Tennant ATLV 4300 Service Manual
  1. Manuals
  2. Brands
  3. Tennant Manuals
  4. Floor Machine
  5. ATLV 4300
  6. Service manual

Tennant ATLV 4300 Service Manual

Hide thumbs Also See for ATLV 4300:
Table of Contents

Advertisement

Quick Links

See also: Operator's Manual
ATLVt t t t 4300
Service Manual
330495
Rev. 03 (5- - 02)
*330495*

Advertisement

Table of Contents
loading

Related Manuals for Tennant ATLV 4300

Summary of Contents for Tennant ATLV 4300

  • Page 1 ATLVt t t t 4300 Service Manual 330495 Rev. 03 (5- - 02) *330495*...
  • Page 2 Engine - - D: Air filter replacement, oil changing, cooling system maintenance/repair, engine troubleshooting, engine removal, and engine repairs. Manual Number -- 330495 Revision: 03 Published: 5--02 Copyright E 1998, 2001, 2002 TENNANT, Printed in U.S.A.

  • Page 3: Table Of Contents

    ..1-17 HYDRAULIC O--RING FITTING TORQUE CHART ..... . . 1-17 ATLV 4300 330495 (12- -01)
  • Page 4 GENERAL INFORMATION ATLV 4300 330495 (8- -94)

  • Page 5: Safety Precautions

    - - In areas with possible falling objects well ventilated. - - Use cardboard to locate leaking unless equipped with overhead guard. hydraulic fluid under pressure. - - Use TENNANT supplied or approved replacement parts. ATLV 4300 330495 (5- -02)
  • Page 6 380 mm (15 in) or less from the ground. - - Set parking brake after machine is loaded. - - Block machine tires. - - Tie machine down to truck or trailer. ATLV 4300 330495 (5- -02)
  • Page 7 FAN WARNING LABEL - - FOR SAFETY LABEL - - Located In The Engine Located Below The Operator Seat. Compartment. NOISE WARNING LABEL - - Located EMISSIONS LABEL - - Located Below The Operator’s Seat. Below The Operator’s Seat. ATLV 4300 330495 (6- -01)

  • Page 8: Specifications

    26 kmh (16 mph) Maximum reverse speed 8 kmh (5 mph) Minimum isle turn 4064 mm (160 in) Minimum turning radius 457 mm (18 in) Maximum rated climb and descent angle 12_ / 21% Empty or Full hopper ATLV 4300 330495 (12- -01)

  • Page 9: Power Type

    HYDRAULIC SYSTEM System Capacity Fluid Type Hydraulic reservoir 19 L (5 gal) TENNANT part no. 65869 -- above 7_ C (45_F) TENNANT part no. 65870 -- below 7_ C (45_F) Hydraulic total 21 L (5.5 gal) BRAKING SYSTEM Type Operation...

  • Page 10: Machine Dimensions

    GENERAL INFORMATION 168 mm (46 in) 2113 mm (83 in) ATLV 4300 965 mm 1320 mm (38 in) (52 in) 2590 mm (102 in) MACHINE DIMENSIONS ATLV 4300 330495 (6- -01)
  • Page 11 GENERAL INFORMATION ATLV 4300 330495 (12- -01)

  • Page 12: Maintenance

    Check for debris and clean Dust filter bag (option) Check for debris and clean Dust panel filter (option) Check for debris and clean Water dust control (option) Check for debris and spray nozzle adjustment ATLV 4300 330495 (12- -01) 1-10...
  • Page 13 Engine oil, 10W--30--CD/SE rated HYDO TENNANT or approved hydraulic fluid . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) . . . Water and permanent-type ethylene glycol anti-freeze, --34_ C (--30_ F) ..Distilled water Note: Also check procedures indicted (H) after the first 50-hours of operation.

  • Page 14: Pushing, Towing, And Transporting The Machine

    Turn the bypass valve 90_ from the normal position before pushing or towing the machine. The illustration shows the bypass valve in the pushing or towing position. ATLV 4300 330495 (6- -01) 1-12...

  • Page 15: Transporting The Machine

    5. Position the machine onto the truck or trailer as far as possible. If the machine starts to veer off the centerline of the truck or trailer, stop and turn the steering wheel to center the machine. ATLV 4300 330495 (6- -01) 1-13...
  • Page 16 FOR SAFETY: When unloading machine off truck or trailer, use winch. Do not drive the machine off the truck or trailer unless the loading surface is horizontal AND 380 mm (15 in) or less from the ground. ATLV 4300 330495 (6- -01) 1-14...

  • Page 17: Machine Jacking

    STORING MACHINE Before storing the machine for an extended period of time, the machine needs to be prepped to lessen the chance of rust, sludge, and other undesirable deposits from forming. Contact TENNANT service personnel. ATLV 4300 330495 (6- -01) 1-15...

  • Page 18: Hardware Information

    They include the following: 0.75 in 215--280 313--407 (291--380) (424--552) Locktite 515 sealant -- gasket forming material. TENNANT Part No. 75567,15 oz 1.00 in 500--650 757--984 (440 ml) cartridge. (678--881) (1026--1334) NOTE: Decrease torque by 20% when using a Locktite 242 blue -- medium strength thread thread lubricant.

  • Page 19: Hydraulic Fitting Information

    (122 Nm) 0.62 0.88--14 40 ft lb (54 Nm) NOTE: Do not use sealant on o- -ring threads. 0.75 1.12--12 70 ft lb (95 Nm) 1.31--12 90 ft lb (122 Nm) *Aluminum bodied components ATLV 4300 330495 (6- -01) 1-17...
  • Page 20 GENERAL INFORMATION ATLV 4300 330495 (12- -01) 1-18...
  • Page 21 TO REPLACE PROPEL HYDROBACK ....2-24 TO SET TRAVEL SPEEDS ..2-26 TO ADJUST PROPEL NEUTRAL 2-27 ATLV 4300 330495 (12- -01)
  • Page 22 CHASSIS ATLV 4300 330495 (10- -98)

  • Page 23: Introduction

    CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat, steering, brakes and tires. ATLV 4300 330495 (10- -98)

  • Page 24: Seat

    4. Disengage the prop rod and drop the seat assembly down slightly. 5. Remove the end of the prop rod through the access hole. 6. Remove the seat assembly from the machine. ATLV 4300 330495 (10- -98)

  • Page 25: To Install Seat Assembly

    8 -- 10 Nm (6 -- 8 ft. lb). 4. Drop the seat down enough to place the end of the prop rod into the access hole. 5. Drop the seat assembly down and remove the hoist. ATLV 4300 330495 (10- -98)

