Tennant 810 Service Manual

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800/810
Gas/LP/Diesel
Service Manual

MM337
Rev. 04 (6--01)

This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT
Model 800/810.
The set is organized into eight major groups: General Information, Chassis, Sweeping, Electrical,
Hydraulics, Engine--G/LPG, Engine--D, Perkins 200 Series, and Engine--D, Perkins 700 Series.
General Information: Machine transport, machine jacking, machine storage, machine specifications, and
machine maintenance chart.
Chassis: Tire/wheel replacement, brake adjustment and replacement, chassis lubrication, steering
adjustment and replacement, and cover/door adjustment.
Sweeping: Hopper repair/replacement, brush repair/replacement. skirt/seal repair/replacement, and
sweeping troubling shooting
Electrical: Battery maintenance and replacement, instrument panel replacement, and electrical
troubleshooting.
Hydraulics: Valve replacement/repair, motor replacement/repair, cylinder replacement/repair, pump
replacement/repair, filter replacement, and hydraulics troubleshooting.
Engine -- G/LPG: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system
maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine
repairs.
Engine -- D, Perkins 200 Series: Air filter replacement, oil changing, cooling system maintenance/repair,
fuel system maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and
engine repairs.
Engine -- D, Perkins 700 Series: Air filter replacement, oil changing, cooling system maintenance/repair,
fuel system maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and
engine repairs.
Manual Number -- MM337
Revision: 04
Published: 6--01

CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Copyright E 1995, 1996, 1997, 2001 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
CONTENTS
Page
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . 1--3
PUSHING, TOWING, AND
TRANSPORTING THE MACHINE . . . . . . . 1--5
PUSHING OR TOWING THE
MACHINE . . . . . . . . . . . . . . . . . . . . . . 1--5
TRANSPORTING THE MACHINE . . . . 1--6
MACHINE JACKING . . . . . . . . . . . . . . . . . . . 1--8
STORING MACHINE . . . . . . . . . . . . . . . . . . 1--8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 1--9
GENERAL MACHINE
DIMENSIONS/CAPACITIES . . . . . . . . . 1--9
GENERAL MACHINE PERFORMANCE . . 1--9
POWER TYPE: GAS/LP . . . . . . . . . . . . . . 1--10
POWER TYPE: DIESEL . . . . . . . . . . . . . . . 1--11
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 1--12
800/810 ELECTRICAL . . . . . . . . . . . . . . . . 1--12
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . 1--12
HYDRAULIC PUMPS: CHAR--LYNN . . . . 1--12
HYDRAULIC MOTORS: GAS/LP . . . . . . . 1--13
HYDRAULIC MOTORS: DIESEL . . . . . . . 1--13
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . 1--13
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--13
MAINTENANCE -- GAS/LPG . . . . . . . . . . . . . 1--14
MAINTENANCE CHART . . . . . . . . . . . . . . 1--14
MAINTENANCE -- DIESEL . . . . . . . . . . . . . . . 1--16
MAINTENANCE CHART . . . . . . . . . . . . . . 1--16
HARDWARE INFORMATION . . . . . . . . . . 1--18
STANDARD BOLT TORQUE CHART 1--18
METRIC BOLT TORQUE CHART . . . 1--18
BOLT IDENTIFICATION . . . . . . . . . . . . 1--19
THREAD SEALANT AND
LOCKING COMPOUNDS . . . . . . . . 1--19

800/810 MM337 (6--01)

1-- 1

GENERAL INFORMATION

1-- 2

800/810 MM337 (8--97)

GENERAL INFORMATION
SAFETY PRECAUTIONS
The following precautions are used throughout this
manual as indicated in their description:
WARNING: To warn of hazards or unsafe
practices which could result in severe
personal injury or death.
FOR SAFETY: To identify actions which
must be followed for safe operation of
equipment.
The machine is suited to sweep disposable debris.
Do not use the machine other than described in
this Operator Manual. The machine is not
designed for use on public roads.
The following information signals potentially
dangerous conditions to the operator or
equipment:
FOR SAFETY:
1. Do not operate machine:
-- unless trained and authorized.
-- unless operator manual is read and
understood.
-- if it is not in proper operating
condition.
-- in flammable or explosive areas unless
designed for use in those areas.
-- in areas with possible falling objects
unless equipped with overhead guard.
2. Before starting machine:
-- check for fuel, oil, and liquid leaks.
-- keep sparks and open flame away from
refueling area.
-- make sure all safety devices are in
place and operate properly.
-- check brakes and steering for proper
operation.
3. When starting machine:
-- keep foot on brake and directional
pedal in neutral.
4. When using machine:
-- use brakes to stop machine.
-- go slow on inclines and slippery
surfaces.
-- use care when reversing machine.
-- move machine with care when hopper
is raised.
-- make sure adequate clearance is
available before raising hopper.
-- do not carry passengers on machine.
-- always follow safety and traffic rules.
-- report machine damage or faulty
operation immediately.
800/810 MM337 (6--01)

5. Before leaving or servicing machine:
-- stop on level surface.
-- set parking brake.
-- turn off machine and remove key.
6. When servicing machine:
-- avoid moving parts. do not wear loose
jackets, shirts, or sleeves.
-- block machine tires before jacking
machine up.
-- jack machine up at designated
locations only. Block machine up with
jack stands.
-- use hoist or jack that will support the
weight of the machine.
-- wear eye and ear protection when
using pressurized air or water.
-- disconnect battery connections before
working on machine.
-- avoid contact with battery acid.
-- avoid contact with hot engine coolant.
-- allow engine to cool.
-- keep flames and sparks away from fuel
system service area. Keep area well
ventilated.
-- use cardboard to locate leaking
hydraulic fluid under pressure.
-- use tennant supplied or approved
replacement parts.
7. When loading/unloading machine
onto/off truck or trailer:
-- Turn off machine.
-- Use truck or trailer that will support the
weight of the machine.
-- Use winch. Do not drive the machine
onto/off the truck or trailer unless the
load height is 380 mm (15 in) or less
from the ground.
-- Set parking brake after machine is
loaded.
-- Block machine tires.
-- Tie machine down t truck or trailer.
WARNING: Engine emits toxic gases.
Severe respiratory damage or
asphyxiation can result. Provide
adequate ventilation. Consult with your
regulatory authorities for exposure
limits. Keep engine properly tuned.
WARNING: Raised hopper may fall.
Engage hopper support bar.
WARNING: Lift arm pinch point. Stay
clear of hopper lift arms.
WARNING: Moving belt and fan. Keep
away.
1-- 3

GENERAL INFORMATION
The following safety labels are mounted on the
machine in the locations indicated. If these or any
label becomes damaged or illegible, install a new
label in its place.

EMISSIONS LABEL -- LOCATED ON THE
FRONT PANEL OF THE OPERATOR
COMPARTMENT.

FOR SAFETY LABEL -- LOCATED
ON THE FRONT PANEL OF THE
OPERATOR COMPARTMENT.

NOISE LABEL -- LOCATED ON THE FRONT
PANEL OF THE OPERATOR COMPARTMENT.

ENGINE FAN AND BELT LABEL -LOCATED ON THE RADIATOR SHROUD.

07623

HOPPER SUPPORT BAR LABEL -- LOCATED
ON THE HOPPER LIFT ARMS CROSS-TUBE
AND ON BOTH HOPPER LIFT ARMS.

1-- 4

HOPPER LIFT ARMS LABEL -- LOCATED
ON BOTH HOPPER LIFT ARMS.

800/810 MM337 (8--97)

GENERAL INFORMATION
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE
PUSHING OR TOWING THE MACHINE
If the machine becomes disabled, it can be
pushed from the front or rear, but towed only from
the rear.
The propelling pump has a bypass valve to
prevent damage to the hydraulic system when the
machine is being pushed or towed. This valve
allows a disabled machine to be moved for a very
short distance and at a speed to not exceed 1.6
kp/h (1 mph). The machine is NOT intended to be
pushed or towed a long distance or at a high
speed.
ATTENTION! Do not push or tow
machine for a long distance and without
using the bypass valve, or the machine
hydraulic system may be damaged.
08576

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.

