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Thomas PROTOUGH 900 Owner/Operator And Parts Manual

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900
Owner's / Operator's
and Parts Manual
Publication No. 50008
November 2004
S/N T9000101 onward

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  • Page 1 Owner’s / Operator’s and Parts Manual Publication No. 50008 November 2004 S/N T9000101 onward...
  • Page 2 DEALER HAVE MADE OR WILL MAKE ANY REPRESENTATION, WAR- RANTY OR AGREEMENT CONCERNING A PRODUCTS MERCHANTABILI- TY OR OTHER QUALITY, ITS SUITABILITY FOR PURCHASER’S PURPOSE (EVEN IF A PURCHASER HAS INFORMED THOMAS OR A THOMAS DEAL- ER OF THAT PURPOSE), ITS DURABILITY, PERFORMANCE OR OTHER CONDITION.

  • Page 3: Table Of Contents

    INDEX 1. SAFETY PRECAUTIONS General Instruction................1.1 Decals ....................1.2 Orientation / Access ................1.3 2. CONTROLS Engine Controls..................2.1 Hydraulic Controls ................2.2 Pneumatic Controls ................2.3 Axle Stop Controls................2.4 3. OPERATION Pre-Start Inspection ................3.1 Starting Instructions ................3.2 Shut Down Procedure ................

  • Page 4: Safety Precautions

    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 machine to help prevent accidents. Equipment should be operated only by those who are responsible and instructed to do so.
  • Page 5 Do not modify or alter, or permit anyone to modify or alter this machine or any of its components or machine functions. Do not bypass the safety systems. Consult your Thomas Equipment Dealer if your safety system is malfunctioning. Do not make mechanical adjustments while the machine is in motion or when the engine is running.

  • Page 6: Decals

    1. SAFETY PRECAUTIONS Amber Reflective Tape 1.2 DECALS #46155 #50259 #50260 TH41064 #41064 (Located on fan inside engine compartment.) Red/White Reflective Tape #46152 (25”) Vehicle Identification Tag #50186 Amber Reflective Tape T90106 #46155 Red/White Amber Reflective Reflective Tape #45748 Tape #46155 #46152 (31”) Red Reflective Tape...
  • Page 7 1. SAFETY PRECAUTIONS 1.2 DECALS Red/White Reflective Red Reflective Amber Reflective Tape Tape Tape #46152 (18”) #46154 #46155 #39191 #39191 #50149 #50149 (18”) (31”) (18”) Red/White Reflective Tape #46152 T90108 Red Reflective WARNING Amber Red/White Red/White Tape #46154 Reflective Reflective Reflective BEFORE LOWERING THIS MACHINE TO THE GROUND...
  • Page 8 1. SAFETY PRECAUTIONS 1.2 DECALS Amber Reflective Red/White Reflective Tape Tape #46155 #46152 (18”) #39191 Red/White #50149 Reflective Tape #46152 (56”) #46152 (white) (6”) #46152 (25”) Vehicle Identification Tag #50186 T90110 #39192 WARNING Amber Reflective Tape #46155 #39191 STAND BACK 10 Feet ( 3Meters ) ROCKS BOUNCE WARNING...

  • Page 9: Orientation / Access

    1. SAFETY PRECAUTIONS 1.3 ORIENTATION / ACCESS The following will familiarize you with the technical terms and location of important components. Major components, control locations and indicator or instruments can be located using the pictures provided. Details of control operations and functions are explained in the Operations Section 3.
  • Page 10 1. SAFETY PRECAUTIONS 1.3 ORIENTATION / ACCESS (continued) Gladhand service brake connector Gladhand emergency brake connector T90009 Trailer Elecrical Front cylinder jack T90114 Instrument panel Rear suspension stop lock T90014 T90011 Shaker deck / head Shaker motor Counterweight T90012 T90013...

  • Page 11: Controls

    2. CONTROLS 2. CONTROLS Engine Controls ........2.1 Hydraulic Controls ......... 2.2 Pneumatic Controls ......... 2.3 Axle Stop Controls ......... 2.4...

  • Page 12: Engine Controls

    2. CONTROLS Instrument panel 2.1 ENGINE CONTROLS Instrument Panel: (T90014) A. Oil pressure. This red indicator, when on means that the engine is not running. When it is flashing there is an oil pressure problem and the engine will shutdown. If it is off, the oil pressure is within limits.

  • Page 13: Hydraulic Controls

    2. CONTROLS 2.2 HYDRAULIC CONTROLS (fig. T90017) A. Hydraulic lift for fifth-wheel hitch. Pull lever towards you to raise the front of the unit for fifth wheel engagement. Push away from you to lower the front of the unit after the tow vehicle is clear.

  • Page 15: Operation

    3. OPERATION 3. OPERATION Pre-Start Inspection ........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 Selection / Combinations..3.5E Transporting..........3.6...

  • Page 16: Pre-Start Inspection

    3. OPERATION 3.1 PRE-START INSPECTION Fuel fill Fuel level A daily inspection should be performed to gauge assure safe operation and minimal down time. The daily maintenance should be performed before start-up. See Section 4 for complete details. Engine: Access cover 1.
  • Page 17 3. OPERATION Hydraulics: 1. Check the fluid level. Add 10W30 motor oil Operating level as required to bring fluid level in the middle of the site gauge (fig. T90021). Make sure the filler cap is secure. 2. Check all hydraulic hoses for chafing, bulges and leaks.

  • Page 18: Starting Instructions

    3. OPERATION 3.2 STARTING INSTRUCTIONS Throttle to idle Hydraulic controls to neutral 1. Perform the pre-starting inspection at the beginning of this section. 2. Ensure the hydraulic controls are in the neutral position ( T90059 3. Place the engine throttle control in the low idle position ( T90059 T90059...