  • Page 26: Brakes And Tires

    3. Make sure the parking brake is engaged. Remove the five wheel nuts. Remove the tire and wheel assembly from the machine. 4. Lift the hopper cover and tilt the hopper back. 5. Disengage the parking brake. ATLV 4300 330495 (10- -98)
  • Page 27 22. Remove the jack stands and lower the machine. 23. Remove the blocks from the front tires and disengage the parking brake. 24. Operate the machine and check the service brakes for proper operation. ATLV 4300 330495 (10- -98)

  • Page 28: To Replace Service Brake Cable

    13. Reinstall the clevis pin and cotter pin into the clevis on the front of the new brake cable. 14. Go to the back of the machine and position the brake cable into the mount hole. Tighten the large jam nut. ATLV 4300 330495 (10- -98)

  • Page 29: To Adjust Service/Parking Brake

    5. Loosen the jam nuts on the cable and adjust until there is a slight pull on the cable. Tighten the jam nuts. Repeat on both sides. 6. Close the hopper and cover. 7. Operate the machine and check the brakes for proper operation. ATLV 4300 330495 (10- -98)

  • Page 30: Parking Brake

    4. Position the new tire and wheel assembly onto the front axle hub. 5. Reinstall the four wheel nuts and tighten finger tight. 6. Remove the jack stands and lower the machine to the floor. 2-10 ATLV 4300 330495 (10- -98)

  • Page 31: To Replace Rear Tire And Wheel

    7. Remove the blocks from the front tires. 8. Check the new tires for wear and rotate every 200 hours of operation. 9. Check the tire pressure every 50 hours of operation. 2-11 ATLV 4300 330495 (10- -98)

  • Page 32: To Align Front Tires

    8. Tighten the jam nut where the ball joint is attached to the clevis. 9. Drive the machine forward with the steering wheel pointed straight ahead. 10. Re--check the tire alignment. Re--adjust if necessary. 2-12 ATLV 4300 330495 (10- -98)

  • Page 33: Steering

    Hold the bolt from turning and re--tighten the jam nut. 6. Turn the steering wheel all the way the other direction and repeat steps 4 and 5. 7. Remove the jack stands and lower the machine. 2-13 ATLV 4300 330495 (10- -98)

  • Page 34: Front Axle

    NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 8. The front axle assembly must be supported before any hardware is removed. Use jack stands or a floor jack. 2-14 ATLV 4300 330495 (10- -98)
  • Page 35 13. Carefully drop the front axle assembly down and out of the machine. 2-15 ATLV 4300 330495 (10- -98)

  • Page 36: To Install Front Axle Assembly

    18 -- 24 Nm (15 -- 20 ft. lb). 9. Line up the mount holes in the ends of the two stabilizer bars with the mount hole in the rubber dampners. Install the M12 hex screws and washers. Hand tighten tight. 2-16 ATLV 4300 330495 (12- -01)
  • Page 37 14. Go back and finish tightening the wheel nuts to 122 -- 162 Nm (90 -- 120 ft. lb). 15. Reconnect the vacuum head to the front axle. 16. Operate the machine and check for proper operation. 2-17 ATLV 4300 330495 (12- -01)

  • Page 38: To Replace Front Axle Leaf Spring

    9. Tighten all the hardware with an impact then hit the bolt with a hammer to seat the knurl. 10. Reinstall the axle assembly. See TO INSTALL FRONT AXLE ASSEMBLY instructions in this section. 2-18 ATLV 4300 330495 (10- -98)

  • Page 39: To Replace Front Axle Rod End

    14. Go back and finish tightening the four wheel nuts to 122 -- 162 Nm (90 -- 120 ft. lb). 15. Check the front wheel alignment. See TO ALIGN FRONT TIRES instructions in this section. 2-19 ATLV 4300 330495 (10- -98)

  • Page 40: Propel Cable

    5. Open the hopper cover and tilt the hopper back. 6. Open the top engine cover. 7. Remove the five pan screws holding the rear engine cover to the machine. Remove the cover. 2-20 ATLV 4300 330495 (10- -98)
  • Page 41 Install the safety clip, rubber washer, and the second cable nut. Lock the second nut against the safety clip and the first cable nut. Spin the clevis down against the second cable nut. Lock the clevis to the nut. 2-21 ATLV 4300 330495 (10- -98)
  • Page 42 Leave the jam nuts loose for now. 24. Place the ball joint into the hole in the bottom of the propel pedal. Tighten the nyloc nut to 8 -- 10 Nm (6 -- 8 ft. lb). 2-22 ATLV 4300 330495 (10- -98)
  • Page 43 25. Set the heel of the foot pedal to 1--1/8 inch. from the floor plate. Tighten the jam nuts on the propel cable. 26. The neutral centering will have to be set at this point. See TO ADJUST PROPEL NEUTRAL instructions in this section. 2-23 ATLV 4300 330495 (10- -98)

  • Page 44: To Replace Propel Hydroback

    8. Loosen the jam nut at the back of the hydroback. Screw the hydroback off the propel cable. Discard the hydroback. 9. Position the new hydroback onto the end of the cable (large end first). 2-24 ATLV 4300 330495 (10- -98)
  • Page 45 Tighten to 8 -- 10 Nm (6 -- 8 ft. lb). Reinstall a plastic tie. 14. The neutral centering will have to be set at this point. See TO ADJUST PROPEL NEUTRAL instructions in this section. 2-25 ATLV 4300 330495 (10- -98)

  • Page 46: To Set Travel Speeds

    16 mph. 4. Loosen the jam nut and screw the bolt up or down to make any adjustments. Retighten the jam nut after the speed adjustment has been made. 2-26 ATLV 4300 330495 (10- -98)

  • Page 47: To Adjust Propel Neutral

    Tighten the two outside hex screws. Re--observe the rear tires for rotation. Repeat step if necessary. 10. Lower the machine and reinstall the rear engine cover. 11. Operate the machine and check the propel for proper operation. 2-27 ATLV 4300 330495 (10- -98)
  • Page 48 CHASSIS 2-28 ATLV 4300 330495 (12- -01)
  • Page 49 ....3--15 TO REPLACE VACUUM FAN IMPELLER SCREEN ... . 3--18 MACHINE TROUBLESHOOTING ..3--19 ATLV 4300 330495 (10- -98)
  • Page 50 VACUUMING ATLV 4300 330495 (10- -98)

  • Page 51: Introduction

    The vacuum fan pulls air from the vacuum head, through the hopper, and out the back of the hopper. ATLV 4300 330495 (10- -98)

  • Page 52: Debris Hopper

    18 -- 24 Nm (15 -- 20 ft. lb). 7. Pivot the hopper forward and backward, make sure the bracket is contacting the pivot spring before the hopper is tilted all the way back. ATLV 4300 330495 (10- -98)

  • Page 53: To Adjust Hopper Level Brackets

    Re--tighten the hardware to 18 -- 24 Nm (15 -- 20 ft. lb). 7. Open and close the hopper cover. Check for proper sealing of the cover to hopper seal. ATLV 4300 330495 (10- -98)