800/810 MM337 (6--01)

1-- 5

GENERAL INFORMATION
TRANSPORTING THE MACHINE
1. Position the rear of the machine at the
loading edge of the truck or trailer.
FOR SAFETY: Use truck or trailer that
will support the weight of the machine.
NOTE: Empty the hopper before transporting the
machine.
2. If the loading surface is not horizontal or is
higher than 380 mm (15 in) from the ground,
use a winch to load machine.
If the loading surface is horizontal AND is
380 mm (15 in) or less from the ground, the
machine may be driven onto the truck or
trailer.

3. To winch the machine onto the truck or
trailer, attach the winching chains to the rear
tie down locations.

The rear tie-down locations are through the
U--bolt section of the main frame under the
side bumpers toward the rear.

1-- 6

800/810 MM337 (6--01)

GENERAL INFORMATION
4. Turn the bypass valve 90_ from the normal
position before winching the machine onto
the truck or trailer. See PUSHING OR
TOWING THE MACHINE section of this
manual. Make sure the machine is centered.
FOR SAFETY: When loading machine
onto truck or trailer, use winch. Do not
drive the machine onto the truck or
trailer unless the loading surface is
horizontal AND is 380 mm (15 in) or less
from the ground.
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.

08576

6. Set the parking brake and block the machine
tires. Tie down the machine to the truck or
trailer before transporting.
The two front tie--down locations are through
the U--bolt section of the main frame in front
of the wheels.

The two rear tie--down locations are through
the U--bolt section of the main frame under
the side bumpers toward the rear.

7. If the loading surface is not horizontal or is
higher than 380 mm (15 in) from the ground,
use a winch to unload machine.
If the loading surface is horizontal AND is
380 mm (15 in) or less from the ground, the
machine may be driven off the truck or
trailer.
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.
800/810 MM337 (6--01)

1-- 7

GENERAL INFORMATION
MACHINE JACKING
Empty the hopper before jacking the machine.You
can jack up the machine for service at the
designated locations. Use a jack or hoist that will
support the wieght of the machine. Always stop
the machine on a flat, level surface and block the
tires before jacking the machine up.
The front jacking locations are the flat bottom
edge of the machine frame next to the front tires.

08485

The rear jacking location is the middle of the rear
bumper.
FOR SAFETY: When Servicing Machine, Block
Machine Tires Before Jacking Machine Up.
FOR SAFETY: When Servicing Machine, Jack
Machine Up At Designated Locations Only.
Block Machine Up With Jack Stands.

08586

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.

1-- 8

800/810 MM337 (6--01)

GENERAL INFORMATION
SPECIFICATIONS
GENERAL MACHINE DIMENSIONS/CAPACITIES
Item

Dimension/capacity

Length

3050 mm (120 in)

Width

1780 mm (70 in)

Height

1335 mm (52.5 in)

Height with overhead guard

2095 mm (82.5 in)

Height with overhead guard and hazard light

2310 mm (91 in)

Height with cab

2095 mm (82.5 in)

Height with cab and hazard light

2310 mm (91 in)

Track

1560 mm (61.5 in)

Wheelbase

1420 mm (56 in)

Main brush diameter

405 mm (16 in)

Main brush length

1270 mm (50 in)

Power Throwt brush diameter

205 mm (8 in)

Power Throwt brush length

1170 mm (46 in)

Side brush diameter

65 mm (26 in)

Sweeping path width

1270 mm (50 in)

Sweeping path width with side brush

1675 mm (66 in)

Main brush pattern width

50 to 65 mm (2.0 to 2.5 in)

Hopper weight capacity

907.2 kg (2000 lb)

Hopper volume capacity

849.5 L (30 cu ft)

Dust filter area

17.7 m2 (190 sq ft)

GVWR

4068 kg (8970 lb)

Ceiling height minimum dumping clearance

3355 mm (11 ft)

GENERAL MACHINE PERFORMANCE
Item

Measure

Maximum forward speed

16 kmh15.9 kmh (10 mph)

Maximum reverse speed

7.3 kmh (4.5 mph)

Minimum aisle turn width, left

3450 mm (135 in)

Minimum aisle turn width, right

4675 mm (184 in)

Maximum rated climb and descent angle

8.5_

800/810 MM337 (2--94)

1-- 9

GENERAL INFORMATION
POWER TYPE: GAS/LP
Engine

Displacement

Net power, governed

Net power, maximum

Ford LSG 2.3 or 2300 cc (140 cu in)
Ford LRG 2.3

37.3 kw (50 hp) @ 2400 rpm

47 kw (63 hp) @
2800 rpm

Ford LRG 2.5

2500 cc (152 cu in)

40.3 kw (54 hp) @ 2400 rpm

59 kw (79 hp) @
3000 rpm

Ford LSG 2.3
Ford LRG 2.3
and
d
Ford LRG 2.5

Type

Cycle Aspiration Cyl

Bore

LRG 2.3
Stroke

Piston Breakerlesstype spark (LSG)
Distributerlesstype spark

4

96 mm 80 mm
(3.78 in) (3.126 in)

Fuel

Cooling system

Electrical system

Gasoline, 87 octane
minimum, unleaded.
Fuel tank: 45.5 L (12 gal)

Water/ethylene glycol
antifreeze

12 V nominal

LPG,
F l ttank:
Fuel
k 15 kkg (33 lb)

Total: 16.7 L (4.4 gal)

50 A alternator

(Start) governed speed

(Low) governed speed

(High) governed speed

1350 + 50 rpm (LSG)
1475 + 50 rpm (LRG)

1100 + 50 rpm (LSG)
2000 + 50 rpm (LRG)

2400 + 50 rpm (LSG)
2400 + 50 rpm (LRG)

Ignition

Natural

4

LRG 2.5
Stroke
96 mm
(3.78 in)

Radiator: 6.2 L (1.6 gal)

Spark plug gap

Firing order

1 to 1.1 mm (0.042 to 0.046 in)

1--3--4--2

Engine lubricating oil with filter (10W30 SAE--SG/SH)
4.7 L (5 qt) (LSG)
Ford LRG 2.5 -- 4.26 L (4.5 qt)

1-- 10

Ford LRG 2.3 -- 4.7 L (5 qt)

800/810 MM337 (6--01)

GENERAL INFORMATION
POWER TYPE: DIESEL
Engine

Type

Ignition

Cycle

Aspiration

Cylinders Bore

Stroke

Perkins 200
Series

Piston

Diesel

4

Natural

4

102 mm
(4 in)

89 mm
(3.5 in)

Displacement

Net power, governed

Net power, maximum

2522 cc (154 cu in)

33.6 kw (45 hp) @ 2400 rpm

44.8 kw (60 hp) @
3000 rpm

Fuel

Cooling system

Electrical system

Diesel
Fuel tank: 45.5 L (12 gal)

Water/ethylene glycol
antifreeze

12 V nominal

Total: 13.6 L (3.6 gal)

50 A alternator

Radiator: 6.1 L (1.6 gal)
Idle speed, no load

Governed speed, under load

600 to 650 rpm

2400 + 50 rpm

Engine lubricating oil with filter
6 L (6.3 qt) 10W30 SAE--CC/CD rated engine oil

Engine

Type

Ignition

Cycle

Aspiration

Cylinders Bore

Stroke

Perkins 704--30
Series

Piston

Diesel

4

Natural

4

100 mm
(3.9 in)

97 mm
(3.8 in)

Displacement

Net power, governed

Net power, maximum

3.0 L. (183 cu in)

44.8 kw (63 hp) @ 2400 rpm

47 kw (63 hp) @
2400 rpm

Fuel

Cooling system

Electrical system

Diesel
Fuel tank: 45.5 L (12 gal)

Water/ethylene glycol
antifreeze

12 V nominal

Total: 13.6 L (3.6 gal)