  • Page 19: Shut Down Procedure

    3. OPERATION 3.2 STARTING INSTRUCTIONS IMPORTANT (continued) 7. Allow the engine to warm up 15 min- This machine is a equipped with an engine utes at the idle position before operat- monitoring system that will shut down the ing at the normal operating speed. engine whenever engine oil pressure is too low, or coolant temperature is too high.

  • Page 20: Set-Up

    3. OPERATION 3.4 SET-UP Follow the pre-starting inspection and start-up instruction previous to this section. The machine must be operated on a level surface. If necessary, grade an area to accommodate. Make sure you leave adequate room for T90072 maneuvering equipment around the machine to remove tailings.
  • Page 21 3. OPERATION 4. Engage the front hydraulic jack Front hydraulic jack (T90113). Raise the unit enough to release the pressure from tow vehicle off of the fifth-wheel plate. Disengage the fifth-wheel on the tow vehicle. 5. Rotate the dump valve to the lower position in order to release the air from the suspension system to lower the rear of the unit to ground level (T90075 on...

  • Page 22: Operating Procedures

    3. OPERATION 3.5 OPERATING PROCEDURES Follow the set up procedures outlined in section 3.4. That section contains important information for getting the best performance and efficien- cy from your machine. 3.5A General The shakerhead assembly contains two sorting decks surfaces called screens. Certain application will require you to change screen sizes for better results.

  • Page 23: Loading Procedure

    3. OPERATION 3.5B Loading Procedure S0010 When loading material into the hopper, keep the bucket as low as possible (fig. S0010). Allow the material to slide down the high side of the hopper plate onto the top screen deck. Hopper high Check tailings for size.

  • Page 24: Removing Finished Material

    3. OPERATION 3.5C Removing Finished Material S0004 After each load is placed into the hop- per, check the finished and tailing piles. Allow adequate area to retrieve finished material from under the hopper and shaker deck area (fig. S0004). For best efficiency, allow at least a full bucket of material to accumulate before retrieving.

  • Page 25: Removing Tailings

    3. OPERATION 3.5D Removing Tailings Do not allow the tailing to pile up high- er 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 CAUTION (fig.
  • Page 26 3. OPERATION 3.5E Screening Selection / Combinations Proper screen selection S0001 The top plate or screen is used to absorb the impact of heavier material and discharge or separate the larger material to a separate pile. The bottom screen further separates materials and dictates the actual final size of product.

  • Page 27: Transporting

    3. OPERATION 3.6 TRANSPORTING Check wheels, tires and axle grease Before transporting the machine, per- form the following checks: Tire pressure 120 PSI (830 kPa). Wheel nuts torque 500 - 550 ft/lbs (680-748 Nm). Check the wheel nut torque and tire pres- sure again after 50 hours.
  • Page 28 3. OPERATION 1. Start engine, with the throttle in idle Front hydraulic jack position (T90075). 2. Engage the front hydraulic jack, raise the front of machine to the travel posi- tion (T90113). 3. Back tow vehicle under unit, engage the T90113 king pin to the tow vehicle fifth wheel (T90077).

  • Page 29: Maintenance

    4. MAINTENANCE 4. MAINTENANCE Service Access ................4.1 Preventative Maintenance Schedule .......... 4.2 Daily Service................4.3 Screen Tension ..............4.3A Engine ................4.3B Hydraulic System............. 4.3C Safety Equipment............. 4.3D Lubrication ................4.3E 50 Hour Service ................. 4.4 Engine Oil and Filter ............4.4A Engine Fuel System ............

  • Page 30: Service Access

    4. MAINTENANCE 4.1 SERVICE ACCESS The following page(s) will depict how to access specific areas for service. Air cleaner Control access Muffler Oil fill Coolant overflow Oil level dip stick Oil filter Engine access Fuel filter Battery T90008 T90120 Engine air precleaner Engine oil drain T90096 Hydraulic oil cooler...
  • Page 31 4. MAINTENANCE 4.1 SERVICE ACCESS (continued) Grease points T90115 T90021 Oil site gauge Fuel line shut off Oil tank drain Fuel fill Fuel site gauge Fuel tank drain T90027 T90042 Suspension bolts Grease Coupler alignment T90022 T90023 ANTI-LOCK BRAKES (ABS) This trailer is equipped with an anti-lock system, as required by FMVSS121, effec- tive March 1, 1998.

  • Page 32: Preventative Maintenance Schedule

    4. MAINTENANCE 4.2 PREVENTATIVE MAINTENANCE SCHEDULE Note: A complete 150 Hour service is to be performed initially at 50 Hours. ITEM SERVICE REQUIRED Screen tension Check the screen bolt tension. See section 4. Suspension Bolts Check the suspension bolt tension. See section 4.

