5C Removing Tailings 3 5D Screening Sel...

Page 16: ...ssure everything is tight and no hoses are chafed or have holes in them T90119 4 Check engine oil level T90120 5 Check engine coolant level T90120 6 Check engine fan belt for cuts or wear T90120 If ne...

Page 17: ...haker suspension mounts for cracks T90023 If cracks are found consult your local dealer 3 Verify there is no debris on the shaker screens and check for bystanders before start up 4 Check the shaker sc...

Page 18: ...lly to the clockwise posi tion T90014b Release when the engine has started Do not engage the starter for more than 15 seconds intervals Repeat the preheat procedure if the engine fails to start Allow...

Page 19: ...r screens The engine idle position is used for engine start up cool down and jack operations DO NOT operate at high idle settings while performing these operations Damage or injury may occur to the ma...

Page 20: ...ck piles as close as possible to prevent exces sive travel times 1 Remove axle stop control pin and repo sition lever to operating position rein stall safety pin T90057 T90011 2 Start the engine and o...

Page 21: ...ension system to lower the rear of the unit to ground level T90075 on page 18 6 Lower the front hydraulic jack to lower the machine to the ground Make sure bystanders and your feet are clear when the...

Page 22: ...more efficient to run the material through a larger screen combination first then change the screens to obtain the final product size This would be desirable when the materi al being sized clogs the...

Page 23: ...e smaller material is in front of the load before lowering onto the top screen deck This will provide some cushion effect Never drop large heavy objects directly onto the top screen deck fig S0012 Imm...

Page 24: ...area fig S0005 This will impede the shaker action and could result in serious damage to the shaker deck assembly Retrieve finished material from under the high hopper side area fig S0006 Drive into t...

Page 25: ...than the shaker deck area Remove tailings by pushing the materi al from the side of the machine fig S0007 Do not use the machine as a back stop fig S0008 Allowing excessive material to pile up under...

Page 26: ...will be lost to waste S0002 Results low yield A top screen with too large an opening or if the bottom screen size is small will clog the bottom screen S0003 Results low yield Proper loading technique...

Page 27: ...vehicle the emergency brakes will engage actuate automatically Check to be sure the axle lock machansim is in the transporting posi tion T90057 Verify that the clearance marker indica tor lights are...

Page 28: ...rear of unit will raise as tow vehicle air system charges with units air system T90075 If Toggle switch is used on unit switch suspension dump valve to the Up Position or to the left rear of unit will...

Page 29: ...G Chassis Maintenance 4 4H 300 Hour Service 4 5 Fuel Filter 4 5A 900 Hour Service 4 6 Engine Cooling System 4 6A Hydraulic System 4 6B As Required Service 4 7 Screen Replacement 4 7A Tire and Wheel Ma...

Page 30: ...depict how to access specific areas for service Hydraulic oil cooler Engine air precleaner Engine oil drain T90025 T90096 Engine access Control access Oil fill Muffler Battery Fuel filter Coolant over...

Page 31: ...off Grease points Fuel fill Oil site gauge Fuel site gauge Fuel tank drain Oil tank drain Grease Coupler alignment Suspension bolts ANTI LOCK BRAKES ABS This trailer is equipped with an anti lock sys...

Page 32: ...ings and pivot points Tires and Wheels Check air pressure and wheel nut torque every 50 hours or before each transport 50 Hour Service Perform complete 50 Hour service See section 4 Engine Oil Filter...

Page 33: ...If necessary tighten the bolts further in 25 lbs ft 34 Nm incre ments until the screen is tight against the crown bar rubbers Start the engine and engage the shaker to verify Refer to section 3 for op...

Page 34: ...and clamps Make sure clamps are tight and no hoses are chafed Check the air restriction indicator Replace the element if the indicator shows red color T90119 Check battery terminal connections Make su...

Page 35: ...Ensure all safety warning and instruc tion decals are in place and legible See section 1 2 for decal placements Ensure all shields are in place Make sure all compartment doors are closed and secured b...

Page 36: ...ire lubrication Grease each one before transporting the machine to a new location Refer to T90115 When performing maintenance ensure the engine is off and the ignition key is removed to prevent accide...