  • Page 54: To Adjust Hopper Cover Pivot Brackets

    Re--tighten the hardware to 18 -- 24 Nm (15 -- 20 ft. lb). 6. Open and close the hopper cover. Check for proper sealing of the cover to hopper seal. ATLV 4300 330495 (10- -98)

  • Page 55: Skirts

    9. Tighten the corner bolts first, then the front bolts, then the center bolt. 10. Reinstall the edge roller wheel onto the mount pin. Reinstall the cotter pin and washer. 11. Operate the machine and check the vacuum head for proper operation. ATLV 4300 330495 (10- -98)

  • Page 56: To Replace Vacuum Head Front Skirt

    REPLACE VACUUM HEAD REAR SKIRT instructions in this section. 8. Reinstall the edge roller wheel onto the mount pin. Reinstall the cotter pin and washer. 9. Operate the machine and check the vacuum head for proper operation. ATLV 4300 330495 (10- -98)

  • Page 57: Vacuum Head

    10. Remove the outer most jam nut. Pull the lift cable out of the mount bracket. 11. Remove the hex screw and nut holding the lift cable clamp to the machine frame. Remove the cable clamp. ATLV 4300 330495 (10- -98)
  • Page 58 18 -- 24 Nm (15 -- 20 ft. lb). 23. Reinstall the slide assembly and tighten the three hex screws to 18 -- 24 Nm (15 -- 20 ft. lb). 24. Reinstall the propel pedal, clevis pin, and cotter pin. 3-10 ATLV 4300 330495 (10- -98)
  • Page 59 ACTUATOR LIFT CABLE instructions in this section. 33. Go back and tighten all jam nuts. 34. Raise the vacuum head and remove the wood block. 35. Operate the machine and check the vacuum head lift actuator for proper operation. ATLV 4300 330495 (10- -98) 3-11...

  • Page 60: To Replace Vacuum Head Secondary Lift Cables

    (one on top, two from under front of frame). 11. Pull the vacuum head cable assembly mount plate back away from the machine frame. 12. Remove the tension spring holding the two cable pulley pivot brackets together. 3-12 ATLV 4300 330495 (10- -98)
  • Page 61 Turn the adjustment nut all the way down to the end of the threads. 22. Raise the vacuum head and remove the wood block. 23. Operate the vacuum head lift. Check for proper operation. ATLV 4300 330495 (10- -98) 3-13...

  • Page 62: To Adjust Vacuum Head Actuator Lift Cable

    6. This procedure will leave the rubber skirts approximately flush with the floor when the head stop is adjusted to the highest position (counter--clockwise). 3-14 ATLV 4300 330495 (10- -98)

  • Page 63: Vacuum Fan

    6. Pull the impeller screen, spacer, and sleeve off the vacuum fan motor shaft. 7. Remove the four hex screws holding the vacuum fan assembly retainer plate to the bottom of the hopper plenum. ATLV 4300 330495 (10- -98) 3-15...
  • Page 64 Tighten the four screws to 18 -- 24 Nm (15 -- 20 ft. lb).Use blue loctite (242) on the threads of this hardware. 17. Reinstall cover assembly onto the hopper plenum. 3-16 ATLV 4300 330495 (10- -98)
  • Page 65 Tighten the screws to 18 -- 24 Nm (15 -- 20 ft. lb). 21. Tilt the hopper forward and close the cover. 22. Operate the machine and check the vacuum fan for proper operation. ATLV 4300 330495 (10- -98) 3-17...

  • Page 66: To Replace Vacuum Fan Impeller Screen

    5. Use blue loctite (242) on the threads of the impeller screen hardware. Reinstall the one M8 hex screw and three M6 flat screws. 6. Close the hopper cover. 7. Operate the machine and check the vacuum fan for proper operation. 3-18 ATLV 4300 330495 (10- -98)

  • Page 67: Machine Troubleshooting

    Water dust control (option) not on Turn on water dust control Water dust control (option) water Fill water dust control tank tank empty Water dust control (option) spray Clean water dust control spray nozzle clogged nozzle ATLV 4300 330495 (5- -02) 3-19...
  • Page 68 VACUUMING 3-20 ATLV 4300 330495 (10- -98)
  • Page 69 ....4--19 TROUBLESHOOTING ....4--25 ATLV 4300 330495 (10- -98)
  • Page 70 ELECTRICAL ATLV 4300 330495 (10- -98)

  • Page 71: Introduction

    ELECTRICAL INTRODUCTION The machines electrical system consists of the batteries, instrument panel, actuators, switches, relays, and circuit breakers. ATLV 4300 330495 (10- -98)

  • Page 72: Electrical System

    ELECTRICAL ELECTRICAL SYSTEM The electrical system on the model ATLV 4300 is a 12 volt system consisting of a battery, alternator, circuit breakers, relays, and switches. BATTERY The battery is located under the operator’s seat and can be accessed by lifting the seat up.

  • Page 73: To Replace Battery

    9. Disengage the prop rod and lower the seat support. 10. Check the new battery for proper operation. If battery needs charging, see TO CHARGE BATTERY instructions in this section. ATLV 4300 330495 (10- -98)

  • Page 74: Instrument Panel

    12. Carefully pull the instrument panel up until the rubber boot clears the steering column. 13. Place the instrument panel back, against the kick panel of the operators compartment. 14. The components located on the instrument panel can now be serviced. ATLV 4300 330495 (10- -98)

  • Page 75: To Install Instrument Panel

    9. Reconnect the battery cable to the battery (red cable to positive post, black cable to negative post). 10. Disengage the prop rod and lower the seat support. 11. Start the machine and check for proper operation. ATLV 4300 330495 (10- -98)

  • Page 76: Circuit Breakers

    Accessory/ Vac/ Hyd CB-2 15 A Horn CB--3 15 A Work Lights (Opt) CB-4 15 A Operating Lights CB-5 15 A Brake/ Turn signals (Opt) CB-6 15 A Options CB-7 15 A Options CB-8 15 A Options ATLV 4300 330495 (10- -98)

  • Page 77: To Replace Circuit Breaker

    NOTE: The mount hole has a “D” shape to match the shape of the circuit breaker. 11. Install the metal retainer ring onto the back of the new circuit breaker. Push the retainer all the way down the circuit breaker. ATLV 4300 330495 (10- -98)
  • Page 78 16. Reconnect the battery cable to the battery (red cable to positive post, black cable to negative post) 17. Disengage the prop rod and lower the seat support. 18. Start the machine and check for proper operation. 4-10 ATLV 4300 330495 (10- -98)

  • Page 79: To Replace Relay

    13. Reconnect the battery cable to the battery (red cable to positive post, black cable to negative post) 14. Disengage the prop rod and lower the seat support. 15. Start the machine and check for proper operation. 4-11 ATLV 4300 330495 (10- -98)