  • Page 33: Daily Service

    4. MAINTENANCE 4.3 DAILY SERVICE Crown bar rubber 4.3A Screen Tension To prevent premature screen or crown bar rubber wear: Every 4 hours of operation, check the crown bar rubber on the top and bottom screens. (T90081 &T90082) Make sure it is intact and not damaged.
  • Page 34 4. MAINTENANCE 4.3B Engine Engine compartment Check engine compartment area for Add coolant signs of fluid leaks ( T90104 Coolant level Check the engine oil level. Add mini- mum API classification CF 10W30 oil if required (fig. C642). Check coolant level. Add 50/50 mixture Battery of ethylene glycol and water if required T90104...
  • Page 35 4. MAINTENANCE Hydraulic Shaker motor 4.3 DAILY SERVICE 4.3C Hydraulic System Check hydraulic hoses, pumps and motors for leaks (T90012, T90102). Check each hydraulic hose for chafing or bulging. Replace immediately as required. T90012 WARNING Never repair or tighten hydraulic hoses or Hydraulic gear pump fittings while the machine is running.
  • Page 36 4. MAINTENANCE 4.3 DAILY SERVICE Lubricate Bearing 4.3E Lubrication There are six (6) lubrication points on this machine that require regular service. Use a high quality lithium based grease. For grease fittings, apply two (2) shots per fitting, for inner tubes, lubricate with enough grease to ensure proper movement.
  • Page 37 Lubricate oil filter seal 4. Remove the engine oil filter with a fil- ter wrench. 5. Apply clean motor oil to the new oil filter gasket (C2202). Use only Thomas approved filters. 6. Install the filter until the gasket con- C2202 tacts the engine block.
  • Page 38 4. MAINTENANCE 4.4 50 HOUR SERVICE Engine oil filler cap 4.4A Engine Oil and Filter (continued) 7. Replace the oil drain plug after the oil has completely drained. 8. Remove the oil filler cap (T90039). T90039 9. Add 8.5 quarts (8 liters) 10W30 motor oil.

  • Page 39: Engine Fuel System

    4. MAINTENANCE 4.4 50 HOUR SERVICE Engine compartment 4.4B Engine Fuel System Check all the fuel lines, supply, return and injection, for leaks and chaffing. Change the engine fuel filter after the first 50 hours and every 300 hours there- after.
  • Page 40 4. MAINTENANCE 4.4 50 HOUR SERVICE 4.4B Engine Fuel System (continued) Open the fuel line shut off at the fuel tank (T90100). Fuel line shut off Open the air bleed screw on the fuel filter housing (T90033). Close the bleed screw when fuel begins to trickle out.
  • Page 41 Air cleaner element must be replaced. Use only Restriction Indicator Thomas approved air filter elements. T90119 On average, for every 3 primary filter ele- ments replaced, replace the inner safety ele- ment.
  • Page 42 4. MAINTENANCE 4.4 50 HOUR SERVICE Engine fan belt 4.4D Engine Fan Belt Check the fan belt condition (T90120). Replace if cracked or chipped. Replace every 2 years or at 600 hours, whichever comes first. Check belt tension half way between the crankshaft and alternator pulley (S0020).
  • Page 43 4. MAINTENANCE 4.4 50 HOUR SERVICE 4.4E Engine Cooling System Add coolant Check the coolant level daily. Add only 50/50 mixture ethylene glycol. Do not use or mix in other types of coolant. Add coolant to the overflow reservoir (T90030) as required to be above the minimum cold level.
  • Page 44 4. MAINTENANCE 4.4 50 HOUR SERVICE Coupling view 4.4F Shaker Shaft Keyed shaft coupling The shaker shaft coupling needs to be checked for wear and alignment after the Spider first 50 hours of operation and every 150 hours thereafter. 1. Check the center spider for wear (S0018).

  • Page 45: Hour Service

    4. MAINTENANCE Coupling alignment 4.4 50 HOUR SERVICE 4.4F Shaker Shaft (continued) 7. Check coupling alignment using a small straight edge and a .005 inch (0.13 mm) feeler gauge (C1484). Note: See figure C1485 for allowable mis- alignment. 8. If the feeler gauge can be inserted under the straight edge, the coupling alignment needs corrected.

  • Page 46: Hour Service

    C2202 Hand tighten 3/4 to 1 1/4 turns after the seal has contacted the filter head. Use only Thomas approved filters. 4. Start the engine and check for leaks around the filter seal. 5. Stop the engine and check the oil level.

  • Page 47: Hour Service

    4. MAINTENANCE 4.4 50 HOUR SERVICE Wheel nut tightening sequence 4.4H Chassis Maintenance 1. Check the wheel nut torque. Use the correct tightening sequence and tighten in 3 increasing torque settings to 500 ~ 550 ft./lbs. (680 ~ 748 Nm.). (fig. T90083). 2.

  • Page 48: Hour Service

    Air Bleed Screw 4.5A Fuel Filter. Change the engine fuel filter after the first 50 hours and every 300 hours there- after. Use only Thomas approved filters. Shut off the fuel line petcock located at the fuel tank (T90100). Turn clock T90095 wise to close.

  • Page 49: Engine Cooling System

    4. MAINTENANCE 4.6 900 HOUR SERVICE Perform a complete 50 and 300 hour service plus the following. 4.6A Engine Cooling System The engine cooling system needs to be flushed, and the coolant replaced after 900 hours of service. 1. Warm the engine to circulate the engine coolant.
  • Page 50 4. MAINTENANCE 4.6B Hydraulic System Hydraulic oil drain After 900 hours of operation, the hydraulic oil needs to be changed and the suction element in the hydraulic oil reservoir needs to be replaced. 1. The reservoir drain plug is accessed at the bottom of the engine compartment (T90062).

  • Page 51: As Required Service

    4. MAINTENANCE Crown bar rubber 4.7 AS REQUIRED SERVICE 4.7A Screen Replacement The shaker screens will need replaced whenever they have worn out, broken or soil conditions require different sizing. The top screen or plate is held in place by tension bars on both sides of the screen or plate (T90034).
  • Page 52 4. MAINTENANCE 5. When replacing the screen or plate, fol- CAUTION low the torque tightening sequence (T90034). Start from the middle, tighten the bolts in a criss - cross pattern to The shaker screens are very heavy. torque the top screen to 466 lbs. (632 Use a lifting aid such as a hoist to prevent Nm), and torque the lower screen to 120 possible injury.