Page 37: ...he engine 3 Remove the oil drain plug T90096 Have a container ready to hold approx imately 8 5 quarts 8 liters of fluid 4 Remove the engine oil filter with a fil ter wrench 5 Apply clean motor oil to...

Page 38: ...CF 10 Replace the oil filler cap 11 Start the engine and check for leaks around the oil filter and drain plug Operate for two to three minutes and shut it off 12 Allow the engine to sit for five minu...

Page 39: ...r 300 hour ser vice information 1 Shut off the fuel line petcock located at the fuel tank T90100 Turn clock wise to close 2 Use a filter wrench and remove the fuel filter T90033 3 Lubricate the new fu...

Page 40: ...d screw on the engine T90033 The air bleed screw is locat ed at the front side of the engine 9 Start the engine and operate for two to three minutes before closing the air bleed screw 10 If the engine...

Page 41: ...indicator shows red depress the button to reset 2 Unlatch the air cleaner cover T90121 3 Pull gently on the primary air filter ele ment to remove S0072 4 Note the condition of the safety sec ondary f...

Page 42: ...ons force 1 4 3 8 in 22 lbs To adjust the fan belt 1 Loosen the bolts retaining the alternator to the engine 2 Use a pry bar to tension the fan belt and tighten the top alternator bolt 3 Check the ten...

Page 43: ...oolant needs to be flushed and changed every year or after 900 hours of operation which ever comes first See section 4 6 for 900 hour service informa tion Check the radiator fins for obstruction of da...

Page 44: ...uplers apart 3 Check the coupler for wear Replace if spider surface face is scared excessively or broken 4 Remove the spider and replace 5 Slide the couplers together Arrange the couplers to have the...

Page 45: ...f the feeler gauge can be inserted under the straight edge the coupling alignment needs corrected 9 Loosen the hydraulic motor mounting box bolts slightly Adjust by moving the motor mount box as requi...

Page 46: ...ar pump or motor failure or if the oil has been contam inated by water or other contaminate To change the filter 1 Shut off the engine 2 Remove the filter using a filter wrench 3 Lubricate the new fil...

Page 47: ...the oil level for the axle bear ings Add SAE 90 Hypoid Gear Hypoid Rear Axle Oil 80W 90 or 75W 90 oil as required fig T90024 by removing the plug 3 Check and adjust tire air pressure to 120 PSI 830 kP...

Page 48: ...s gasket with clean light oil Do not use grease 4 Turn on until gasket contacts the adapter base Hand tighten an addition al 1 2 to 3 4 turn 5 Open the fuel line shut off at the fuel tank T90100 6 Ope...

Page 49: ...from the radiator assembly Be sure to contain all waste coolant 5 Replace the radiator plug and shut off the engine block drain 6 Fill the engine with plain water and warm the engine to operating tem...

Page 50: ...the suction screen element S0074 The suction element is threaded into the reservoir the same as a fitting 5 Replace the suction element Use teflon type pipe thread sealant on the threads when installi...

Page 51: ...the key to prevent accidental start up 2 Depending on which screen is to be replaced remove the 8 side bolts for the top screen or plate 4 each side fig T90034 or the 6 end tension bolts located at t...

Page 52: ...t against the crown bar rubbers 7 Start the engine and engage the shaker to verify The screens must not bounce freely on the crown bar rubbers You will notice if the screens are loose by the rapping n...

Page 53: ...Ensure that all studs lug nuts and mounting faces of the hubs and wheels are clean and free of grease and debris Wheel Installation Mount both wheels over the hub boss es being careful not to damage t...

Page 54: ...turn 4 Tighten the adjusting nut to a final torque of 50 ft lbs while rotating the wheel 5 Final back off of adjustment nut 1 4 turn and install lock washer to nearest hole 6 Torque jam nut to 200 300...

Page 55: ...7E Anti Lock Brakes ABS This machine is equipped with an anti lock brake system as required by FMVSS 121 effec tive March 1 1998 Please refer to your local dealer for maintenance Proper Operation If t...

Page 56: ...nnual ly To inspect the flatness of the bolster plate use a 48 straight edge The bolster plate should be replaced if it is deformed more than is shown below Inspect the diameter of the kingpin Replace...