50 A alternator (std)
100 A alternator (HD)

Radiator: 6.1 L (1.6 gal)
Idle speed, no load

Intermediate speed, under load

Governed speed,
under load

1400 rpm

2000 rpm

2400 + 50 rpm

Engine lubricating oil with filter
10.4 L (11 qt) with remote filter, 10W30 diesel rating above
Fuel Consumption: Gas-- 1.2 gph
LPG-- 6.6 lb ph
Diesel--1.4 gph
Oil Pressure: Gas/LP--10 psi at idle, 35 -- 40 psi at
operating rpm
Diesel-- 7 psi at idle, 29 psi at operating rpm
Vacuum system; CFM -- 585 (16565 L / min)

800/810 MM337 (6--01)

1-- 11

GENERAL INFORMATION
STEERING
Type
Rear wheel, hydraulic cylinder and rotary
valve controlled

Power source
Hydraulic accessory pump

Emergency steering
Manual

ELECTRICAL SYSTEM
800/810 Electrical
Battery: Diesel-- Group 31, 12V, Cc Amps: 730
Gas/LP--Group 24 12V, Cc Amps: 475
Motors: Shaker motors,12V,
Normal amp draw--4.5
Starter motor: Diesel, Amp draw cold-380 @ 10Volts,
Amp draw hot--355 @ 11.5
Starter motor: Gas/LP, Amp draw cold-185 @ 10Volts
Amp draw hot--155 @ 11.5
Standard alternator: Diesel/Gas/LP,
Output -- 50 amps @ 5000 rpm
Volts -- 14.5
HYDRAULIC SYSTEM
System

Capacity

Fluid Type

Hydraulic reservoir

47.3 L (12.5 gal)

Hydraulic total

56.8 L (15 gal)

TENNANT part no. 65869 -- above 7_ C (45_ F)
TENNANT part no. 65870 -- below 7_ C (45_ F)

HYDRAULIC PUMPS: CHAR--LYNN
Propelling

23.2 GPM (88 L / min)

4500 PSI Relief (31027 kPa)--Normal throttle

Accessory (brush)

6.2 GPM (23 L / min)

2200 PSI Relief (15170 kPa)--Normal throttle

Accessory (steering)

4.7 GPM (18 L / min)

1300 PSI Relief (8963 kPa)--Normal throttle

Accessory (vacuum)

6.2 GPM (23 L / min)

2000 PSI Relief (13790 kPa)--Normal throttle

1-- 12

800/810 MM337 (6--01)

GENERAL INFORMATION
HYDRAULIC MOTORS: GAS/LP
Main brush (2 speed), Char--lynn

400 / 500 RPM

Side brush, Char--lynn

100 RPM

Vacuum fan, Barnes

8500 RPM

Propelling, Char--lynn

150 RPM

HYDRAULIC MOTORS: DIESEL
Main brush, Char--lynn

385 RPM

Side brush, Char--lynn

78 RPM

Vacuum fan, Barnes

8500 RPM

Propelling, Char--lynn

150 RPM

BRAKING SYSTEM
Type

Operation

Service brakes

Hydraulic drum brakes (2), one per front wheel, foot brake master cylinder activated

Parking brake

Utilize service brakes, cable actuated

TIRES
Location

Type

Size

Pressure

Front (2)

Pneumatic

6.5 x 23.5 in

690 -- 758 kPa (100 -- 110 psi)

Rear (1)

Pneumatic

6.5 x 23.5 in

690 -- 758 kPa (100 -- 110 psi)

800/810 MM337 (2--94)

1-- 13

GENERAL INFORMATION
MAINTENANCE - GAS/LPG
6
11
16

7

5

10

8

4
2

9

3
12
13

1
15
14

07623

MAINTENANCE CHART

Interval
Dailyy

Key
Description
10 Engine
g
air filter
12
13

Engine crankcase
Brush compartment skirts

15

Hopper lip skirts

13

Main brush

1

50 Hours

1-- 14

2
13
2
16

Side brush

Hopper dust filter
Main brush
Hopper dust filter
Main brush adjustment

Procedure
Check indicator
Empty dust cap
Check oil level
Check for damage, wear, and
adjustment
Check for damage, wear, and
adjustment
Check for damage, wear, and
adjustment
Check brush pattern
Check for damage, wear, and
adjustment
Check brush pattern
Shake
Rotate end-for-end
Check or clean
Lubricate

No. of
Lubricant/ Service
Points
Fluid
-1
-1
EO
1
-6
--

3

--

1

---

1
1

----SPL

1
2
1
2
1

800/810 MM337 (6--01)

GENERAL INFORMATION
Interval Key
Description
6
Hydraulic fluid reservoir
100 Hours
7
Hydraulic fluid cooler
8
Radiator

200 Hours

400 Hours

800 Hours

-13
12
12
12
-12
8
11
5
3
12

8
4
6

9
12

9
11
-16
1600
Hours

14
12

Procedure
Check fluid level
Clean cooler fins
Clean core exterior
Check coolant level
Clean screen
Tires
Check pressure
Main brush & hopper seals Check for damage or wear
Engine crankcase
H Change oil and filter element
Engine fan belt
H Check tension
Air cond. belt (option)
Check tension
Air cond. filter (option)
Clean or replace if necessary
Engine
Steam clean exterior
Radiator hoses and clamps Check for tightness and wear
Rear wheel support
Lubricate
bearings
Parking brake
Check adjustment
Side brush pivot pins
Lubricate
Clean or replace and adjust spark
Engine
plugs
Replace PCV valve
Replace fuel filters, gasoline
Cooling system
Flush
Brake master cylinder
Check fluid level
Replace filler cap
Hydraulic
y
reservoir
Replace suction strainer
Change hydraulic fluid
Hydraulic fluid filter
H Change filter element
Clean PCV hoses, tubes, & fitEngine
tings
Torque intake manifold bolts
Check timing belt
Hydraulic hoses
Check for wear and damage
Propelling motor
H Torque shaft nut
Rear wheel
H Torque wheel nuts
Battery
H Clean and tighten battery cable
connections
Front wheel bearings
Check, lubricate, and adjust
Engine
Replace timing belt

No. of
Lubricant/ Service
Points
Fluid
HYDO
1
1
1
WG
1
-1
-3
-12
EO
1
-1
-1
-1
-1
-2
SPL
2
-SPL
---WG
BF
GL
GL
HYDO
---

1
1
1

1
1
1
1
1
1

-------

8
1
45
1
1
1

SPL
--

2
1

LUBRICANT/FLUID
BF . . . . Brake fluid
EO . . . . Engine oil, SAE--SG/SH rated
HYDO . Tennant Company or approved hydraulic fluid
SPL . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)
WG . . . Water and permanent-type ethylene glycol anti-freeze, --34_ C (--30_ F)
NOTE: Also check procedures indicted (H) after the first 50-hours of operation.
800/810 MM337 (6--01)

1-- 15

GENERAL INFORMATION
MAINTENANCE -- DIESEL
6
11
16

7

5

10

8

4
2

9

3
12
13

1
15
14

07623

MAINTENANCE CHART

Interval
Dailyy

Key
Description
10 Engine
g
air filter
12
13

Engine crankcase
Brush compartment skirts

15

Hopper lip skirts

13

Main brush

1

50 Hours

1-- 16

2
13
2
12
16

Side brush

Hopper dust filter
Main brush
Hopper dust filter
Fuel lines
Main brush adjustment

Procedure
Check indicator
Empty dust cap
Check oil level
Check for damage, wear, and
adjustment
Check for damage, wear, and
adjustment
Check for damage, wear, and
adjustment
Check brush pattern
Check for damage, wear, and
adjustment
Check brush pattern
Shake
Rotate end-for-end
Check or clean
Check for wear and leaks
Lubricate

No. of
Lubricant/ Service
Points
Fluid
-1
-1
EO
1
-6
--

3

--

1

---

1
1

-----SPL

1
2
1
2
1
1

800/810 MM337 (6--01)

GENERAL INFORMATION
Interval Key
Description
6
Hydraulic fluid reservoir
100 Hours
7
Hydraulic fluid cooler
8
Radiator