  • Page 53: Tire And Wheel Maintenance

    4. MAINTENANCE 4.7 AS REQUIRED SERVICE 4.7B Tire and Wheel Maintenance Inspect tires for cuts, cracks or uneven wear. Check tire pressure and never over inflate tires. Refer to the recommended inflation pressure on the tire sidewall. Wheels and studs should be checked for cracks, deformation and proper and secure attachment.

  • Page 54: Brake Maintenance

    4. MAINTENANCE 4.7 AS REQUIRED SERVICE Outer Wheel Oil Seal Bearing 4.7C Wheel Bearing and Seal Maintenance Visually inspect the oil seal for leaks Axle Ring and fill to the full oil level line (T90085). Minimum Oil Level Wheel Bearing Adjustment Inner Wheel 1.

  • Page 55: Anti-Lock Brakes (Abs)

    4. MAINTENANCE 4.7 AS REQUIRED SERVICE 1. Remove the wheels and drums. 2. Inspect the brake cam rollers, anchor pins, camshaft support bushings and cam shaft for wear. Replace components as necessary. Refer to axle manufacturers service manual for proper procedures. 3.

  • Page 56: Brake Chambers

    4. MAINTENANCE 4.7 AS REQUIRED SERVICE 4.7G Brake Chambers This machine is equipped with air/spring brake chambers on the axles and tailgate latch mechanism. Prior to removal make sure air pressure is released and spring is caged. (Refer to chamber manufacturer ser- vice manual for proper caging and removal instructions.) CAUTION...

  • Page 57: Battery Maintenance And Boosting

    4. MAINTENANCE 4.8 BATTERY MAINTENANCE AND WARNING BOOSTING Inspect the batteries on a regular basis for To prevent personal injury DO NOT damage such as a cracked or broken case or charge a frozen battery because it can cover which would allow electrolyte loss. explode.

  • Page 58: Electrical Schematic - Chassis

    4. MAINTENANCE 4.9 ELECTRICAL SCHEMATIC - CHASSIS S0242...

  • Page 59: Electrical Schematic - Engine

    4. MAINTENANCE 4.10 ELECTRICAL SCHEMATIC - ENGINE WIRE HARNESS T90117...

  • Page 60: Hydraulic Schematic

    4. MAINTENANCE 4.11 HYDRAULIC SCHEMATIC TANK COOLER GEAR PUMP CONTROL VALVE SHAKER MOTOR FRONT BULKHEAD REAR BULKHEAD LIFT CYLINDER S0261...
  • Page 61 4. MAINTENANCE 4.11 HYDRAULIC SCHEMATIC - Conveyor Option TANK COOLER GEAR PUMP CONTROL VALVE SHAKER MOTOR REAR BULKHEAD FRONT BULKHEAD CONVEYOR MOTOR LIFT CYLINDER S0262...

  • Page 62: Pneumatic Layout

    4. MAINTENANCE 4.12 PNEUMATIC LAYOUT (up to S/N T9000106) TO EXHAUST TOTAL HOURS 50268 50267 50022 50278 50155 50201 50156 50283 50122 50284 966049 33867 50163 50173 14492 50185 50203 50154 50271 50050 13838 1458 14797 50288 50286 50287 50011 966013 966014 966015...
  • Page 63 4. MAINTENANCE 4.12 PNEUMATIC LAYOUT (S/N T9000107 onward) TOTAL HOURS 50268 50267 50022 50278 14223 966037 966014 50283 50122 50284 50117 33867 50163 50173 966020 966021 966022 50154 50271 966049 13838 1458 50249 50288 50286 50287 50011 966013 50201 966015 14492 * See Section 9.6.2 for more information.

  • Page 64: Troubleshooting

    4. MAINTENANCE 4.13 TROUBLESHOOTING 4.13A Screener Symptom Probable Cause Solution Cylinders will not Engine RPM too low Check and adjust operate Hydraulic fluid low Replenish Fluid leak Check and repair Shakerhead will Hydraulic fluid low Replenish not move Broken key Check and replace Hydraulic pump or Check pressure / flow...

  • Page 65: Engine

    4. MAINTENANCE 4.13 TROUBLESHOOTING 4.13B Engine Symptom Probable Cause Solution Will not start Low cranking speed Check battery charge No fuel Replenish. Check for air in fuel system. Check for blockage. Faulty stop solenoid Check and replace Faulty fuel pump Check and replace Faulty injection system Check and repair...
  • Page 66 4. MAINTENANCE 4.13 TROUBLESHOOTING 4.13B Engine Symptom Probable Cause Solution Lack of power Faulty fuel pump Check and replace Faulty injection system Check and repair Incorrect valve timing Check and repair Clogged air filter Check and replace Air in fuel system Bleed fuel lines Blocked fuel system Check and repair...

  • Page 67: Specifications

    5. SPECIFICATIONS 5. SPECIFICATIONS Dimensional Specifications ........5.1 Performance Specifications ........5.2 Fastener Torque Specifications ....... 5.3...