  • Page 80: Actuator

    6. Loosen the jam nut against the long, black cable nut. 7. Un--screw the long, black cable nut from the end of the lift cable. 8. Disconnect the actuator from the main electrical harness. 4-12 ATLV 4300 330495 (10- -98)
  • Page 81 Leave loose for now. 19. See TO ADJUST vacuum HEAD ACTUATOR LIFT CABLE instructions in the vacuum section. 20. Operate the machine and check the vacuum head lift actuator for proper operation. 4-13 ATLV 4300 330495 (10- -98)

  • Page 82: To Replace Engine Alternator

    10. Reinstall the longer lower hex bolt and nut. Leave loose for now. 11. Reinstall the shorter hex bolt in the top of the alternator. Leave loose for now. 12. Reinstall the fan/alternator belt. 4-14 ATLV 4300 330495 (10- -98)
  • Page 83 See schematic in this section. 16. Reconnect the battery cables to the battery. 17. Close the engine cover and lower the seat assembly. 18. Start the engine and check the alternator for proper operation. 4-15 ATLV 4300 330495 (10- -98)

  • Page 84: To Replace Engine Starter

    18 -- 24 Nm (15 -- 20 ft lb). 9. Reconnect the battery cables to the battery and check the starter for proper operation. 10. Close the engine cover and pivot the seat assembly down. 4-16 ATLV 4300 330495 (10- -98)

  • Page 85: Electrical Schematic

    ELECTRICAL ELECTRICAL SCHEMATIC 352281 4-17 ATLV 4300 330495 (6- -01)
  • Page 86 ELECTRICAL ELECTRICAL SCHEMATIC 352281 4-18 ATLV 4300 330495 (6- -01)

  • Page 87: Wire Harness

    ELECTRICAL WIRE HARNESS 4-19 ATLV 4300 330495 (6- -01)
  • Page 88 ELECTRICAL WIRE HARNESS 4-20 ATLV 4300 330495 (6- -01)
  • Page 89 ELECTRICAL WIRE HARNESS 4-21 ATLV 4300 330495 (6- -01)
  • Page 90 ELECTRICAL WIRE HARNESS 4-22 ATLV 4300 330495 (6- -01)
  • Page 91 ELECTRICAL WIRE HARNESS 4-23 ATLV 4300 330495 (6- -01)
  • Page 92 ELECTRICAL WIRE HARNESS 4-24 ATLV 4300 330495 (6- -01)

  • Page 93: Troubleshooting

    ELECTRICAL TROUBLESHOOTING The troubleshooting charts that follow are organized so they lead you through the circuits. They include flow charts and instructions for you as to where to insert your test instruments. ATLV 4300 330495 (10- -98) 4-25...
  • Page 94 4C/YEL at the starter motor solenoid M1. Replace the ignition switch Repair Replace the starter motor Repair or connections or solenoid or starter motor replace wire replace battery assembly 4C/YEL cables Starter motor turns 4-26 ATLV 4300 330495 (10- -98)
  • Page 95 Disconnect the 4/YEL wire from the starter solenoid to prevent the starter motor from turning. Turn the key switch to the start positionand notice if the plunger on the solenoid moves. Engine runs ATLV 4300 330495 (10- -98) 4-27...
  • Page 96 18/GRN at the vacuum switch and 20/BRN at the thermal sentry switch. battery no battery voltage voltage present Replace if the defective thermal sentry Replace if the defective vacuum fan switch. solenoid valve coil. Vacuum fan runs 4-28 ATLV 4300 330495 (10- -98)
  • Page 97 21/Brn and 22/YEL wires to any 13/BLK wire. battery voltage Head lift operates correctly Replace the head lift actuator. ATLV 4300 330495 (10- -98) 4-29...
  • Page 98 ELECTRICAL 4-30 ATLV 4300 330495 (10- -98)
  • Page 99 ... . 5--26 TROUBLESHOOTING ....5--27 EATON HYDRAULIC REPAIR MANUAL . . . 5--33 ATLV 4300 330495 (10- -98)
  • Page 100 HYDRAULICS ATLV 4300 330495 (10- -98)

  • Page 101: Introduction

    HYDRAULICS INTRODUCTION The hydraulic system consists of the propel pump, accessory pump, control valve, drive motors, steering cylinder, and vacuum fan motor. ATLV 4300 330495 (10- -98)

  • Page 102: Hydraulic Fluid Reservoir

    The hydraulic fluid filter is located in front of the hydraulic reservoir near the rear of the engine compartment. Replace the filter element every 800 hours of operation. ATLV 4300 330495 (10- -98)

  • Page 103: Hydraulic Fluid

    The quality and condition of the hydraulic fluid plays a very important role in how well the machine operates. TENNANT’s hydraulic fluid is specially selected to meet the needs of TENNANT machines. TENNANT’s hydraulic fluids provide a longer life for the hydraulic components. There are two...

  • Page 104: Hydraulic Fluid Cooler

    Tighten until snug then 1/4 turn. 8. Reinstall the rear engine cover. 9. Remove the drain pan. Tilt the hopper forward and close the hopper cover. 10. Start the machine and check the new hydraulic fluid filter for any leaks. ATLV 4300 330495 (10- -98)

  • Page 105: Hydraulic Pumps

    NOTE: Make sure to retain the O- -ring. 9. Locate the propel pump directional arm on the back side of the propel pump. Remove the two hex screws holding the pump arm to the pump hub. ATLV 4300 330495 (10- -98)
  • Page 106 31 -- 40 Nm (27 -- 35 ft. lb). 19. Reconnect the one small hydraulic hose to the accessory pump. See hose diagram in this section. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. ATLV 4300 330495 (10- -98)
  • Page 107 23. Reinstall the rear engine cover. 24. Tilt the hopper forward, close the hopper cover, and close the top engine cover. 25. Start the machine and operate the propel circuit. Check for proper operation. ATLV 4300 330495 (10- -98)

  • Page 108: To Replace Accessory Pump

    NOTE: Make sure to retain the O- -ring. 9. Remove the hydraulic fittings from the old accessory pump and install into the new pump in the same orientation. 5-10 ATLV 4300 330495 (10- -98)
  • Page 109 12. Reinstall the left hand side panel and left hand grill. 13. Tilt the hopper forward, close the hopper cover, and close the top engine cover. 14. Start the machine and operate the hydraulic circuit. Check for proper operation. 5-11 ATLV 4300 330495 (10- -98)

