Trojan 2000 Loader Reliability Restoration and Field Adaptation

[MikePhua]

The Trojan 2000 and Its Industrial Legacy
The Trojan 2000 wheel loader was produced during the peak of Trojan Industries’ influence in the North American construction and aggregate sectors. Trojan, founded in the mid-20th century, specialized in robust, no-nonsense earthmoving equipment. The 2000 series was designed for mid-range loading tasks, often found in gravel pits, snow removal operations, and municipal yards. With an operating weight of approximately 28,500 lbs, a standard width of 8 ft 7 in, and a height of 10 ft 2 in, the Trojan 2000 offered a balance of power and maneuverability for its class.
Though the company eventually ceased production, many Trojan 2000 units remain in service, maintained by dedicated owners who value their mechanical simplicity and rugged build.
Terminology Note

• Air-over-Hydraulic Brakes: A braking system where compressed air activates hydraulic pressure to engage brake cylinders.
  
• Master Cylinder: A hydraulic component that converts mechanical input into fluid pressure for braking.
  
• Bus Bar: A solid metal strip used to distribute electrical power, often replacing flexible cables for durability.
  
• Lift Cylinder: A hydraulic actuator responsible for raising and lowering the loader arms.
  

Common Mechanical Challenges
Owners of the Trojan 2000 often report a mix of age-related wear and design quirks. The most frequent issues include:

• Brake System Confusion: The air-over-hydraulic setup can be difficult to diagnose. Some machines show dry master cylinders with no fluid, yet brakes still function due to residual pressure or bypassed components.
  
• Hydraulic Leaks: Lift cylinders and wheel hubs are prone to seal degradation, especially in machines stored outdoors.
  
• Electrical Instability: Original wiring often suffers from corrosion or poor grounding. Upgrades using copper bus bars and modern batteries significantly improve reliability.
  
• Battery Configuration: Many units were retrofitted with mismatched truck batteries. Replacing them with uniform high-CCA batteries and proper bus connections resolves starting issues.
  

In one case, a snow removal operator in Alberta replaced two mismatched batteries with four new units wired through custom copper bus bars. The loader, previously unreliable in cold starts, became a dependable workhorse even in sub-zero conditions.
Brake System Restoration Strategy
The air-over-hydraulic brakes require careful inspection. Recommendations include:

• Locate the master cylinder under the operator’s left foot panel
  
• Clean and refill with DOT-approved brake fluid if applicable
  
• Inspect air lines for leaks, especially near the compressor and actuators
  
• Replace cracked seals and broken lines
  
• Test air pressure buildup and release timing
  

Some operators report that previous owners neglected the brakes entirely, relying on flat terrain. However, in hilly environments, full brake restoration is essential for safety.
Hydraulic System Maintenance
To maintain lift performance and prevent leaks:

• Replace hydraulic seals every 1,000 hours or sooner if seepage is visible
  
• Use manufacturer-recommended hydraulic fluid and monitor levels weekly
  
• Flush the system annually to remove debris and moisture
  
• Inspect cylinder rods for scoring or pitting
  
• Rebuild lift cylinders if movement becomes jerky or uneven
  

A contractor in Michigan rebuilt both lift cylinders after noticing uneven bucket lift. The repair restored smooth operation and prevented further wear on the loader arms.
Electrical System Upgrades
Electrical faults are common in aging Trojan loaders. Solutions include:

• Replace all battery cables with solid bus bars for consistent current flow
  
• Clean and tighten all ground connections
  
• Install sealed connectors to prevent moisture ingress
  
• Test voltage drop across starter and solenoid circuits
  
• Use a multimeter to verify continuity in control switches
  

Routine battery testing and terminal cleaning can prevent starting delays and intermittent control failures.
Operator Anecdote and Field Use
One operator in Montana uses his Trojan 2000 for snow removal across a 20-acre property. After installing new brakes, rebuilding the lift cylinders, and upgrading the electrical system, the loader became a reliable winter tool. Despite its age, the machine handles deep snow and icy terrain with ease, thanks to its weight and torque.
Manufacturer History and Decline
Trojan Industries was once a respected name in wheel loaders, competing with brands like Michigan, Clark, and Case. The company focused on mechanical durability and ease of service. However, as electronic controls and emissions standards evolved, Trojan struggled to adapt. Production ceased in the late 1990s, but parts remain available through specialty suppliers and salvage networks.
Recommendations for Long-Term Operation

• Maintain a detailed service log for all repairs and upgrades
  
• Inspect brake and hydraulic systems monthly
  
• Upgrade electrical components to modern standards
  
• Store the machine indoors or under cover to prevent weather-related wear
  
• Use the loader regularly to prevent seal dry-out and battery drain
  

Conclusion
The Trojan 2000 wheel loader may be a relic of a bygone era, but with proper care and thoughtful upgrades, it remains a capable and dependable machine. Its mechanical simplicity allows owners to perform most repairs themselves, and its robust frame handles demanding tasks with ease. Whether clearing snow, loading gravel, or maintaining rural roads, the Trojan 2000 continues to prove that old iron still has a place in modern operations.