  • Page 68: Performance Specifications

    5. SPECIFICATIONS 5.1 DIMENSIONAL SPECIFICATIONS (see fig. T90038) A. Overall Length, mm (in.)............7950 (313) B. Transport Height (overall), mm(in.) .......... 3658 (144) C. Overall Width, mm (in.) .............. 2413 (95) D. Hopper Length, mm (in.)............4129 (162.6) E. Loading Height, mm (in.) ............3327 (131) Operating Height, mm (in.) ............
  • Page 69 5. SPECIFICATIONS T90038...
  • Page 70 5. SPECIFICATIONS T90050...
  • Page 71 5. SPECIFICATIONS 5.2 PERFORMANCE SPECIFICATIONS Hydraulics Pump Type / Brand ..................Gear Pump Displacement, cc (cu. in.) ............19.7 (1.20) Pump Capacity, (theoretical) lpm (gpm)..........52.2 (13.8) Shaker Motor Type / Brand ...............Piston Shaker Motor Displacement, cc (cu. in.) ...........40.6 (2.48) System Relief, bar (psi) @ zero flow ..........206.8 (3000) Control Valve(s)................1 Double Spool Cylinders ......................1 Oil Cooler, kJ / m (Btu / m)..............448 (425)

  • Page 72: Fastener Torque Specifications

    5. SPECIFICATIONS 5.3 FASTENER TORQUE SPECIFICATIONS The amount of twisting force (torque) on a bolt or screw is normally measured by the use of a torque wrench. The correct tightening of bolts is one of the most sin- gularly important operations done when repairing or conducting maintenance on your unit.
  • Page 73 5. SPECIFICATIONS 5.3 FASTENER TORQUE SPECIFICATIONS Metric Bolt Markings and Torque Values Standard Metric Bolt Dimensions and Grades Metric - M8 - 1.25 x 25 M8 - 1.25 x 25 Major thread diameter in millimeters Distance between threads in millimeters Length in millimeters Grade markings 10.9...

  • Page 75: Replacement Screens

    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: Screen Selection Tips

    Keep the screen properly tensioned. See section 4.3A. The screens must be kept tight enough to prevent unwanted movement between the shaker deck and screen material. The screens should be rotated 180º occasionally to allow the wear to be shared evenly on both ends of the screen. For screen selection assistance, contact Thomas Equipment: 1-800-538-0187.

  • Page 77: Ordering Information

    This is if you are using both decks to achieve your end product. The maximum size wire cloth opening you can use with the ProTough 900 would be 7" if using both top and bottom screens.

  • Page 78: Replacement Screen Information

    6. REPLACEMENT SCREENS 6.2 REPLACEMENT SCREEN INFORMATION Due to the large number of screen sizes and variations available; Thomas provides 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.

  • Page 79: Parts

    PROTOUGH 900 PARTS 7. PARTS 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 SHAKERHEAD 7.2 Shakerhead, Shaft, Suspension & Wire Cloth ......7.2.1 HYDRAULICS 7.3 Hydraulic Circuit .................7.3.1 Control Valve ................7.3.2 Cylinder..................7.3.3...
  • 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...

  • Page 82: Front Lift Assembly 7.1.1

    FRONT LIFT ASSEMBLY 7.1.1 4, 5, 6 4, 5, 6 S0230...
  • Page 83 FRONT LIFT ASSEMBLY 7.1.1 Item Part No. Qty. Description 966107 Jack, Outer Tube Assy 51859 Pin, 1.25” x 6.25” 33153 Cylinder 45490 Bolt, Hex 5/8 x 2” 1361 Washer, Flat 5/8” 45450 Nut, Lock 5/8” 966109 Jack Inner Tube Welded Assy 966105 Jack Base Welded Assy 51868...

  • Page 84: Tire, Wheel And Mud Flaps 7.1.2

    TIRE, WHEEL and MUD FLAPS 7.1.2 S0218...
  • Page 85 TIRE, WHEEL and MUD FLAPS 7.1.2 Item Part No. Qty. Description 50010 Tire & Wheel Assy, 315/80 R22.5 W/22.5 x 9.00 35313 Mudflaps (pair) 45898 Strip, Mud Flap Retainer 16771 Nut, Nylok 5/16 1651 Washer, Flat 5/16 2580 Bolt, Hex 5/16 x 1 1/4 50246 Nut, Wheel...

  • Page 86: Brake Parts 7.1.3

    BRAKE PARTS 7.1.3 S0221 S0220 S0219...
  • Page 87 BRAKE PARTS 7.1.3 Item Part No. Qty. Description 50373 Slack Adjuster 50374 ABS Sensor 50391 30/30 Spring Brake 50256 Axle, 25000 lbs w/Air Brakes...

  • Page 88: Axle Lock 7.1.4

    AXLE LOCK 7.1.4 S0232...
  • Page 89 AXLE LOCK 7.1.4 Item Part No. Qty. Description 50324P Tube, Travel Lock Bushing 966091 Mechanical Axle Stop, Welded Assy 1699 Washer, Flat 7/8” 50191 Bumper, 3 1/2” x 3” x 6” 50107 Nut, Flexlock 7/8” 50108 Bolt, Hex 7/8” x 6” 23385 Washer, Flat 1/2”...

  • Page 90: Compartment Doors 7.1.5

    COMPARTMENT DOORS 7.1.5 3, 4 S0223 3, 4 13, 14, 15 12, 19 S0224 S0225 S0226 S0227...
  • Page 91 COMPARTMENT DOORS 7.1.5 Item Part No. Qty. Description 50072P Hood Plate 966046SP Rear Door Assy 1193 Bolt, 3/8” 1643 Washer, Flat 3/8” 47167 Latch, Paddle Locking Handle 43329 Key for #47167 963830 Left Door Assembly 50444 Right Engine Compartment Door 47166 Sheet, Striker Pin Mount 47169...

  • Page 92: Access Panels 7.1.6

    ACCESS PANELS 7.1.6 6,17,18 S0241 9,10,11 4,13 T90106 T90107 6, 7 S0252...
  • Page 93 ACCESS PANELS 7.1.6 Item Part No. Qty. Description 50192SPR Suspension Access Panel, Right (Front) 50192SPL Suspension Access Panel, Left (Rear) 1190 Bolt, Hex 5/16” 1651 Washer, Flat 5/16” 966048P Gooseneck Access Panel 1643 Washer, Flat 3/8” 1673 Bolt, Hex 3/8” 966040P Rear Access Plate, Conveyor Opening 50332...