200 Hours

400 Hours

800 Hours

-13
12
12
12
-12
8
11
5
3
12
12
8
4
6

9
9
11
-16
1600
Hours

14

Procedure
Check fluid level
Clean cooler fins
Clean core exterior
Check coolant level
Clean screen
Tires
Check pressure
Main brush & hopper seals Check for damage or wear
Engine crankcase
H Change oil and filter element
Engine fan belt
H Check tension
Air cond. belt (option)
Check tension
Air cond. filter (option)
Clean or replace if necessary
Engine
Steam clean exterior
Radiator hoses and clamps Check for tightness and wear
Rear wheel support
Lubricate
bearings
Parking brake
Check adjustment
Side brush pivot pins
Lubricate
Fuel filter, Engine
Replace
Water separator / fuel filter Replace
Cooling system
Flush
Brake master cylinder
Check fluid level
Replace filler cap
Hydraulic
y
reservoir
Replace suction strainer
Change hydraulic fluid
Hydraulic fluid filter
H Change filter element
Hydraulic hoses
Check for wear and damage
Propelling motor
H Torque shaft nut
Rear wheel
H Torque wheel nuts
Battery
H Clean and tighten battery cable
connections
Front wheel bearings
Check, lubricate, and adjust

No. of
Lubricant/ Service
Points
Fluid
HYDO
1
1
1
WG
1
-1
-3
-12
EO
1
-1
-1
-1
-1
-2
SPL
2
-SPL
--WG
BF
GL
GL
HYDO
------

1
1
1
1
1
1
1
1
1
49
1
1
1

SPL

2

LUBRICANT/FLUID
BF . . . . Brake fluid
EO . . . . Engine oil, 10W30 diesel rating above CD grade only
HYDO . Tennant Company or approved hydraulic fluid
SPL . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)
WG . . . Water and permanent-type ethylene glycol anti-freeze, --34_ C (--30_ F)
NOTE: Also check procedures indicted (H) after the first 50-hours of operation.

800/810 MM337 (6--01)

1-- 17

GENERAL INFORMATION
HARDWARE INFORMATION
The following charts state standard plated
hardware tightening ranges for normal assembly
applications. Decrease the specified torque by
20% when using a thread lubricant. Do not
substitute lower grade hardware for higher grade
hardware. If higher grade hardware than specified
is substituted, tighten only to the specified
hardware torque value to avoid damaging the
threads of the part being threaded into, as when
threading into speed nuts or weldments.
STANDARD BOLT TORQUE CHART
Thread
Size

SAE Grade 5
Torque ft lb (Nm)

SAE Grade 8
Torque ft lb (Nm)

0.25 in
0.31 in
0.38 in
0.44 in
0.50 in
0.62 in
0.75 in
1.00 in

7--10 (9--14)
15--20 (20--27)
27--35 (37--47)
43--56 (58--76)
65--85 (88--115)
130--170 (176--231)
215--280 (291--380)
500--650 (678--881)

10--13 (14--38)
20--26 (27--35)
36--47 (49--64)
53--76 (72--103)
89--116 (121--157)
117--265 (159--359)
313--407 (424--552)
757--984 (1026--1334)

NOTE: Decrease torque by 20% when using a
thread lubricant.
METRIC BOLT TORQUE CHART
Thread
Size
M4
M5
M6
M8
M10
M12
M14
M16
M20
M24

Class 8.8
Torque ft lb (Nm)

Class 10.9
Torque ft lb (Nm)

2 (3)
4 (5)
7 (9)
18 (24)
32 (43)
58 (79)
94 (127)
144 (195)
260 (352)
470 (637)

3 (4)
6 (8)
10 (14)
25 (34)
47 (64)
83 (112)
133 (180)
196 (265)
336 (455)
664 (900)

NOTE: Decrease torque by 20% when using a
thread lubricant.

1-- 18

800/810 MM337 (2--94)

GENERAL INFORMATION
BOLT IDENTIFICATION
Identification
Grade Marking

Specification
and Grade
SAE--Grade 5
SAE--Grade 8
ISO--Grade 8.8
ISO--Grade 10.9

THREAD SEALANT AND LOCKING
COMPOUNDS
Thread sealants and locking compounds may be
used on this machine. They include the following:
Locktite 515 sealant -- gasket forming
material. TENNANT Part No. 75567,15 oz
(440 ml) cartridge.
Locktite 242 blue -- medium strength thread
locking compound. TENNANT Part No.
32676, 0.5 ml tube.
Locktite 271 red -- high strength thread
locking compound. TENNANT Part No.
19857, 0.5 ml tube.

800/810 MM337 (8--97)

1-- 19

GENERAL INFORMATION

1-- 20

800/810 MM337 (6--01)

CHASSIS
CONTENTS
Page
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
TO REMOVE SEAT ASSEMBLY . . . . . 2--3
TO REPLACE SEAT ASSEMBLY . . . . . 2--3
TO ADJUST SEAT POSITION . . . . . . . 2--4
TO ADJUST SEAT RIDE STIFFNESS 2--4
STATIC DRAG CHAIN . . . . . . . . . . . . . . . . . 2--4
BRAKES AND TIRES . . . . . . . . . . . . . . . . . . 2--5
SERVICE BRAKES . . . . . . . . . . . . . . . . . 2--5
TO REPLACE BRAKE SHOES . . . . . . . 2--5
TO ADJUST BRAKES . . . . . . . . . . . . . . 2--7
FRONT TIRES AND WHEELS . . . . . . . 2--8
TO REPACK FRONT WHEEL
BEARINGS . . . . . . . . . . . . . . . . . . . . . 2--8
PARKING BRAKE
(FOOT ACTIVATED) . . . . . . . . . . . . . 2--9
TO ADJUST FOOT ACTIVATED
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 2--9
PARKING BRAKE
(HAND ACTIVATED) . . . . . . . . . . . . . 2--9
TO ADJUST HAND ACTIVATED
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 2--9
REAR TIRE AND WHEEL, AND WHEEL
SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . 2--10
TO REPLACE REAR WHEEL
HOUSING PIVOT BEARINGS . . . 2--11

800/810 MM337 (8--97)

2-- 1

CHASSIS

2-- 2

800/810 MM337 (8--97)

CHASSIS
CHASSIS
This section includes information on the main
chassis related components for example the seat,
steering, brakes and tires.

SEAT
The seat assembly is removable on both the 800
and the 810. The seat can also be adjusted on
both models. Tools are needed to remove the
seat.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
TO REMOVE SEAT ASSEMBLY
1. Tilt the seat assembly forward and hold it in
this position.
2. Remove the M6 hex screw and nyloc nut
holding the prop rod to the seat bottom.
3. Set the seat back down.
4. Remove the two M8 hex bolts, washers,
and sleeves from the front of the seat.
5. Lift the seat assembly out of the machine.
TO REPLACE SEAT ASSEMBLY
1. Position the seat assembly back on the
machine.
2. Install the two sleeves, washers, and M8
hex bolts. Hand tighten.
3. Tilt the seat assembly forward and hold it in
this position.
4. Reinstall the seat prop rod to the bottom of
the seat using the M6 hex screw, nyloc nut,
and washers. Hand tighten until snug.
5. Lower the seat.

800/810 MM337 (8--97)

2-- 3

CHASSIS
TO ADJUST SEAT POSITION
1. Pull adjustment lever forward, located lower
left side of seat
2. Move seat to desired position.
3. Release adjustment lever.

08443

TO ADJUST SEAT RIDE STIFFNESS
1. Turn knob (located in front of seat) clockwise
to increase ride stiffness, counter-clockwise
to decrease ride stiffness.

STATIC DRAG CHAIN
A static drag chain prevents the buildup of static
electricity in the machine. The chain is attached to
the machine by a rear main brush skirt retaining
bolt.
Make sure the chain is touching the floor at all
times.

08449

2-- 4

800/810 MM337 (8--97)

CHASSIS
BRAKES AND TIRES
SERVICE BRAKES
The hydraulic service brakes are located on the
front wheels. The brakes are operated by the foot
brake pedal.
Check the brake adjustment every 200 hours of
operation.
TO REPLACE BRAKE SHOES
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Jack up one front corner of the machine.
Place a jack stand under machine.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Remove the six wheel nuts and the tire/
wheel assembly.

08579

3. Remove the small hub cap from the center
of the brake drum.
4. Remove the cotter pin, slotted nut, flat
washer, and bearing cone.
5. Slide the brake drum off the axle.
6. Remove the springs holding the brake shoes
together.
7. Remove the retainer clips holding the brake
shoes to the backing plate. Remove and
discard the old shoes.