Page 57: ...to the negative terminal of the booster battery 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 dis connect the end...

Page 58: ...SSIS S0242 Red Clearance Light Red Clearance Light Red Clearance Light Red Clearance Light Amber Clearance Light Amber Clearance Light ABS Light Trailer Connection Brake Light Turn Signal Brake Light...

Page 59: ...57 4 MAINTENANCE 4 10 ELECTRICAL SCHEMATIC ENGINE WIRE HARNESS T90117...

Page 60: ...FRONT BULKHEAD REAR BULKHEAD OIL TANK GEAR PUMP OIL COOLER SHAKER MOTOR CONTROL VALVE LIFT CYLINDER 58 4 MAINTENANCE 4 11 HYDRAULIC SCHEMATIC S0261...

Page 61: ...59 4 MAINTENANCE FRONT BULKHEAD REAR BULKHEAD OIL TANK GEAR PUMP OIL COOLER SHAKER MOTOR CONTROL VALVE LIFT CYLINDER CONVEYOR MOTOR 4 11 HYDRAULIC SCHEMATIC Conveyor Option S0262...

Page 62: ...3 50022 4 50278 5 50155 6 50201 7 50156 8 50283 9 50122 10 50284 11 966049 12 33867 13 50163 14 50173 15 14492 16 50185 17 50203 18 50154 19 50271 20 50050 21 13838 20 1458 23 14797 24 50288 25 50286...

Page 63: ...7 10 19 5 12 12 6 31 15 4 1 50268 2 50267 3 50022 4 50278 5 14223 6 966037 7 966014 8 50283 9 50122 10 50284 11 50117 12 33867 13 50163 14 50173 15 966020 16 966021 17 966022 18 50154 19 50271 20 966...

Page 64: ...draulic fluid low Replenish operates slow Engine RPM low Check and adjust Hydraulic pump or Check pressure flow motor leakage wear Broken key Check and replace Bearing damage Check and replace Loud ho...

Page 65: ...r Check and replace Worn engine components Check repair replace ie rings valves cylinder Difficult starting Low cranking speed Check battery charge Faulty stop solenoid Check and replace Blocked fuel...

Page 66: ...gs valves cylinder Black exhaust Clogged air filter Check and replace Faulty injection system Check and repair Incorrect valve timing Check and repair Worn engine components Check repair replace ie ri...

Page 67: ...65 5 SPECIFICATIONS 5 SPECIFICATIONS Dimensional Specifications 5 1 Performance Specifications 5 2 Fastener Torque Specifications 5 3...

Page 68: ...l Conveyor mm in 905 35 6 M Optional Conveyor Height mm in 1280 50 4 5 2 PERFORMANCE SPECIFICATIONS Material Capacity Maximum Single Load 5 cubic Yard Cycle Time Average 30 seconds Shaker Head Decks 2...

Page 69: ...67 5 SPECIFICATIONS T90038...

Page 70: ...68 5 SPECIFICATIONS T90050...

Page 71: ...splacement cc cu in 2197 134 1 ISO Net Horsepower kW hp 34 3 46 2800 rpm Torque 2000 rpm Nm lbs ft 108 5 80 Fuel Type Diesel No 2 D ASTM D975 Cold Starting Aide Glow Plug Air Filtration Dual Dry Cartr...

Page 72: ...cturer s recommendation be followed for correct tightening sequence and tightness to eliminate problems created by bolts and screws being too tight or too loose S A E Bolt Grade and Recommended Torque...

Page 73: ...9 14 18 7 8 17 25 29 14 10 33 50 50 25 12 60 85 95 40 14 90 133 145 65 16 140 200 210 100 18 200 285 290 135 20 290 400 Standard Metric Bolt Dimensions and Grades Metric M8 1 25 x 25 M8 1 25 x 25 Majo...

Page 74: ...72...

Page 75: ...73 6 REPLACEMENT SCREENS 6 REPLACEMENT SCREENS Screen Selection Tips 6 1 Application 6 1A Selection 6 1B Tips 6 1C Ordering Information 6 1D Replacement Screen Information 6 2...

Page 76: ...ut it must feed the bottom screen deck at a particular rate Just how well the top deck feeds the bottom deck determines production efficiency B Selection Screen selection process starts with some basi...