  • Page 95: Shakerhead 7.2

    SHAKERHEAD 7.2 Shakerhead, Shaft, Suspension & Wire Cloth ....7.2.1...

  • Page 96: Shakerhead, Shaft, Suspension & Wire Cloth 7.2.1

    SHAKERHEAD, SHAFT, SUSPENSION & WIRE CLOTH 7.2.1 4,5,6 14,15,16 5,6,57 14,15,16 14,15,16 14,15,16 S0268 5,6,57 4,5,6 14,15,16 S0267 4,5,6 10 11 S0266...
  • Page 97 SHAKERHEAD, SHAFT, SUSPENSION & WIRE CLOTH 7.2.1 15,16,55 15,16,55 21,22,56 14,15,16 24,25 14,15,16 4,5,6 14,15,16 5,6,57 S0265...
  • Page 98 SHAKERHEAD, SHAFT, SUSPENSION & WIRE CLOTH 7.2.1 14,15,16 5,6,57 14,15,16 15,16,55 14,15,16 20,21,22 14,15,16 14,15,16 S0266...
  • Page 99 SHAKERHEAD, SHAFT, SUSPENSION & WIRE CLOTH 7.2.1 Item Part No. Qty. Description 966071 Shakerhead Bolted Assembly 966094 Drive Shaft 966095 Bearing Housing Assembly 50336 Bearing, Housing 50330 Snap Ring 37184 Grease Fitting 50250 Bearing 45497 Bolt, Hex 3/4” x 3 1/2” 45460 Washer, Flat 3/4”...
  • Page 100 SHAKERHEAD, SHAFT, SUSPENSION & WIRE CLOTH 7.2.1 Item Part No. Qty. Description 50175 Nut, Flexlock 3/8” 50356P Backing, Inner Screen 50358P Retainer, Lower Screen 50380P Retainer, Bolt Alignment 50363P Retainer, Screen 50337P Shaker Center 50338P Shaker Left End 50339P Shaker Right End 50340P Shaker Lower Front 50341P...
  • 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...

  • Page 104: Hydraulic Circuit 7.3.1

    HYDRAULIC CIRCUIT 7.3.1 TANK COOLER GEAR PUMP CONTROL VALVE SHAKER MOTOR See Figure 7.3.1A REAR FRONT BULKHEAD BULKHEAD See Figure 7.3.1B LIFT CYLINDER S0243...
  • Page 105 HYDRAULIC CIRCUIT 7.3.1 Item Part No. Qty. Description 964930 Hose, Hydraulic 3/8 x 106” (Shakerhead motor case drain to rear bulkhead) 37017 Elbow, 90º 50248 Pump, Gear Hydraulic Assy 33882 Connector 1193 Bolt, Hex 3/8” x 1” (secure pump to housing) 50273 Washer, Hardened Flat 3/8”...
  • Page 106 HYDRAULIC CIRCUIT 7.3.1 (Continued) TANK COOLER GEAR PUMP CONTROL VALVE SHAKER MOTOR See Figure 7.3.1A REAR FRONT BULKHEAD BULKHEAD See Figure 7.3.1B LIFT CYLINDER S0243...
  • Page 107 HYDRAULIC CIRCUIT 7.3.1 (Continued) Item Part No. Qty. Description 48736 Connector, Bulkhead 37849 Tie, Cable 14 1/2” x 5/16” (secure hoses) 41620 Connector 50417 Connector, Bulkhead 39041 Connector, Bulkhead 39042 Connector, Bulkhead, 90º 29438 Connector 50264 Grommet, 1 1/4” x 1/4” x 1 7/8” x 9/16” 50263 Grommet, 3/4”...

  • Page 108: Control Valve 7.3.2

    CONTROL VALVE 7.3.2 S0237...
  • Page 109 CONTROL VALVE 7.3.2 Item Part No. Qty. Description 50252 Valve, Hydraulic Control, 2 spool w/handles (includes items 2 & 3) 50068 Relief Valve 50021 Valve Handle...

  • Page 110: Cylinder 7.3.3

    CYLINDER 7.3.3 C2676...
  • Page 111 CYLINDER 7.3.3 Item Part No. Qty. Description 33153 Cylinder, 3.000 x 15.5 32511 Seal Kit, Hydraulic Cylinder 30641 Bushing, Hardened 6297 Nut, Cylinder, Hex 2010 Fitting, Grease (Straight) 35451 Fitting, Grease (90º)

  • Page 112: Gear Pump 7.3.4

    GEAR PUMP 7.3.4 S0238...
  • Page 113 GEAR PUMP 7.3.4 Item Part No. Qty. Description 50248 Pump, Gear Hydraulic Assy (includes items 2, 3 & 4) 50085 Ring, Retainer Pump 50088 Kit, Seal Repair Pump 50089 Shaft, Pump Drive...

  • Page 114: Shaker Motor 7.3.5

    SHAKER MOTOR 7.3.5 S0239...
  • Page 115 SHAKER MOTOR 7.3.5 Item Part No. Qty. Description 50247 Motor, Hydraulic Assembly (includes all items listed below) 50078 Ring, Outer Retaining 50079 Ring, Inner Retaining 50080 Bearing, Thrust 50081 Shaft, Motor Drive 50084 Complete Seal Kit * Items not shown in diagram.

  • Page 116: Hydraulic Oil Tank 7.3.6

    HYDRAULIC OIL TANK 7.3.6 S0083...
  • Page 117 HYDRAULIC OIL TANK 7.3.6 Item Part No. Qty. Description 963179 Oil Tank Complete Assy (includes items 2, 3, 4 & 8) 966039 Oil Tank Welded Assy 36733 Breather, Oil Filler Locking 35026 Gauge, Level Oil Tank 5170 Bolt, Hex 1/4” x 1” 1650 Washer, Flat 1/4”...