  • Page 110: Hydraulic Motors

    8. Go to the top of the hopper cover and remove the vacuum fan assembly from the machine. Set the assembly up side down on a flat surface. 5-12 ATLV 4300 330495 (10- -98)
  • Page 111 M8 hex screw and three M6 flat screws. 18. Tighten the M8 hex screw to 18 -- 24 Nm (15 -- 20 ft.. lb) and the M6 flat screws to 8 -- 10 Nm (6 -- 8 ft. lb). 5-13 ATLV 4300 330495 (10- -98)
  • Page 112 Tighten the screws to 18 -- 24 Nm (15 -- 20 ft. lb). 24. Tilt the hopper forward and close the cover. 25. Operate the machine and check the vacuum fan for proper operation. 5-14 ATLV 4300 330495 (10- -98)

  • Page 113: To Replace Steering Wheel Motor

    16. Remove the four M6 hex screws holding the steering column to the motor. Remove the motor from the machine. Note the orientation of the motor and fittings. 5-15 ATLV 4300 330495 (10- -98)
  • Page 114 (red cable to positive post, black cable to negative post). 31. Disengage the prop rod and lower the seat support. 32. Start the machine and check for proper operation. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-16 ATLV 4300 330495 (10- -98)

  • Page 115: To Replace Drive Wheel Motor

    NOTE: Note that the two longer bolts go in the upper mount holes. 12. Remove the hydraulic fittings from the old drive motor and install in the new motor in the same orientation. 5-17 ATLV 4300 330495 (10- -98)
  • Page 116 25. Tilt the hopper forward and lower the hopper cover. 26. Remove the jack stands and lower the machine. 27. Remove the blocks from the front tires and disengage the parking brake. Operate the machine and check for proper operation. 5-18 ATLV 4300 330495 (10- -98)

  • Page 117: Steering Cylinder

    7. Grab the front tires and move inward until the ball end clevis mount hole lines up with the end of the new steering cylinder. Make sure the steel spacers are in place at the end of the cylinder. 5-19 ATLV 4300 330495 (10- -98)
  • Page 118 10. Check the front wheel alignment. See TO ALIGN FRONT TIRES instructions in this section. 11. Remove the jack stands and lower the machine to the floor. 12. Operate the machine and check the new steering cylinder for proper operation. 5-20 ATLV 4300 330495 (10- -98)

  • Page 119: Steering Cylinder Breakdown

    HYDRAULICS STEERING CYLINDER BREAKDOWN 5-21 ATLV 4300 330495 (10- -98)

  • Page 120: Control Valve

    8. Position the new valve assembly on the mount bracket. Reinstall the hardware and tighten to 8 -- 10 Nm (6 -- 8 ft. lb). 5-22 ATLV 4300 330495 (10- -98)
  • Page 121 10. Reconnect the solenoid valve to the main electrical harness. 11. Reinstall the rear engine cover. 12. Tilt the hopper forward and lower the hopper cover. 13. Operate the machine and check the new steering cylinder for proper operation. 5-23 ATLV 4300 330495 (10- -98)
  • Page 122 HYDRAULICS 5-24 ATLV 4300 330495 (10- -98)

  • Page 123: Hydraulic Schematic

    HYDRAULICS HYDRAULIC SCHEMATIC 5-25 ATLV 4300 330495 (6- -01)

  • Page 124: Hydraulic Hose Group

    HYDRAULICS HYDRAULIC HOSE GROUP 5-26 ATLV 4300 330495 (6- -01)

  • Page 125: Troubleshooting

    HYDRAULICS TROUBLESHOOTING The troubleshooting charts that follow are organized to lead you through the circuits. ATLV 4300 330495 (10- -98) 5-27...
  • Page 126 REPAIR / REPLACE CARTRIDGE RV1 RELIEF PRESSURE OK? CARTRIDGE STEERING INLET REPAIR / REPLACE PRESSURE OK? STEERING CONTROL STEERING REPAIR / REPLACE COLUMN OK? STEERING COLUMN VACUUM FAN REPAIR / REPLACE WORKS OK? PUMP 5-28 ATLV 4300 330495 (10- -98)
  • Page 127 SV1 VALVE REPAIR / REPLACE CARTRIDGE SV1 VALVE CARTRIDGE SHIFTING OK? MOTOR INLET REPAIR / REPLACE FLOW MOTOR REPAIR / REPLACE PLUMBING OK? PLUMBING PC1 CHECK VALVE REPAIR / REPLACE SHIFTING PC1 CHECK VALVE CARTRIDGE ATLV 4300 330495 (10- -98) 5-29...
  • Page 128 HYDRAULICS VACUUM FAN WILL NOT TURN OFF REPAIR / REPLACE FAN TURNS PC1 PILOT CHECK SLOWLY CARTRIDGE REPAIR SV1 STEM ELECTRICAL MAGNETIZED? SYSTEM REPAIR / REPLACE SV1 STEM SV1 STEM CARTRIDGE CARTRIDGE SHIFTING OK? 5-30 ATLV 4300 330495 (10- -98)
  • Page 129 CIRCUIT FLOW ADJUST TOW DUMP VALVE CIRCUIT FLOW REPAIR / REPLACE PROPEL PUMP REPAIR / REPLACE RELIEF PRESSURE RELIEF CARTRIDGE MOTOR INLET REPAIR / REPLACE FLOW OK? PROPEL MOTOR REPAIR / REPLACE PLUMBING OK? PLUMBING ATLV 4300 330495 (10- -98) 5-31...
  • Page 130 HYDRAULICS 5-32 ATLV 4300 330495 (10- -98)
  • Page 131 Char-Lynn ® No. 7-124 July, 1999 Hydraulic Motor Repair Information 2000 Series Disc Valve Geroler Motor...
  • Page 132 2000 Series Disc Valve Motors Valve Plate Seal Geroler Splined Drive Shaft Seal Face Seal Wear Plate Bearing and Shaft Shaft Seal Assembly Back-up Bearing Washer Valve Housing Drive O-ring/ Seal Plug S/A Valve Exclusion Housing Dash Pot Bolt Seal Spring Outer Spring...
  • Page 133 2000 Series Disc Valve Motors Disassembly 2 Remove 4 bolts from motor. Cleanliness is extremely important when repairing a hydraulic motor. Work in a clean area. Before disconnecting the lines, clean the port area of the motor thoroughly. Use a wire brush to remove foreign material and debris from around the exterior joints of the motor.
  • Page 134 2000 Series Disc Valve Motors Disassembly 15 Remove the 76,0 [3.00] diameter seal from wear plate, Outer Face Seal see Figure 7. Bearing Seal Wear Housing Plate Pin (2) and Spring (2) Inner Face Seal Shaft Face Seal Valve Balance Ring Figure 5 Figure 8 7 Remove balance ring assembly.
  • Page 135 2000 Series Disc Valve Motors Reassembly Check all mating surfaces. Replace any parts that have scratches or 26 Alignment studs can be very helpful in reassembly of the motor. burrs that could cause leakage. Clean all metal parts in clean solvent. See special tool listing page 2.
  • Page 136 2000 Series Disc Valve Motors Reassembly 34 Align the notch on the outside of the valve plate with the notch on the Geroler as shown in Figure 12. Important: Install face seals in the positions shown in Figure 15, or the Timing Step # 2 —...
  • Page 137 2000 Series Disc Valve Motors Reassembly 40 Install tie bolts. If you use alignment Studs, install 2 bolts opposite the studs. Finger tighten the bolts. Remove the alignment studs and Tie Bolts replace with the two remaining bolts. Torque all four bolts alternately to 50 Nm [450 lb-in].
  • Page 138 2000 Series Disc Valve Motors Bearingless Motor Seal Flange This motor is the same as the standard motor without the shaft/ bearing assembly, and bearing housing. The mounting flange replaces the bearing housing, see Figure 20. Follow same disassembly and reassembly procedures as rear section of standard motor.
  • Page 139 2000 Series Disc Valve Motors Reassembly — Speed Sensor 1 Rotate the motor shaft until a (gear/target) tooth is centered in the speed sensor port. If this is not done, the sensor may be damaged during the operation of the motor. 2 Make sure the lock nut and its threads are clean and dry for the proper torque.
  • Page 140 2000 Series Disc Valve Motors Product Identification For Additional Literature Contact Eaton Corp. Hydraulics Date Code Char-Lynn ® 00 00 Division 15151 Highway 5 Eden Prairie, MN 55344. Product number Specifications and performance data, Catalog No. 11-878 Week of Last Replacement part numbers and kit information —...
  • Page 141 2000 Series Disc Valve Motors Notes:...
  • Page 142 2000 Series Disc Valve Motors Eaton Corporation Eaton Ltd. Eaton B.V. Sumitomo Eaton Hydraulic Co. Hydraulics Division Hydraulics Division Boeing Avenue 11 8 Temasek Blvd. 15151 Hwy. 5 Glenrothes, Fife 1119 PC Schiphol-Rijk 42-01 Suntec Tower Three Eden Prairie, MN 55344 Scotland, KY7 4NW The Netherlands Singapore 03988...
  • Page 143 07-06-630 Eaton ® EN-0401 Medium Duty Piston Pump Repair Information Model 70160 Variable Displacement Piston Pump 20,3 cm /r [1.24 in /r] or 23,6 cm /r [1.44 in /r] Displacements - 03 Manual Controlled...
  • Page 144 Model 70160 Introduction Table of Contents Introduction ......................2 Identification ......................3 Tools Required ....................3 Parts Drawing ...................... 4 - 5 Parts List ......................6 - 7 Repair information Disassembly ....................8 - 10 Reassembly ....................11 - 12 Fault - Logic Troubleshooting ................