Page 77: ...ProTough 900 would be 7 if using both top and bottom screens Anything 7 or larger the material could get lodged between the cross pipe and the bottom screen which could damage both the shaker head an...

Page 78: ...vides standard a configuration with every screening plant sold from the factory Top Deck 1 1 2 x 1 1 2 clear opening x 3 8 diameter of wire material Bottom Deck 3 4 x 5 slots clear opening x 1 4 diame...

Page 79: ...3 6 ELECTRICAL 7 4 Engine Electrical 7 4 1 Chassis Electrical 7 4 2 ENGINE 7 5 Intake System up to S N T9000104 7 5 1 Intake System S N T9000105 onward 7 5 2 Exhaust System 7 5 3 Radiator and Mounts...

Page 80: ...78...

Page 81: ...MAINFRAME 7 1 Front Lift Assembly 7 1 1 Tire Wheel and Mud Flaps 7 1 2 Brake Parts 7 1 3 Axle Lock 7 1 4 Compartment Doors 7 1 5 Access Panels 7 1 6 79...

Page 82: ...FRONT LIFT ASSEMBLY 7 1 1 S0230 80 2 11 3 4 5 6 10 9 9 8 1 4 5 6 7...

Page 83: ...Assy 2 51859 1 Pin 1 25 x 6 25 3 33153 1 Cylinder 4 45490 8 Bolt Hex 5 8 x 2 5 1361 8 Washer Flat 5 8 6 45450 8 Nut Lock 5 8 7 966109 2 Jack Inner Tube Welded Assy 8 966105 1 Jack Base Welded Assy 9 5...

Page 84: ...TIRE WHEEL and MUD FLAPS 7 1 2 82 S0218 4 3 5 2 6 1 7...

Page 85: ...Tire Wheel Assy 315 80 R22 5 W 22 5 x 9 00 2 35313 1 Mudflaps pair 3 45898 2 Strip Mud Flap Retainer 4 16771 8 Nut Nylok 5 16 5 1651 8 Washer Flat 5 16 6 2580 8 Bolt Hex 5 16 x 1 1 4 7 50246 20 Nut W...

Page 86: ...BRAKE PARTS 7 1 3 84 1 S0221 2 S0220 3 S0219 4...

Page 87: ...Item Part No Qty Description 1 50373 2 Slack Adjuster 2 50374 2 ABS Sensor 3 50391 2 30 30 Spring Brake 4 50256 1 Axle 25000 lbs w Air Brakes BRAKE PARTS 7 1 3 85...

Page 88: ...AXLE LOCK 7 1 4 8 8 9 1 3 6 6 8 8 3 1 3 5 4 7 10 4 7 10 5 3 2 S0232 86...

Page 89: ...ck Bushing 2 966091 1 Mechanical Axle Stop Welded Assy 3 1699 4 Washer Flat 7 8 4 50191 2 Bumper 3 1 2 x 3 x 6 5 50107 2 Nut Flexlock 7 8 6 50108 2 Bolt Hex 7 8 x 6 7 23385 4 Washer Flat 1 2 8 1773 4...

Page 90: ...COMPARTMENT DOORS 7 1 5 10 5 S0224 4 9 16 17 18 S0226 11 13 14 15 8 12 19 S0225 88 S0223 1 3 4 2 3 4 S0227 6 7...

Page 91: ...bly 7 50444 1 Right Engine Compartment Door 8 47166 1 Sheet Striker Pin Mount 9 47169 1 Snapper Pin 3 8 x 1 5 8 Long 10 43274 4 Pop Rivets 1 8 x 1 2 375 11 47168 1 Striker Pin 12 6393 1 Nut 7 16 13 11...

Page 92: ...ACCESS PANELS 7 1 6 90 S0241 T90107 T90106 S0252 9 10 11 16 5 6 7 1 15 2 15 14 12 8 6 17 18 3 4 3 4 6 7 4 13...

Page 93: ...8 Washer Flat 3 8 7 1673 8 Bolt Hex 3 8 8 966040P 1 Rear Access Plate Conveyor Opening 9 50332 10 Bolt Carriage 1 2 x 1 1 4 10 23385 10 Washer Flat 1 2 11 20860 10 Nut Hex 1 2 12 50054P 2 Hydraulic Co...