08579

8. Position the new brake shoes onto the
backing plate.
9. Reinstall the retainer clips.

800/810 MM337 (8--97)

2-- 5

CHASSIS
10. Reconnect brake springs to brake shoes.
11. Pack the wheel bearings with Lubriplate
EMB grease.
12. Slide the brake drum back on the axle.
13. Slide the outer bearing, flat washer and nut
onto the shaft.
14. Tighten nut with hand wrench until wheel
binds, then back nut off to nearest hole.
15. Insert a new cotter pin through nut and hole.
16. After making sure the wheel spins
freely,carefully install the small center cap.
17. Reinstall tire and wheel assembly. Tighten
the six wheel nuts to 95 -- 115 Nm
(70 -- 85 ft lb).
18. Remove the jack stands and lower the
machine.
NOTE: Always replace brake shoes in sets.
19. Repeat the procedure on the other wheel.

2-- 6

800/810 MM337 (8--97)

CHASSIS
TO ADJUST BRAKES
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Jack up one front corner of the machine.
Place a jack stand under machine.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Remove the six wheel nuts and the tire/
wheel assembly.

08579

3. Remove the small hub cap from the center
of the brake drum.
4. Remove the cotter pin, slotted nut, flat
washer, and bearing cone.
5. Slide the brake drum off the axle.
6. Turn adjustment wheel located at bottom of
brake shoes until drum fits snugly over
brake shoes.
7. Slide the brake drum back on the axle.
8. Slide the outer bearing, flat washer and nut
onto the shaft.
9. Tighten nut with hand wrench until wheel
binds, then back nut off to nearest hole.
10. Insert a new cotter pin through nut and hole.
11. After making sure the wheel spins freely,
carefully install the small center cap.
12. Reinstall tire and wheel assembly. Tighten
the six wheel nuts to 95 -- 115 Nm
(70 -- 85 ft lb).
13. Remove the jack stands and lower the
machine.
14. Operate the machine and check the brake
pedal for proper adjustment.

800/810 MM337 (8--97)

2-- 7

CHASSIS
FRONT TIRES AND WHEELS
The standard machine tires are pneumatic.
inspect the front wheel bearings for seal damage,
and repack and adjust every 1600 hours of
operation. Use Lubriplate EMB grease
(TENNANT part no. 01433--1).
TO REPACK FRONT WHEEL BEARINGS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Jack up one front corner of the machine.
Place a jack stand under machine.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Remove the six wheel nuts and the tire/
wheel assembly.

08579

3. Remove the small hub cap from the center
of the brake drum.
4. Remove the cotter pin, slotted nut, flat
washer, and bearing cone.
5. Slide the brake drum off the axle.
6. Pack the wheel bearings with Lubriplate
EMB grease.
7. Slide the brake drum back on the axle.
8. Slide the outer bearing, flat washer and nut
onto the shaft.
9. Tighten nut with hand wrench until wheel
binds, then back nut off to nearest hole.
10. Insert a new cotter pin through nut and hole.
11. After making sure the wheel spins freely,
carefully install the small center cap.
12. Reinstall tire and wheel assembly. Tighten
the six wheel nuts to 95 -- 115 Nm
(70 -- 85 ft lb).
13. Remove the jack stands and lower the
machine.

2-- 8

800/810 MM337 (8--97)

CHASSIS
PARKING BRAKE (FOOT ACTIVATED)
The parking brake is set with foot pedal on
machines with serial numbers (0 -- 1102) on
model 800 and (0 -- 2045) on model 810.
Adjust the parking brake whenever it becomes
very easy to set, when the machine rolls after
setting the parking brake, and after every 200
hours of operation.
Adjust the parking brake so it will hold the
Machine on a smooth 8 degree incline.
TO ADJUST FOOT ACTIVATED BRAKE

08574

1. Loosen 2 jam nuts on threaded rod
connected to brake pedal.
2. Turn rod either clockwise or
counter-clockwise to increase or decrease
the tension on cables.
3. Once rod is at the correct length where the
brakes hold the machine, tighten the jam
nuts on the rod.
PARKING BRAKE (HAND ACTIVATED)
The parking brake is set with a hand lever on
machines with serial numbers (1103 and up) on
model 800 and (2046 and up) on model 810.
Adjust the parking brake whenever it becomes
very easy to set, when the machine rolls after
setting the parking brake, and after every 200
hours of operation
Adjust the parking brake so it will hold the
Machine on a smooth 8 degree incline.
TO ADJUST HAND ACTIVATED BRAKE
1. At the end of the handle, there is a knob that
can be turned clockwise or
counter-clockwise.
2. Release the parking brake and turn knob to
increase or decrease the tension on the
brake cables. Set the parking brake to test
readjust as necessary.
3. Adjust this knob until the brakes sufficiently
hold the machine in place.

800/810 MM337 (8--97)

2-- 9

CHASSIS
REAR TIRE AND WHEEL, AND WHEEL
SUPPORT
The rear wheel support pivots the rear wheel. The
support has one grease fitting for the bearings.
The rear wheel support bearings must be
lubricated every 200 hours of operation. Use
Lubriplate EMB grease (TENNANT part no.
01433--1).
Check the rear tire pressure every 100 hours of
operation. The proper tire air pressure is
690 --758 kPa (100 -- 110 psi).
Torque the rear wheel nuts to 122 -- 142 Nm
(90 -- 105 ft lb) after the first 50-hours of
operation, and every 800 hours thereafter.

08451

Torque the rear wheel hub nut to 270 -- 340 Nm
(200 -- 250 ft lb).

2-- 10

800/810 MM337 (8--97)

CHASSIS
TO REPLACE REAR WHEEL HOUSING PIVOT
BEARINGS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Engage the parking brake, block the front
tires.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Jack up the rear of machine. Use jack
stands to support the machine.
3. Remove the rear tire and wheel assembly.
4. Turn steering wheel clockwise as far as it
will go so the steering cylinder is completely
retracted.
5. Disconnect the battery cables from machine.
WARNING: Always disconnect battery
cables from machine before working on
or near electrical components.
6. Remove the seat assembly from the
machine. See TO REMOVE SEAT
ASSEMBLY instructions in this section.
7. Remove the access cover panel from the
operator’s compartment to gain access to
steering bracket.
8. Remove the hose clamp, channel, sleeve
and hardware from the steering bracket.
9. Remove the hex screw and nyloc nut
holding the ball joint to the rear casting.
10. Remove and plug the hydraulic hoses from
the drive motor. Mark the hoses for proper
assembly orientation.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.

800/810 MM337 (8--97)

2-- 11

CHASSIS
11. Place a floor jack under the rear wheel
support. Raise the wheel support until the
weight is removed from the support
bearings. Do not lift the machine off the jack
stands.
12. Remove the lock ring retainer by first
loosening the retainer’s 12 cap screws.
Thread three of the cap screws in the three
open threaded holes. This will drive the ring
retainer off the shaft. After the ring is off the
shaft, return the three cap screws to their
original threaded holes.

Torque
Sequence
Lock
Ring
Retainer

Threaded
Hole

Cap
Screw

13. Remove the bottom pivot plate bolts and the
pivot plate. Count the number of threads
exposed below slotted nut on pivot shaft.
14. Remove the slotted nut and tabbed lock
washer. Save the slotted nut and the tabbed
lock washer.
15. Remove the washer and bearing cone.
Discard the washer.
16. Lower the drive housing and remove it from
under the machine.
17. The upper bearing cone is pressed on. A
bearing puller must be used to remove it.
Removal of the upper bearing mount plate
will make this easier.
18. Pre-grease the new bearing cone and press
on shaft. Reinstall upper bearing mount
plate if removed. Tighten the five M20 hex
screws to 300 -- 390 Nm (220 -- 290 ft lb).
19. Place the rear drive housing back under the
machine. Raise the housing back in position
with the floor jack.