  • Page 145: Identification

    Model 70160 Identification Numbers - Manually Variable Displacement Piston Pump Stamped on each unit's mounting flange. Single Pump - Product Number: A - Product Number Description 7 0 1 6 0 - R A A - 03 70160 = Single Piston Pump 78162 = Single Piston Pump with Gear Pump 78161 = Tandem Piston Pumps 78163 = Tandem Piston Pumps with Gear Pump...

  • Page 146: Parts Drawing

    Model 70160 Parts Drawing Pump drawn below is typical of a righthand rotation pump. Port (D1) 50-1 Press Fit into Cover plate Press Fit Press Fit 51-1 Shaft assembly for single pump or front pump Port of tandem. (D2) Press Fit Shaft assembly for rear pump of tandem.
  • Page 147 Model 70160 Parts Drawing 55-1 55-2 K2-4 55-4 55-3 49-1 55-5 K2-3 K1-1 (K2-2) 20-1 K2-3 K2-2 21-1 (K2-1) K4-3 (K3-3) K4-2 (K4-4) (K4-1) (K3-2) 34-1 (K3-1) 55-1 55-2 55-4 49-1 55-3 55-5 20-1 21-1...

  • Page 148: Parts List

    Model 70160 Parts List Item Qty. Description Drive Shaft Backplate Assembly Housing Assembly Rotating Kit Assembly Camplate Washer Retaining Ring Retaining Ring Thrust Bearing Bearing Race + 11 Shaft Seal, Drive Viton Shaft Seal, Drive Spacer + 12 Housing Gasket Camplate Insert Washer + 16...
  • Page 149 Model 70160 Parts List Item Qty. Description Righthand (CW) Rotation Lefthand (CCW) Rotation Plug Assembly 49-1 Plug Assembly + 50-1 O-ring, 1.98 mm Dia. x 11.89 mm ID. [.078 in. Dia. x .468 in. ID.] Plug Assembly + 51-1 O-ring, 1.98 mm Dia. x 11.89 mm ID. [.078 in. Dia. x .468 in. ID.] Bypass Valve sub-assembly + 55-1 Retaining Ring...

  • Page 150: Repair Information

    Model 70160 Repair Information - Disassembly The same charge pressure relief valve spring retainer is used Disassembly with either the standard or high The following disassembly procedure applies to a single pump pressure (see Figure 6). with or without gear pump The Figure 6 repair procedure for tandem Use a 7/8 in.
  • Page 151 Model 70160 Repair Information - Disassembly 21 Remove the valve plate from the piston block assembly. 13 When the needle bearing Numbered End Flange Note: This valve plate may have stuck to the backplate assembly is replaced, the assembly that was previously removed. numbered end of the bearing must face toward the flange side of the 22 Valveplate directional rotation (CW or CCW) is identified...
  • Page 152 Model 70160 Repair Information - Disassembly 28 With the retaining ring Figure 25 Figure 31 removed, use a small press to press the shaft seal and input shaft assembly from the housing assembly. Figure 32 29 With the input shaft assembly removed, disassemble the 34 Use an o-ring pick or similar tool to remove the o-ring assembly for inspection by...

  • Page 153: Reassembly

    Model 70160 Repair Information - Reassembly Reassembly Lubricate and install the o-ring seal into counter-bore of housing Before reassembling the pump, replace all worn and (see Figure 41). damaged parts, assemblies, seals and o-rings. Lubricate the seals and o-rings with petroleum jelly to help retain them 10 Install the trunnion cover over during reassembly and to provide lubrication to the input and the control shaft and into the pump...
  • Page 154 Model 70160 Repair Information - Reassembly 18 Lubricate and install the 25 Align the spline of the Figure 47 Figure 53 thrustplate over the input shaft gerotor’s inner ring, then lubricate assembly and into the camplate. and install the inner ring and outer The thrustplate must rest firmly in ring over the input shaft and onto its pocket located in the camplate.