Page 94: ...92...

Page 95: ...SHAKERHEAD 7 2 Shakerhead Shaft Suspension Wire Cloth 7 2 1 93...

Page 96: ...SHAKERHEAD SHAFT SUSPENSION WIRE CLOTH 7 2 1 94 S0268 S0267 S0266 14 15 16 14 15 16 59 60 50 14 15 16 58 14 15 16 50 5 6 57 4 5 6 3 50 58 7 2 14 15 16 58 5 6 57 4 5 6 59 60 10 11 12 13 8 3 7 4 5 6 9 8...

Page 97: ...SHAFT SUSPENSION WIRE CLOTH 7 2 1 S0265 1 19 45 34 14 15 16 43 15 16 55 17 47 51 52 36 60 59 54 46 21 22 56 15 16 55 49 48 38 35 23 41 42 24 25 44 53 28 29 30 26 27 5 6 57 14 15 16 58 4 5 6 3 14 15 1...

Page 98: ...14 15 16 SHAKERHEAD SHAFT SUSPENSION WIRE CLOTH 7 2 1 96 S0266 60 50 5 6 57 58 14 15 16 59 14 15 16 32 33 20 21 22 31 40 14 15 16 15 16 55 18 14 15 16...

Page 99: ...x 1 125 10 45562 1 Coupling Spline 11 45253 1 Spider Hytrel 12 45663 1 Coupling Straight Shaft 13 25408 1 Key Square 3 8 x 1 1 2 14 1240 160 Bolt Hex 1 2 x 2 15 30485 408 Washer Flat 1 2 16 50097 220...

Page 100: ...t 41 50343P 1 Shaker Lower Front 42 50344P 6 Screen Lower Support 43 50348P 1 Upper Screen Support Rear 44 50349P 12 Retaining Long Strap 45 50359P 4 Corner Center Bracket 46 50360P 1 Back Plate 47 96...

Page 101: ......

Page 102: ...100...

Page 103: ...HYDRAULICS 7 3 Hydraulic Circuit 7 3 1 Control Valve 7 3 2 Cylinder 7 3 3 Gear Pump 7 3 4 Shaker Motor 7 3 5 Hydraulic Oil Tank 7 3 6 101...

Page 104: ...KHEAD OIL TANK GEAR PUMP OIL COOLER SHAKER MOTOR CONTROL VALVE LIFT CYLINDER 14 15 36 1 15 12 11 13 37 34 5 4 3 35 22 2 20 33 9 40 8 10 7 6 7 39 41 41 21 See Figure 7 3 1A 44 43 44 17 18 18 38 42 42 1...

Page 105: ...sy 1643 4 Washer Flat 3 8 secure oil cooler 50175 4 Nut Flexlock 3 8 secure oil cooler 13 14866 1 Elbow 90 14 40564 1 Filter Hydraulic Line Spin on 5170 2 Bolt Hex 1 4 x 2 secure filter 1650 2 Washer...

Page 106: ...REAR BULKHEAD OIL TANK GEAR PUMP OIL COOLER SHAKER MOTOR CONTROL VALVE LIFT CYLINDER 14 15 36 1 15 12 11 13 37 34 5 4 3 35 22 2 20 33 9 40 8 10 7 6 7 39 41 41 21 See Figure 7 3 1A 44 43 44 17 18 18 3...

Page 107: ...Hydraulic 3 4 x 97 7 8 Cooler outlet to filter inlet 37 964931 1 Hose Hydraulic 3 4 X 27 15 16 Hydraulic valve to cooler 38 964933 1 Hose Hydraulic 3 8 x 66 11 16 Front bulkhead to oil tank 39 964927...

Page 108: ...CONTROL VALVE 7 3 2 106 S0237 2 1 3...

Page 109: ...Item Part No Qty Description 1 50252 1 Valve Hydraulic Control 2 spool w handles includes items 2 3 2 50068 1 Relief Valve 3 50021 2 Valve Handle CONTROL VALVE 7 3 2 107...