  • Page 119: Electrical 7.4

    ELECTRICAL 7.4 Engine Electrical............7.4.1 Chassis Electrical.............7.4.2...

  • Page 120: Engine Electrical 7.4.1

    ENGINE ELECTRICAL 7.4.1 S0253...
  • Page 121 ENGINE ELECTRICAL 7.4.1 Item Part No. Qty. Description 50005 Control Box (up to S/N T9000109) 49687 Control Box (S/N T9000110 onward) 44961 Switch, Starter (includes #3) 44960 Ignition Key (pair) 50017 Harness, Engine Wire 50095 Engine...

  • Page 122: Chassis Electrical 7.4.2

    CHASSIS ELECTRICAL 7.4.2 ELECTRICAL SCHEMATIC - CHASSIS S0242...
  • Page 123 CHASSIS ELECTRICAL 7.4.2 Item Part No. Qty. Description 50037 Harness, Main 50041 Harness, Rear Connection 50036 Harness, Top Marker Light Right Side 50033 Harness, Connector 50034 Harness, Front Marker Lights 50040 Harness, ABS Lights 50042 Harness, Rear Bumper Marker 50043 Harness, Rear Top Marker 46151 Amber Cleanance Lamp...

  • Page 125: Engine 7.5

    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..........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 Throttle Control .............7.5.11 Fuel System............7.5.12 Engine Accessories ..........7.5.13...
  • Page 126 INTAKE SYSTEM 7.5.1 (S/N T9000101, T9000103, T9000105 & T9000106) S0271 S0273...
  • Page 127 Service Indicator 50431 Coupling, 1/8” NPT Brass Female 2 1/4” OD Muffler Pipe x 16” Long Part numbers in ( ) are Kubota part numbers. They can be ordered through Kubota Dealers or special order through Thomas Dealers. S0259 S0272...

  • Page 128: Intake System (Up To S/N T9000104)

    INTAKE SYSTEM 7.5.2 (S/N T9000102, T9000104 & T9000107 onward) S0229...

  • Page 129: Intake System (S/N T9000105 Onward)

    INTAKE SYSTEM 7.5.2 (S/N T9000102, T9000104 & T9000107 onward) Item Part No. Qty. Description 49331 Air Cleaner Assy (Includes #’s 2, 3, 4, 5, 8 and 11) 42420 Cover, Assembly 42421 Vacuator Valve 42417 Primary Air Filter Element 42418 Safety Air Filter Element 43389 Hose, Air 2”...

  • Page 130: Exhaust System 7.5.3

    EXHAUST SYSTEM 7.5.3 S0246...
  • Page 131 EXHAUST SYSTEM 7.5.3 Item Part No. Qty. Description 50226 Muffler 19378 Bolt 50225 Cap, Muffler 50224 Band, Muffler Cap 50118 Pin, Joint 50227 Pin, Split 18619 Washer, Plain 39835 Bolt 18527 44318 Washer, Lock 42691 Gasket, Exhaust Outlet...

  • Page 132: Radiator And Mounts 7.5.4

    RADIATOR and MOUNTS 7.5.4 S0247...
  • Page 133 RADIATOR and MOUNTS 7.5.4 Item Part No. Qty. Description 36021 Radiator 35765 Shroud, Fan 19572 Cap, Radiator 50094 Label, Caution 50232 Cushion, Rubber 50231 Label, Caution Radiator 39489 Label, Instruction 18467 Cushion 39167 Cushion 19574 Bolt 18469 Washer 19573 Pin, Snap 18491 50237 Support, Radiator RH...

  • Page 134: Water Pipe 7.5.5

    WATER PIPE 7.5.5 S0248...
  • Page 135 WATER PIPE 7.5.5 Item Part No. Qty. Description 22205 Hose, Bottom Radiator 18478 Band, Pipe 22204 Hose, Top Radiator...

  • Page 136: Fuel Filter 7.5.6

    FUEL FILTER 7.5.6 S0256...
  • Page 137 FUEL FILTER 7.5.6 Item Part No. Qty. Description 42560 Assy, Fuel Filter 42561 Filter, Fuel 19333 Bolt...

  • Page 138: Alternator And Pulley 7.5.7

    ALTERNATOR and PULLEY 7.5.7 S0249...
  • Page 139 ALTERNATOR and PULLEY 7.5.7 Item Part No. Qty. Description 42604 Alternator 39689 Bolt 18492 Washer, Plain 18527 18406 Washer, Spring 19563 Stay, Dynamo 23106 Bolt 50169 Terminal 47983 Guard, Alternator 36875 Pulley, Fan Drive 19444 Key, Feather 35568 Belt, Fan 50238 Assy Terminal 50239...

  • Page 140: Oil Filter 7.5.8

    OIL FILTER 7.5.8 S0250...
  • Page 141 OIL FILTER 7.5.8 Item Part No. Qty. Description 33023 Filter, Engine Oil...

  • Page 142: Water Flange And Thermostat 7.5.9

    WATER FLANGE and THERMOSTAT 7.5.9 S0245...
  • Page 143 WATER FLANGE and THERMOSTAT 7.5.9 Item Part No. Qty. Description 33148 Flange Complete, Water 31494 Pipe, Water Return 19577 Gasket, Water Flange 19379 Bolt 19397 Stud 19360 Bolt 18495 18451 Washer, Spring 19580 Pipe, Water Return 2 19582 Clamp, Pipe 19585 Cover, Thermostat 19586...