  • Page 155: Fault - Logic Troubleshooting

    Model 70160 Fault - Logic Troubleshooting Explanatory This fault - logic troubleshooting guide is a Diagram diagnostic aid in locating transmission problems. Symptom: Match the transmission symptoms with the problem Action statements and follow the action steps shown in the Step box diagrams.
  • Page 156 Model 70160 Fault - Logic Troubleshooting Symptom: Neutral Difficult or Impossible to Find Inspect Inspect External Control Servo Control Linkage (If used) Defective Defective Repair Repair Replace Replace Symptom: System Operating Hot Inspect Heat Check Inspect Check Exchanger Oil Level in Heat Charge Bypass Valve...
  • Page 157 Model 70160 Fault - Logic Troubleshooting Symptom: Operates in One Direction Only Inspect Inspect Inspect External Control Servo Control System Relief Linkage (If used) Valves Defective Defective Defective Repair Repair Repair Replace Replace Replace Symptom: System Response Sluggish Check Inspect Inspect Pump Inspect Charge...
  • Page 158 Model 70160 Fault - Logic Troubleshooting Symptom: System Will Not Operate In Either Direction Inspect Pump Check Check External Check Bypass Valve Oil Level in Control Charge Reservoir Linkage (If used) Pressure Below Level Defective Defective Fill to Repair Repair Proper Level Replace...
  • Page 159 Model 70160 Fault - Logic Troubleshooting Diagram Action Step Comments Inspect External Control Linkage for: 11 Inspect Charge Relief Valve for: a. misadjustment or disconnection a. improper charge relief pressure setting * b. binding, bending or breakage b. damaged or broken spring c.

  • Page 160: Start-Up Procedure

    Model 70160 Start-up Procedure When starting a new or rebuilt transmission system, it is 6 After the system starts to show signs of fill, slowly move extremely important to follow the start-up procedure. It pump camplate to a slight cam angle. Continue to operate prevents the chance of damaging the unit which might occur if system slowly with no load on motors until system the system was not properly purged of air before start-up.
  • Page 161 Model 70160 Notes:...
  • Page 162 Model 70160 Information contained in this catalog is accurate as of the publication date and is subject to change without notice. Performance values are typical values. Customers are responsible for selecting products for their applications using normal engineering methods. ACCREDITED BY Eaton Hydraulics THE DUTCH COUNCIL FOR CERTIFICATION...
  • Page 163 Char-Lynn ® No. 7-310 January, 1995 Power Steering Repair Information 2 Series Steering Control Unit...
  • Page 164 Power Steering 2 Series Steering Control Units Thrust Bearing O-ring Quad Seal Housing Seal Bearing Race (2) Dust Seal Check Ball O-ring Plug Manual Steering Relief Valve O-ring Spacer Plug Drive Centerin O-ring Springs Wear Plate Sleeve Spool Screw Gerotor Spring Retaining Ring...
  • Page 165 Power Steering 2 Series Steering Control Units Screw Disassembly Cleanliness is extremely important when repairing hydraulic Seal Steering Control Units (SCU). Work in a clean area. Before Ring disconnecting the hydraulic lines, clean the port area of the Gerotor SCU. Before disassembly, drain the oil, then plug the ports and thoroughly clean the exterior of the SCU.
  • Page 166 Power Steering 2 Series Steering Control Units Centering Springs and Spacers Sleeve Spring Retaining Ring Spool Figure 3 7 Remove the pin that holds the spool and sleeve together 9 Remove the retaining ring and springs. (see Figure 3). Caution: The centering springs are under tension. Remove 8 Carefully slide the spool out of the sleeve.
  • Page 167 Power Steering 2 Series Steering Control Units 20 Lubricate and install a new o-ring seal in the groove in Thrust Bearing the housing. Dust Seal and Race (2) 21 Install the wear plate and align the holes in the wear plate with threaded holes in the housing.
  • Page 168 Power Steering 2 Series Steering Control Units Product Numbers 2 Series (Standard — 69 Bar [1000 PSI]) Relief Valve Displacement cm /r [in /r] and Product Number System Ports Setting 31 [1.9] 39 [2.4] 51 [3.1] 63 [3.8] 74 [4.5] 100 [6.1] Bar [PSI] None...
  • Page 169 Power Steering 2 Series Steering Control Units...
  • Page 170 Power Steering 2 Series Steering Control Units How to Order Replacement Parts Char-Lynn Date Code ® Each Order Must Include the Following: 00 00 Product number 000 0000 000 1. Product Number 4. Part Number Week of Last Number(s) of Year Year Eaton Corp.
  • Page 171 No. 7-624 Eaton ® October,1995 Gear Pumps Repair Information Series 26 Model 26000 Single Gear Pumps...
  • Page 172 Series 26 - Model 26000 Single Gear Pumps Introduction Table of Contents Introduction ..........................Identification ..........................Tools Required ........................... Exploded View Drawing ......................Parts List ............................ Disassembly ..........................5 & 6 Reversibility ..........................Inspection ........................... Reassembly ..........................9 & 10 Specific Backplate Parts List .......................

  • Page 173: Tools Required

    Series 26 - Model 26000 Single Gear Pumps Identification and Tools Required 26 0 01 - R Z A B 95 01 31 JB Serial Number Code: Product Number: Series Testers Initials 26 = Gear Pump ( SAE "A" Mount ) Day of Month (two digits) Month (two digits) Features...
  • Page 174 Series 26 - Model 26000 Single Gear Pumps Parts Cap Screws Drawing Washer Front Plate Optional Drive Gear Retaining Assembly Ring Shaft seal Drive Gear Washer Assembly Righthand (CW) Rotation Pump Plug Drive Gear Assembly Body O-ring Backup Gasket Seal Cap Screws Wear Plate Washer...

  • Page 175: Parts List

    Series 26 - Model 26000 Single Gear Pumps Disassembly Parts List Item Repair Information - Model 26000 Description Qty. Work in a clean area; cleanliness is extremely important when Front plate Assembly repairing hydraulic pumps. Before disconnecting the lines, Backplate clean port area of pump.

  • Page 176: Disassembly

    Series 26 - Model 26000 Single Gear Pumps Disassembly 8 Remove idler gear assembly from body. 11 Remove back-up gasket and seal from wear plate by extracting with a o-ring tool. 9 To separate body from the plate it remained with, place drive gear assembly in gear pocket and tap protruding end with plastic hammer or rawhide mallet.

  • Page 177: Reversibility

    Series 26 - Model 26000 Single Gear Pumps Reversibility Changing Input Rotation of Pump Place pump in a protected jaw vise with shaft end up. 7 Hold o-ring in groove of front plate with petroleum jelly. Remove the eight cap screws. Reassemble front plate over drive shaft end, being careful not to damage shaft seal.

  • Page 178: Inspection

    Series 26 - Model 26000 Single Gear Pumps Inspection Inspect Parts for Wear Front plate and Backplate Inspection General 1 Oil groove in bushings in front plate should be in line with dowel pin holes and 180° apart. The oil grooves in the 1 Clean and dry all parts.