Page 110: ...CYLINDER 7 3 3 C2676 108 4 3 2 1 2 2 5 6...

Page 111: ...Description 1 33153 1 Cylinder 3 000 x 15 5 2 32511 1 Seal Kit Hydraulic Cylinder 3 30641 1 Bushing Hardened 4 6297 1 Nut Cylinder Hex 5 2010 1 Fitting Grease Straight 6 35451 1 Fitting Grease 90 CYL...

Page 112: ...GEAR PUMP 7 3 4 S0238 2 110 3 3 3 3 3 1 4...

Page 113: ...Item Part No Qty Description 1 50248 1 Pump Gear Hydraulic Assy includes items 2 3 4 2 50085 1 Ring Retainer Pump 3 50088 1 Kit Seal Repair Pump 4 50089 1 Shaft Pump Drive GEAR PUMP 7 3 4 111...

Page 114: ...SHAKER MOTOR 7 3 5 112 S0239 1 3 3 2 4 5...

Page 115: ...r Hydraulic Assembly includes all items listed below 2 50078 1 Ring Outer Retaining 3 50079 2 Ring Inner Retaining 4 50080 1 Bearing Thrust 5 50081 1 Shaft Motor Drive 50084 1 Complete Seal Kit Items...

Page 116: ...HYDRAULIC OIL TANK 7 3 6 114 2 8 3 4 7 5 6 6 S0083...

Page 117: ...des items 2 3 4 8 2 966039 1 Oil Tank Welded Assy 3 36733 1 Breather Oil Filler Locking 4 35026 1 Gauge Level Oil Tank 5 5170 4 Bolt Hex 1 4 x 1 6 1650 8 Washer Flat 1 4 2 on each bolt 7 6645 4 Nut Ny...

Page 118: ...116...

Page 119: ...ELECTRICAL 7 4 Engine Electrical 7 4 1 Chassis Electrical 7 4 2 117...

Page 120: ...ENGINE ELECTRICAL 7 4 1 118 S0253 1 2 3 4 5...

Page 121: ...tion 1 50005 1 Control Box up to S N T9000109 49687 1 Control Box S N T9000110 onward 2 44961 1 Switch Starter includes 3 3 44960 1 Ignition Key pair 4 50017 1 Harness Engine Wire 5 50095 1 Engine ENG...

Page 122: ...CHASSIS ELECTRICAL 7 4 2 120 ELECTRICAL SCHEMATIC CHASSIS ABS S0242 1 2 3 4 5 6 7 7 8 9 9 9 11 10 9 11 12 13 13 12 15 11 11 16 17 18 19 20 18 19 20 14...

Page 123: ...1622 2 Bolt Stove 3 16 x 1 2811 2 Washer Lock 3 16 6467 2 Nut Hex 3 16 11 46150 4 Red Clearance Lamp 15885 8 Bolt Stove 3 16 x 3 4 2811 8 Washer Lock 3 16 6467 8 Nut Hex 3 16 12 49008 2 Amber Turn In...

Page 124: ...122...

Page 125: ...T9000105 onward 7 5 2 Exhaust System 7 5 3 Radiator and Mounts 7 5 4 Water Pipe 7 5 5 Fuel Filter 7 5 6 Alternator and Pulley 7 5 7 Oil Filter 7 5 8 Water Flange and Thermostat 7 5 9 Fan 7 5 10 Throt...

Page 126: ...INTAKE SYSTEM S N T9000101 T9000103 T9000105 T9000106 7 5 1 124 S0271 S0273...

Page 127: ...8 0 2 Air Cleaner Band 15 38430 1394 0 1 Air Cleaner Support 16 38430 1397 0 2 Cushion 17 19416 1157 3 1 Air Cleaner Stay 18 01123 50820 2 Bolt 19 19416 9101 0 2 Bolt 20 04512 60140 2 Spring Washer 21...

Page 128: ...INTAKE SYSTEM S N T9000102 T9000104 T9000107 onward 7 5 2 126 S0229 1 2 4 5 16 17 15 9 13 9 12 9 6 14 9 8 11 10 7 3 9 19 18...