2-- 12

800/810 MM337 (8--97)

CHASSIS
20. Pre-grease the second bearing cone and
install with a new hardened washer, tab lock
washer, and slotted nut. Lubricate the face
of the tab lock washer so the locking nut can
turn freely.
21. Tighten the slotted nut by rocking the casting
back and forth. Torque slotted nut to 68 Nm
(50 ft lb). Then tighten nut another1/8 turn.
Bend tabs on washer to lock slotted nut.
22. Reinstall the bottom pivot plate. Only HAND
TIGHTEN the hex screws at this time.
23. Slide the lock ring retainer into place on the
pivot shaft. This will center bottom plate to
pivot shaft. Do not tighten at this time.
24. Hold the lock ring retainer in place while
tightening the five M20 hex screws to
300 -- 390 Nm (220 -- 290 ft lb) on the
bottom pivot plate.
25. Alternately tighten the cap screws. Torque
cap screws to 14 Nm (10 ft lb), then to
28 Nm (20 ft lb), and then to 40 Nm (30 ft lb)
in the pattern shown.
26. Remove the floor jack from under the rear
wheel support.
27. Reconnect the hydraulic hoses. Make sure
each hose is placed on the fitting it was
removed from.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
28. Install the hydraulic cylinder ball joint on
steering bracket. Torque the hex screw to
290 -- 380 Nm (215 -- 280 ft lb).

800/810 MM337 (8--97)

Torque
Sequence
Lock
Ring
Retainer

Threaded
Hole

Cap
Screw

2-- 13

CHASSIS
29. Install existing hose clamp, channel and
sleeve on steering bracket with existing
hardware.
30. Reinstall the rear tire and wheel assembly.
Tighten the six wheel nuts to 122 -- 142 Nm
(90 -- 105 ft lb). Use a crisscross pattern
when torquing wheel nuts.
31. Remove the machine jack stands and lower
the machine to the floor.
32. Rock the machine side to side and listen for
a clicking sound from the rear wheel
support. If you hear the sound, repeat steps
11 -- 25.
33. Reinstall access cover panel in operator’s
compartment.
34. Reinstall seat assembly. See TO REPLACE
SEAT ASSEMBLY instructions in this
section.
35. Reconnect the battery cables.
36. Operate the machine and check for proper
operation of the rear drive area.

2-- 14

800/810 MM337 (8--97)

SWEEPING
CONTENTS
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . 3--3
REGENERATIVE FILTER SYSTEM
(RFS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
DEBRIS HOPPER . . . . . . . . . . . . . . . . . . . . . 3--5
TO REMOVE HOPPER . . . . . . . . . . . . . 3--5
TO INSTALL HOPPER . . . . . . . . . . . . . . 3--7
TO ADJUST AND LEVEL HOPPER
HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . 3--7
HOPPER DUMP DOOR . . . . . . . . . . . . . . . . 3--8
TO REMOVE HOPPER DUMP
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 3--8
TO INSTALL HOPPER DUMP
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
TO ADJUST HOPPER DUMP
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
HOPPER DUST FILTER . . . . . . . . . . . . . . 3--10
TO REMOVE OR REPLACE HOPPER
DUST FILTER . . . . . . . . . . . . . . . . . . 3--10
THERMO SENTRYt . . . . . . . . . . . . . . . . . 3--12
TO REPLACE THERMO SENTRYt . 3--12
BRUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . 3--13
MAIN BRUSH . . . . . . . . . . . . . . . . . . . . . 3--13
TO REPLACE MAIN BRUSH . . . . . 3--13
TO CHECK AND ADJUST MAIN
BRUSH PATTERN . . . . . . . . . . . 3--14
TO REPLACE MAIN BRUSH IDLER
PLUG BEARING . . . . . . . . . . . . . . . 3--16
TO REPLACE MAIN BRUSH SHAFT
BEARINGS . . . . . . . . . . . . . . . . . . . . 3--17
POWER THROWt . . . . . . . . . . . . . . . . 3--19
TO REPLACE POWER
THROWt BRUSH . . . . . . . . . . . 3--19
TO REPLACE POWER THROWt
BRUSH IDLER BEARINGS . . . . . 3--20
SIDE BRUSH . . . . . . . . . . . . . . . . . . . . . 3--21
TO REPLACE SIDE BRUSH . . . . . 3--21
TO ADJUST SIDE BRUSH TIP
ANGLE . . . . . . . . . . . . . . . . . . . . . 3--22
TO ADJUST SIDE BRUSH RIDE
HEIGHT . . . . . . . . . . . . . . . . . . . . 3--23

800/810 MM337 (8--97)

SKIRTS AND SEALS . . . . . . . . . . . . . . . . .
TO REPLACE HOPPER LIP
SKIRTS . . . . . . . . . . . . . . . . . . . . . . .
BRUSH COMPARTMENT SKIRTS . .
TO REPLACE AND ADJUST BRUSH
DOOR SKIRTS . . . . . . . . . . . . . . . . .
REAR SKIRTS . . . . . . . . . . . . . . . . . . . .
TO REPLACE AND ADJUST THE
REAR SKIRT . . . . . . . . . . . . . . . . . .
TO REPLACE AND ADJUST THE
REAR DEFLECTOR SKIRT . . . . . .
BRUSH DOOR SEALS . . . . . . . . . . . . .
HOPPER SEALS . . . . . . . . . . . . . . . . . .
TO REPLACE HOPPER WHEEL
POCKET SEALS . . . . . . . . . . . . . . .
HOPPER DOOR SEALS . . . . . . . . . . .
HOPPER SIDE SKIRT . . . . . . . . . . . . .
HOPPER DUST SEAL . . . . . . . . . . . . .
HOPPER COVER SEAL . . . . . . . . . . .
HOPPER LIFT ARMS . . . . . . . . . . . . . . . . .
TO REMOVE HOPPER LIFT ARM . .
TO INSTALL HOPPER LIFT ARM . . .
HOPPER VACUUM FAN SEAL . . . . . . . .
VACUUM FAN . . . . . . . . . . . . . . . . . . . .
TO REPLACE VACUUM FAN
IMPELLER . . . . . . . . . . . . . . . . . . . .
MACHINE TROUBLESHOOTING . . . . . .

Page
3--24
3--24
3--25
3--25
3--26
3--26
3--27
3--28
3--28
3--29
3--30
3--30
3--30
3--30
3--31
3--31
3--32
3--33
3--33
3--33
3--36

3-- 1

SWEEPING

3-- 2

800/810 MM337 (8--97)

SWEEPING
INTRODUCTION
The side brush sweeps debris into the path of the
main brush. The main brush sweeps debris from
the floor into the hopper. The vacuum system
pulls dust and air through the hopper and the
hopper dust filter.

800/810 MM337 (8--97)

3-- 3

SWEEPING
REGENERATIVE FILTER SYSTEM (RFS)
The Regenerative Filter System (RFS) is an
option that alternately turns on the filter shaker
motors when the filters need cleaning because of
a build--up of dust or debris.
Normally the RFS does not require the operator to
stop the machine to shake the filters during
sweeping operation (except in extreme and
severe dust environments). However, it is
recommended that the filters are shaken at the
operator’s initiative each time the hopper is
dumped. This can be accomplished during transit
to a dump sight. AVOID shaking the filters while
hopper is in a rolled out position. To initiate a
shaking cycle, press the filter button on the
instrument panel.
In very severe dust environments, the plugged
filter indicator on the instrument panel may remain
lit. When this occurs, it is recommended that the
operator stop the machine and initiate one or two
shake cycles to clear a possible plugged filter
condition. After shaking, roll the hopper out to
evacuate the dust tray. Resume sweeping
operation.
If the hopper is over full, the light may come on.
Check the hopper load and dump if necessary.
If the filter light remains on after all the above
conditions are corrected, the filters may be
plugged or the RFS may be inoperative. Filters
may be shaken by the operator initiative by
pressing the filter button on the instrument panel if
there is a failure in the RFS control system.
Successful operation of the RFS option requires
clean, undamaged filters. Plugged filters may
cause the RFS to cycle continuously even at start
up. The option also requires good sealing of the
upper lid to the hopper, as well as a good seal
between the two upper filter chambers.
It is recommended that the machine be driven for
some test sweeping with the RFS option at initial
start up. This next step assumes the hopper cover
and upper filter chamber of the hopper was
cleaned thoroughly prior to installation of the RFS
option. Sweep for 30 minutes and open the
hopper cover to check the integrity of the seals.
Look at the top of the shaker panels and the
underside of the hopper cover. Check for any
signs of dust tracking that may be caused by a
bad seal or filter. Repair a necessary. Perform this
check periodically while using the sweeper with
the RFS option.