  • Page 144: Fan 7.5.10

    FAN 7.5.10 S0251...
  • Page 145 FAN 7.5.10 Item Part No. Qty. Description 50244 39732 Bolt, Flange 21428 Pulley, Fan Metal 39731 Collar, Fan...

  • Page 146: Throttle Control 7.5.11

    THROTTLE CONTROL 7.5.11 S0255...
  • Page 147 THROTTLE CONTROL 7.5.11 Item Part No. Qty. Description 39199 Knob, Red Ball 963299 Throttle Handle Welded Assy. 42047 Joint, Ball Socket 2279 Washer, Lock 1/4” 5405 Nut, Hex 1/4” 50241P Bracket, Throttle 50012 Cable, Push Pull 68” Long 46188 Sheet, Throttle Frame 966106 Throttle Plate Welded Assy.

  • Page 148: Fuel System 7.5.12

    FUEL SYSTEM 7.5.12 S0257...
  • Page 149 FUEL SYSTEM 7.5.12 Item Part No. Qty. Description 966038 Fuel Tank & Fittings Complete (includes items 1a,2-8,10,11,19) 966036 Fuel Tank Welded Assembly 36733 Fuel Cap (up to S/N T9000106) 37880 Paddle Lock w/Key - Key Code 201 (up to S/N T9000106) 40922 Locking Fuel Cap (S/N T9000107 onward) 49669...

  • Page 150: Engine Accessories 7.5.13

    ENGINE ACCESSORIES 7.5.13 S0254...
  • Page 151 ENGINE ACCESSORIES 7.5.13 Item Part No. Qty. Description 966041 Solenoid Assy. 4 ft. Seal, Radiator Foam (cut to size) 42737 Reservoir, Coolant 1651 Washer 16771 44850 Cover, Coolant Reservoir 34919 Clamp, Circle Two Ear 9.5 ft. Hose, Fuel 5 5/16” 1.83 ft.
  • Page 153 PNEUMATICS 7.6 Pneumatic Layout (up to S/N T9000106) ....7.6.1 Pneumatic Layout (S/N T9000107 onward)....7.6.2...
  • Page 154 PNEUMATICS (up to S/N T9000106) 7.6.1 TO EXHAUST TOTAL HOURS 14,15,16 17, 25 S0277...
  • Page 155 PNEUMATICS (up to S/N T9000106) 7.6.1 Item Part No. Qty. Description 50268 Service Gladhand 50267 Emergency Gladhand 50022 Bulkhead Connector 50278 Spring Brake Sensor Valve 50155 Connector 50201 Hose, Brake 3/8” x 42” 50156 Elbow, 90 Degree 50283 ECU Valve 50122 Sensor Extension Cable 50284...
  • Page 156 PNEUMATICS (S/N T9000107 onward) 7.6.2 Pneumatic Layout TOTAL HOURS S0258...
  • Page 157 PNEUMATICS (S/N T9000107 onward) 7.6.2 Item Part No. Qty. Description 50268 Service Gladhand 50267 Emergency Gladhand 50022 Bulkhead Connector 50278 Spring Brake Sensor Valve 14223 Plug, Hex Head 966037 Hose, Air 3/8” x 540” (Black) 966014 Hose, Air 3/8” x 9” (Blue) 50283 ECU Valve 50122...
  • Page 159 CONVEYOR 7.7 (Optional at time of purchase) Conveyor..............7.7.1 Hydraulic Circuit w/ Conveyor .......7.7.2...
  • Page 160 CONVEYOR 7.7.1 S0231...
  • Page 161 CONVEYOR 7.7.1 Item Part No. Qty. Description 50293 Motor, Gear 5 hp 2000 PSI 50294 Pulley, Drum 50295 Pulley, Wing 50296 Bearing, Pillow Block 50298 Bearing, Take-up 50299 Pulley, Idler 50300 Pulley, Return 50301 Conveyor Frame 50309 Belt, Conveyor 2-Ply 50322 Scrapper, Conveyor 50326...
  • Page 162 HYDRAULIC CIRCUIT W/CONVEYOR 7.7.2 TANK COOLER GEAR PUMP CONTROL VALVE SHAKER MOTOR See Figure 7.7.2A FRONT REAR BULKHEAD BULKHEAD See Figure 7.7.2B CONVEYOR MOTOR LIFT CYLINDER S0244...
  • Page 163 HYDRAULIC CIRCUIT W/CONVEYOR 7.7.2 Item Part No. Qty. Description 964930 Hose, Hydraulic 3/8 x 106” (Shakerhead motor case drain to rear bulkhead) 37017 Elbow, 90º 50248 Hydraulic Pump 33882 Connector 1193 Bolt, Hex 3/8” x 1” (secure pump to housing) 50273 Washer, Hardened Flat 3/8”...
  • Page 164 HYDRAULIC CIRCUIT W/CONVEYOR 7.7.2 (Continued) TANK COOLER GEAR PUMP CONTROL VALVE SHAKER MOTOR See Figure 7.7.2A REAR FRONT BULKHEAD BULKHEAD See Figure 7.7.2B CONVEYOR MOTOR LIFT CYLINDER S0244...
  • Page 165 HYDRAULIC CIRCUIT W/CONVEYOR 7.7.2 (Continued) Item Part No. Qty. Description 48736 Connector, Bulkhead 37849 Tie, Cable 14 1/2” x 5/16” (secure hoses) 41620 Connector 50417 Connector, Bulkhead 39041 Connector, Bulkhead 39042 Connector, Bulkhead, 90º 29438 Connector 50264 Grommet, 1 1/4” x 1/4” x 1 7/8” x 9/16” 50263 Grommet, 3/4”...

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