Page 129: ...ded Air Inlet 8 38855 1 Electrical Service Indicator 9 6268 5 Clamp Hose 32 10 12117 1 Clamp Hose 40 11 42406 1 Fitting Brass Tap Restriction 1 8 12 45988 1 Tube 13 46168 1 Tube Air Duct 14 50002 1 Pr...

Page 130: ...EXHAUST SYSTEM 7 5 3 S0246 128...

Page 131: ...fler 2 19378 4 Bolt 3 50225 1 Cap Muffler 4 50224 1 Band Muffler Cap 5 50118 1 Pin Joint 6 50227 1 Pin Split 7 18619 1 Washer Plain 8 39835 1 Bolt 9 18527 1 Nut 10 44318 1 Washer Lock 11 42691 1 Gaske...

Page 132: ...RADIATOR and MOUNTS 7 5 4 130 S0247...

Page 133: ...Washer 12 19573 2 Pin Snap 13 18491 2 Nut 14 50237 1 Support Radiator RH 15 50236 1 Support Radiator LH 16 50235 1 Stay Radiator Support 17 18728 4 Bolt 18 18495 4 Nut 19 18451 4 Washer Spring 20 184...

Page 134: ...WATER PIPE 7 5 5 132 S0248...

Page 135: ...Item Part No Qty Description 1 22205 1 Hose Bottom Radiator 2 18478 4 Band Pipe 3 22204 1 Hose Top Radiator WATER PIPE 7 5 5 133...

Page 136: ...FUEL FILTER 7 5 6 134 S0256...

Page 137: ...FUEL FILTER 7 5 6 135 Item Part No Qty Description 1 42560 1 Assy Fuel Filter 2 42561 1 Filter Fuel 3 19333 2 Bolt...

Page 138: ...ALTERNATOR and PULLEY 7 5 7 136 S0249...

Page 139: ...Plain 4 18527 1 Nut 5 18406 1 Washer Spring 6 19563 1 Stay Dynamo 7 23106 1 Bolt 8 50169 1 Terminal 9 47983 1 Guard Alternator 10 36875 1 Pulley Fan Drive 11 19444 1 Key Feather 12 35568 1 Belt Fan 1...

Page 140: ...OIL FILTER 7 5 8 138 S0250...

Page 141: ...OIL FILTER 7 5 8 139 Item Part No Qty Description 1 33023 1 Filter Engine Oil...

Page 142: ...WATER FLANGE and THERMOSTAT 7 5 9 140 S0245...

Page 143: ...turn 3 19577 1 Gasket Water Flange 4 19379 2 Bolt 5 19397 1 Stud 6 19360 1 Bolt 7 18495 1 Nut 8 18451 2 Washer Spring 9 19580 1 Pipe Water Return 2 10 19582 2 Clamp Pipe 11 19585 1 Cover Thermostat 12...

Page 144: ...FAN 7 5 10 142 S0251...

Page 145: ...FAN 7 5 10 Item Part No Qty Description 1 50244 1 Fan 2 39732 4 Bolt Flange 3 21428 1 Pulley Fan Metal 4 39731 1 Collar Fan 143...

Page 146: ...THROTTLE CONTROL 7 5 11 1 4 4 4 5 5 5 6 7 8 9 10 14 10 11 12 2 3 3 15 3 S0255 144 11 13 16...

Page 147: ...1 4 6 50241P 1 Bracket Throttle 7 50012 1 Cable Push Pull 68 Long 8 46188 1 Sheet Throttle Frame 9 966106 1 Throttle Plate Welded Assy 10 31744 5 Screw Hex Head 11 1650 3 Washer Flat 1 4 12 46189 1 S...

Page 148: ...FUEL SYSTEM 7 5 12 S0257 3 4 13 14 15 5 1 7 10 12 20 17 8 16 9 6 6 2 4 3 18 146 12 9 9 21 11 19...

Page 149: ...3 34903 2 Elbow 90 Degree 4 34919 2 Clamp Circle Two Ear 5 698 1 604 Tube Clear Vinyl 6 42574 2 Elbow Straight 7 14797 1 Petcock Shut off 8 23861 1 Hose End 9 19949 4 Clamp Fuel Line 10 42572 1 Bushi...

Page 150: ...ENGINE ACCESSORIES 7 5 13 S0254 148 1 2 3 6 9 7 8 4 5 10 11 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26...