3-- 4

800/810 MM337 (8--97)

SWEEPING
DEBRIS HOPPER
The debris hopper collects the debris swept up by
the main brush. The hopper includes the following
main components: hopper dust filters, hopper
dump door, and dust skirts. All adjustments have
been made at the factory and require no regular
maintenance. If the hopper components are
repaired or replaced, some components may
need to be re--adjusted for best performance. The
hopper may need to be removed from the
machine for some repair or service work.
TO REMOVE HOPPER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Make sure the hopper has been emptied of
all debris.
2. Set the parking brake, Raise the hopper and
engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
3. Remove the two M8 hex screws holding
each fender to the hopper bumper.
Disengage the prop arm and lower the
hopper.
4. Open hopper cover and remove eight M8
hex screws attaching LH and RH fenders to
hopper.
5. Open the front headlight panel. Spread the
front fenders apart and pull the headlight
panel out of the hole on each end.

6. Remove the headlight panel and both front
fenders from the machine.
7. Start the machine and open hopper dump
door.
8. Remove the two M10 hex screws from the
bottom front corners of the hopper.
9. Remove the five M10 hex screws from both
sides of hopper. (accessed inside hopper)

800/810 MM337 (8--97)

3-- 5

SWEEPING
10. Start the engine and roll the hopper slightly
forward. Hook an over head hoist to the two
adjustment bolts on the back of the hopper.
11. Remove the five M10 hex screws from on
top of hopper in front.
12. Unbolt the bracket holding the hydraulic
hose tee fittings at the front of the hopper.
13. Start the engine, close the dump door, and
roll the hopper all the way out. Use the over
head hoist to help roll the un--bolted hopper
forward.
14. Unplug the hopper wire harness from the
main harness. Remove any ties holding the
harness to the lift arm.
15. The hopper can now be lifted up and out of
the lift arms using the over head hoist.
16. Set the hopper on the floor.

3-- 6

800/810 MM337 (8--97)

SWEEPING
TO INSTALL HOPPER
1. Engage parking brake, Lift the hopper back
into the machine using the rear adjustment
bolts and a chain or strap.
2. Roll the hopper back half way. Open the
hopper dump door.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
3. Reinstall all the hopper hardware. Align
holes by rocking hopper and using a drift
punch.
4. Tighten the M10 hex screws to 37 -- 48 Nm
(27 -- 35 ft lb).
5. Reinstall the hydraulic hose tee bracket.
Tighten the M8 hex screws to 18 -- 24 Nm
(13 -- 18 ft lb).
6. Reinstall the front headlight panel and RH
and LH fenders. Tighten the ten M8 hex
screws to 18 -- 24 Nm (13 -- 18 ft lb).
7. Reconnect the hopper harness to the main
harness. Reattach the harness to the lift
arms.
8. Close the hopper dump door, roll the hopper
back, raise the hopper, engage the prop
arm.
9. Reinstall the four M8 hex screws in the
bottom of both fenders. Tighten to
18 -- 24 Nm (13 -- 18 ft lb).
10. Disengage the prop arm and lower the
hopper.

TO ADJUST AND LEVEL HOPPER HEIGHT
1. The two M12 hex screws at the rear of
hopper should be set at 45 mm (1.75 in)
from the head of bolt to the edge of bracket.

800/810 MM337 (8--97)

3-- 7

SWEEPING
HOPPER DUMP DOOR
The hopper dump door is used to control the
hopper debris when dumping.

TO REMOVE HOPPER DUMP DOOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Make sure the hopper has been emptied of
all debris.
2. Set the parking brake, Raise the hopper and
engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
3. Remove the two M8 hex screws holding
each fender to the hopper bumper.
Disengage the prop arm and lower the
hopper.
4. Open hopper cover and remove eight M8
hex screws attaching LH and RH fenders to
hopper.
5. Open the front headlight panel. Spread the
front fenders apart and pull the headlight
panel out of the hole on each end.
6. Remove the headlight panel and both front
fenders from the machine.
7. Start the machine and open hopper dump
door.
8. Brace the dump door up with jack stands.
9. Remove the cotter keys from pins at the rod
end of the dump door cylinders.
10. Slide the clevis pins out of each cylinder and
door. Make sure dump door is supported
before removing the pins.
11. Loosen the set screws on both centering
sleeves on upper hopper door pins.
12. Remove the M12 hex screws and nyloc
nuts.
13. The hopper door can now be removed from
the machine.
3-- 8

800/810 MM337 (8--97)

SWEEPING
TO INSTALL HOPPER DUMP DOOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Position the dump door in front of the
machine with the pivot ears pointing up.
2. Align the upper bearing sleeves with the
holes in bumper ears. Install the M12 hex
screws and nyloc nuts. Tighten to
64 -- 83 Nm (47 -- 60 ft lb).
3. Center the dump door and tighten the set
screws on the centering sleeves.
4. Align the holes in rod end of the dump door
cylinder with the holes in dump door. Slide
the clevis pin through the hole and install the
washer and cotter key.
5. Start the machine and close the dump door.
6. Reinstall the headlight panel, RH and LH
fenders. Tighten the ten M8 hex screws to
18 -- 24 Nm (13 -- 18 ft lb).
7. Reconnect the hopper harness to the main
harness. Reattach the harness to the lift
arms.
8. Close the hopper dump door, roll the hopper
back, raise the hopper, engage the prop
arm.
9. Reinstall the four M8 hex screws in the
bottom of both fenders. Tighten to
18 -- 24 Nm (13 -- 18 ft lb).
10. Disengage the prop arm and lower the
hopper.

TO ADJUST HOPPER DUMP DOOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Engage the parking brake and open the
hopper dump door.
2. Use the two 0.50 in x 3.5 in hex screws
located in the lower corner of front bumper
to adjust hopper dump door in and out for
proper seal.

800/810 MM337 (8--97)

3-- 9

SWEEPING
HOPPER DUST FILTER
The dust filters filter the air pulled up from the
hopper. The dust filters are equipped with a
shaker to remove the accumulated dust particles.
The dust filters shaker is operated by the filter
shaker switch.
Shake the dust filters before dumping the hopper
and at the end of every work shift. Check and
clean the dust filters every 50 hours of operation.
Extremely dusty conditions may require more
frequent cleaning of dust filters.
To clean the dust filters, use one of the following
methods:
D SHAKING -- Press the filter shaker switch.
D AIR -- Blow compressed air through the dust
filter from the inside. This may be done with
the dust filter in the machine, or for more
efficient cleaning remove the dust filter from
the machine and the prescreen wrap from
the filter element. Always wear eye
protection when using compressed air.
FOR SAFETY: When Servicing Machine, Wear
Eye And Ear Protection When Using
Pressurized Air Or Water.
D WATER -- Remove the fabric presceen wrap
from the filter element. Wash the prescreen
wrap in a water and mild detergent solution.
Rinse the prescreen wrap until it is clean. Air
dry the wet prescreen wrap; do not use
compressed air. NEVER wash the filter
element with water.

08594

TO REMOVE OR REPLACE HOPPER DUST
FILTER
1. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
2. Open the hopper cover.
3. Disconnect the shaker motor wire
connectors.

3-- 10

800/810 MM337 (8--97)

SWEEPING
4. Remove the four retaining screws from the
filter shaker frame.
5. Pull the filter shaker frame out of the hopper.
6. To ease in the removal of the shaker frame
the hopper should be rolled forward slightly.
7. Carefully turn over the shaker frame and
element.
8. Remove the four filter retaining screws from
the shaker frame.
08591

9. Remove the retainer ring from the shaker
frame. Remove the filter.
NOTE: At this point inspect the shaker assembly
for worn pivot bearings or torn dust seal. Repair or
replace as necessary. Also lubricate the eccentric
roller bearings.
10. Make sure the prescreen wrap is tightly
wrapped around and securely fastened on
the new filter element. Put the new filter on
the filter shaker frame.
11. Place the retainer ring over the filter. Make
sure the retaining ring fits inside the lip of
the filter element all the way around. Line up
the slots on the retainer ring with the
retaining screws holes.
12. Mount using the retaining screws.