  • Page 179: Reassembly

    Series 26 - Model 26000 Single Gear Pumps Reassembly General Information Install new seal and new backup gasket into wear plate. It is important that the relationship of the backplate, body, wear Note in the middle of the backup gasket a flat section or plate and front plate is correct.
  • Page 180 Series 26 - Model 26000 Single Gear Pumps Reassembly 7 Install new o-ring in groove of backplate. 8 Make sure port orientation is correct and then slide backplate over gear shafts until dowel pins are engaged. 9 Secure with cap screws and new washers . Tighten cap screws evenly in a crisscross pattern 34 to 38 N•m [25 to 28 lbf•ft] torque.

  • Page 181: Specific Backplate Parts List

    Series 26 - Model 26000 Single Gear Pumps Specific Backplate Parts List Relief Valve Backplate Item Description Qty. Relief Valve Backplate O-ring 19A4 Relief Valve Assembly 19A3 19A2 19A1 Relief Valve 19A1 19A2 O-ring 19A3 Backup Ring 19A4 O-ring Disasembly and Reassembly Plug Assembly 1 After removing relief valve , remove and replace o-rings 19B1...
  • Page 182 Series 26 - Model 26000 Single Gear Pumps Specific Backplate Parts List Tandem Backplate Tandem Flow Divider Backplate Disasembly and Reassembly 1 Remove relief valve plug, shim, spring, and poppet from Item backplate. Do not remove internal relief valve seat. Seat is Description Qty.
  • Page 183 Series 26 - Model 26000 Single Gear Pumps Placing Series 26 Gear Pump Back into Operation When test stand is available . Start Pump Mount Pump Connect Run For Test Stand Fluid Supply 3 Minutes Each Load Load Load Zero Intermittently Intermittently Intermittently...

  • Page 184: Trouble Shooting

    Series 26 - Model 26000 Single Gear Pumps Trouble Shooting Problem Possible Cause Correction Cavitation a. Oil too heavy. a. Change to proper viscosity b. Oil filter plugged. b. Clean filter. c. Suction line plugged or too small. c. Clean line and check size of line. Oil heating a.
  • Page 185 Series 26 - Model 26000 Single Gear Pumps Note Wear Plate Identification A product improvement has been made to the Model 26000 gear pump with a new designed wear plate. To identify the new wear plate, look for grooves placed in the seal side of the wear plate as shown below. New Groove Wear Plate Wear Plate...
  • Page 186 Order parts from 6-634 Parts Information booklet. Each order must include the following information. 1. Product and/or Part Number 2. Serial Number Code 3. Part Name 4. Quantity ACCREDITED BY THE DUTCH COUNCIL FOR CERTIFICATION Reg. No. 24 Eaton Corporation Eaton Ltd.
  • Page 187 ..6-11 TO INSTALL ENGINE ... 6-14 ENGINE SPEEDS ....6-16 ATLV 4300 330495 (12- -01)
  • Page 188 ENGINE- -DIESEL ATLV 4300 330495 (10- -98)

  • Page 189: Introduction

    ENGINE- -DIESEL INTRODUCTION This section includes repair information on the engine and related systems, such as fuel, electrical, and drive belts. Also, engine removal and installation. ATLV 4300 330495 (10- -98)

  • Page 190: Cooling System

    FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. Flush the radiator and the cooling system every 1600 hours of operation, using a dependable cleaning compound. ATLV 4300 330495 (10- -98)

  • Page 191: Engine Oil

    Proper belt tension is 10 mm (0.40 in) from a force of 4 to 5 kg (8 to 10 lb) applied at the mid-point of the longest span. Check and adjust the belt tension every 100 hours of operation. ATLV 4300 330495 (10- -98)

  • Page 192: Air Filter

    Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element. ATLV 4300 330495 (10- -98)

  • Page 193: Fuel Filter/Water Separator

    Properly discard the old filter. 7. Place a small amount of oil on the rubber O--ring on the new filter. 8. Screw the new filter onto the filter head. Tighten until snug then 1/4 turn. ATLV 4300 330495 (10- -98)
  • Page 194 Clean up any spilled diesel fuel. 10. Remove the drain pan. Reinstall the rear engine cover. 11. Tilt the hopper forward and close the hopper cover. 12. Start the machine and check the new filter for any leaks. ATLV 4300 330495 (10- -98)

  • Page 195: Fuel Lines

    Dirt in the lines can cause fuel injection pump malfunction. FUEL PUMP Check the fuel pump every 100 hours of operation. Check the clamps and fuel lines that connect to the fuel pump every 50 hours of operation. ATLV 4300 330495 (10- -98)

  • Page 196: Priming Fuel System

    5. Turn the key to the start position until fuel, free from air, appears at the banjo fitting on the injector pump. Tighten the connection. 6. Clean up any spilled fuel. Operate the machine and check for proper operation. 6-10 ATLV 4300 330495 (10- -98)

  • Page 197: To Remove Engine

    Remove the radiator hoses from the engine. Disconnect the hose leading to the overflow tank. 13. Remove the four M10 hex screws holding the bottom of the radiator/cooler/shroud assembly to the machine frame. ATLV 4300 330495 (10- -98) 6-11...
  • Page 198 23. Disconnect the engine throttle cable at the engine lever. Loosen the throttle cable clamp mount screw. Remove the throttle cable from the mount clamp. 24. Drain the engine oil. 6-12 ATLV 4300 330495 (10- -98)
  • Page 199 Be careful not to catch the engine on any hydraulic hoses or electrical wires on the way out of the engine compartment. ATLV 4300 330495 (10- -98) 6-13...

  • Page 200: To Install Engine

    Tighten the cable clamp. 8. Reconnect the electrical harness to the engine and related component (alternator, starter, oil sender, temp sender,glow plugs, ect.). See harness diagram or electrical schematic in the ELECTRICAL section of this manual. 6-14 ATLV 4300 330495 (10- -98)
  • Page 201 NOTE: Make sure to mark the hoses for proper re- -assembly! If the hoses are connected incorrectly- -- -engine damage may result! ATLV 4300 330495 (10- -98) 6-15...

  • Page 202: Engine Speeds

    Check all systems carefully for proper operation ENGINE SPEEDS The idle speed of the model ATLV 4300 is set at the factory at 1200±50 rpm. The top engine speed should not exceed 3050±50 rpm. To set the engine speed, use the position of the end of the throttle cable in the cable clamp on the engine bracket to set the upper engine speed.
  • Page 203 We Need Your Help... As part of Tennant’s Zero Defects Program, we want to know about errors you have found or suggestions you may have regarding our machine manuals. If you find an error or have a suggestion, please complete this postage-paid form and mail it to us.
  • Page 205 We Need Your Help... As part of Tennant’s Zero Defects Program, we want to know about errors you have found or suggestions you may have regarding our machine manuals. If you find an error or have a suggestion, please complete this postage-paid form and mail it to us.

Table of Contents