Page 151: ...ear Vinyl 10 38870 1 Battery 11 40561 1 Sheet Battery Clip 12 1387 1 Bolt Hex 3 8 x 1 1 4 13 1643 1 Washer Flat 3 8 14 7465 1 Nut Nylok 3 8 15 966082 2 Engine Mount Front 16 966083 2 Engine Mount Rear...

Page 152: ...150...

Page 153: ...PNEUMATICS 7 6 Pneumatic Layout up to S N T9000106 7 6 1 Pneumatic Layout S N T9000107 onward 7 6 2 151...

Page 154: ...PNEUMATICS up to S N T9000106 7 6 1 152 33 33 TOTAL HOURS 19 20 8 4 17 25 32 32 34 24 21 11 1 3 30 28 6 2 27 TO EXHAUST 19 18 3 14 15 16 29 26 5 7 6 9 10 12 13 18 22 23 31 10 S0277...

Page 155: ...r 14 50173 1 Tank Air 15 14492 1 Plug Pipe 16 50185 2 Rubber Isolator Pad 17 50203 1 Height Control Valve Connecting Rod 18 50154 2 Connector 19 50271 2 Tee 20 50050 1 Pressure Relief Valve 21 13838 1...

Page 156: ...PNEUMATICS S N T9000107 onward 7 6 2 154 16 16 TOTAL HOURS 8 25 6 15 17 24 21 20 1 3 30 28 29 2 27 11 19 18 3 14 26 9 12 13 22 Pneumatic Layout 9 23 7 10 19 5 12 12 6 31 15 4 S0258...

Page 157: ...bow 90 Degree 12 33867 4 Plug Hex Head 13 50163 1 Connector 14 50173 1 Tank Air 15 966020 1 Hose Air 3 8 x 480 Black 16 966021 2 Hose Air 3 8 x 480 Red 17 966022 1 Hose Air 3 8 x 37 Black 18 50154 1 C...

Page 158: ...156...

Page 159: ...CONVEYOR 7 7 Optional at time of purchase Conveyor 7 7 1 Hydraulic Circuit w Conveyor 7 7 2 157...

Page 160: ...CONVEYOR 7 7 1 158 2 S0231 1 10 6 7 5 4 3 11 12 14 15 8 9 11 12 13...

Page 161: ...Pillow Block 5 50298 2 Bearing Take up 6 50299 4 Pulley Idler 7 50300 1 Pulley Return 8 50301 1 Conveyor Frame 9 50309 1 Belt Conveyor 2 Ply 10 50322 1 Scrapper Conveyor 11 50326 8 Bolt Assy 5 8 x 2 1...

Page 162: ...NK GEAR PUMP OIL COOLER SHAKER MOTOR CONTROL VALVE LIFT CYLINDER 14 15 36 1 15 12 11 13 37 34 5 4 3 35 22 2 20 33 9 40 8 10 7 6 7 39 41 41 21 See Figure 7 7 2A 44 43 44 17 18 38 42 19 25 24 See Figure...

Page 163: ...Elbow 90 12 45956 1 Oil Cooler 1643 4 Washer Flat 3 8 secure oil cooler 50175 4 Nut Flexlock 3 8 secure oil cooler 13 14866 1 Elbow 90 14 40564 1 Filter Hydraulic Line Spin on 5170 2 Bolt Hex 1 4 x 2...

Page 164: ...IL TANK GEAR PUMP OIL COOLER SHAKER MOTOR CONTROL VALVE LIFT CYLINDER 14 15 36 1 15 12 11 13 37 34 5 4 3 35 22 2 20 33 9 40 8 10 7 6 7 39 41 41 21 See Figure 7 7 2A 44 43 44 17 18 38 42 19 25 24 See F...

Page 165: ...bulkhead to oil tank 39 964927 1 Hose Hydraulic 1 2 x 50 11 16 Hydraulic valve to cylinder 40 964928 1 Hose Hydraulic 1 2 x 65 11 16 Hydraulic valve to cylinder 41 964935 2 Hose Hydraulic 3 4 x 123 Hy...

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Thomas PROTOUGH 900, Owner/Operator And Parts Manual

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