08592

13. Check the seal on the shaker frame for
damage. Make sure the vibration isolators
are mounted in all four corners of the filter
shaker frame.
14. Put the filter and shaker frame in the hopper.
15. Install the four retaining screws and tighten.
16. Connect the shaker motor wire connectors.
17. Check the shaker ring to filter clearance.
Make sure the cam is in the lowest position.
There should be 0.125 in clearance around
the entire shaker ring. Use three 0.125 in
drill bits as gauges. The shaker ring is
adjusted with the two jam nuts on the shaker
stem.
08593

NOTE: Make sure that the jam nuts are TIGHT
when the adjustment is complete.

800/810 MM337 (8--97)

3-- 11

SWEEPING
THERMO SENTRYt
The Thermo Sentryt senses the temperature of
the air pulled up from the hopper. If there is a fire
in the hopper, the Thermo Sentryt stops the
vacuum fan and cuts off the air flow. The Thermo
Sentryt is located on the vacuum fan housing.
Reset the Thermo Sentryt by pushing in its reset
button.
08928

TO REPLACE THERMO SENTRYt
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Open engine cover and side door.
2. Disconnect Thermo Sentryt from wire
harness.
3. Remove the two bolts holding the Thermo
Sentryt to the vacuum fan housing.
4. Mount new Thermo Sentryt with existing
hardware.
5. Connect the wires back to the Thermo
Sentryt.
6. Close engine cover and side door.

3-- 12

800/810 MM337 (8--97)

SWEEPING
BRUSHES
MAIN BRUSH
The main brush is cylindrical and spans the width
of the machine, sweeping debris into the hopper.
Check the brush daily for wear or damage.
Remove any string or wire tangled on the main
brush, main brush drive hub, or main brush idler
hub.
Check the main brush pattern daily. The pattern
should be 50 to 65 mm (2 to 2.5 in) wide. Adjust
the main brush pattern by turning the main brush
pressure knob located next to the operator seat.
Rotate the main brush end-for-end every
50 hours of operation for maximum brush life and
best sweeping performance.
Replace the main brush when the remaining
bristles measure 30 mm (1.25 in) in length.
TO REPLACE MAIN BRUSH
1. Raise the main brush.
08487

2. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
3. Open the right side main brush access door.
4. Unlatch and remove the brush idler plate.
5. Grasp the main brush; pull it off the brush
drive plug and out of the main brush
compartment.
08488

6. Put the new or rotated end-for-end main
brush on the floor next to the access door.
7. Slide the main brush onto the drive plug.
Rotate the brush until it engages the drive
plug, and push it all the way onto the plug.
8. Slide the main brush idler plate plug into the
main brush.
9. Latch the idler plate on the machine frame.
10. Close the right side main brush access door.
08489

800/810 MM337 (8--97)

3-- 13

SWEEPING
TO CHECK AND ADJUST MAIN BRUSH
PATTERN
1. Apply chalk, or some other material that will
not blow away easily, to a smooth, level
floor.
2. Raise the side brush and main brush and
position the main brush over the chalked
area.
3. Start the main brush.
4. Lower the main brush for 15 to 20 seconds
while keeping a foot on the brakes to keep
the machine from moving. This will lower the
rotating main brush.
NOTE: If chalk or other material is not available,
allow the brushes to spin on the floor for two
minutes. A polish mark will remain on the floor.
5. Raise the main brush.
6. Stop the main brush.
7. Drive the machine off the test area.
8. Observe the width of the brush pattern. The
proper brush pattern width is 65 to 75 mm
(2.5 to 3.5 in).

00582

9. To increase the width of the main brush
pattern, turn the main brush down pressure
Heavy.
knob counter-clockwise,

08442

3-- 14

800/810 MM337 (8--97)

SWEEPING
10. To decrease the width of the main brush
pattern, turn the main brush down pressure
knob clockwise
Light.

08441

11. If the main brush pattern is tapered, more
than 15 mm (0.5 in) on one end than the
other, adjust the taper at the drive end of the
brush.

00601

A. Loosen the brush drive end plate
mounting bolts.
B. Turn the taper adjustment nut
counter-clockwise to increase the
pattern width at the brush drive end,
and clockwise to decrease the pattern
width at the brush drive end. Tighten
the drive end plate mounting bolts.
C. Check the main brush pattern and
readjust as necessary. Then adjust the
width of the main brush pattern.
08450

12. For maximum brush life always use the
minimum pattern to get good pickup. If the
brush is adjusted to a large pattern for an
uneven surface or a depression, it should be
returned to the lighter pattern as soon as
possible.

08490

800/810 MM337 (8--97)

3-- 15

SWEEPING
TO REPLACE MAIN BRUSH IDLER PLUG
BEARING
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Remove the main brush idler arm from the
machine. See TO REPLACE MAIN BRUSH
instructions in this section.
2. Remove the plastic cap from the idler plug.
3. Clean the area around where the cap was
mounted to the idler plug.
4. Remove the M12 hex screw, nyloc hex nut,
and washer holding the idler plug to the idler
arm. Save the hardware.
5. Remove the four M6 hex screws holding the
idler shaft in the idler plug. Remove the shaft
and cover. Save the hardware.
6. Remove the bearing seal plate, retainer and
bearing.
7. Clean the inside of the idler plug.
8. Place a new bearing, the seal plate and the
retainer in the idler.
9. Thread the four screws and flat washers into
place.
10. Install the idler shaft and tighten the four
bolts to 8 -- 10 Nm (6 -- 8 ft lb).
11. Slide the idler plug on the idler arm shaft.
Secure it with the hardware removed earlier.
Tighten hardware to 68 -- 81 Nm
(50 -- 60 ft lb).
12. Apply RTV to contact area where plastic cap
will fit one end of idle plug. Snap plastic cap
into place.
Note: If you replace idler arm latch, use blue
locktite on hardware to hold in place.

3-- 16

800/810 MM337 (8--97)

SWEEPING
TO REPLACE MAIN BRUSH SHAFT
BEARINGS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Remove the main brush. See TO REPLACE
MAIN BRUSH instructions in this section.
2. Remove the two M12 hex screws holding
main brush motor arm to brush shaft. Place
arm to the side without disconnecting
hydraulic hoses.
3. Remove the brush lift cable clevis from the
brush shaft arm.
4. Remove two M10 hex screws holding
bearing flange to main frame. Do this on
both sides.
5. Drop main brush shaft out of machine.
6. Secure brush shaft in vice.
7. Remove M8 hex screw holding brush pattern
adjustment tab on idler side of brush shaft.
Remove tab.
8. Remove the remaining hex screw in three
hole bearing flange.
9. Loosen the bearing set screws and slide the
bearings off the shaft.
10. Slide the new bearings on the shaft with the
collar facing the ends of the shaft end. Be
sure to have a bearing flange on each side
of each bearing. Leave collars loose.
11. Reinstall one hex screw into bearing flange
on each side. Tighten to 18 -- 24 Nm
(13 -- 18 ft lb).
12. Reinstall the brush shaft in the machine.
NOTE: Make sure bearing flanges are on the
inside of main frame.
13. Align two remaining holes in bearing flanges
with holes in main frame. Install M10 hex
screws and tighten to 37 -- 48 Nm
(26 -- 34 ft lb).

800/810 MM337 (8--97)

3-- 17

SWEEPING
14. Center brush shaft in machine. Tighten
bearing collars by turning on shaft. Hand
tighten set screws.
15. Reinstall main brush lift cable clevis pin.
16. Reinstall main brush motor arm using M12
hex screws. Tighten to 64 -- 83 Nm
(47 -- 61 ft lb).
17. Reinstall brush pattern adjustment tab using
M8 hex screw. Tighten to 18 -- 24 Nm
(13 -- 18 ft lb).
18. Reinstall main brush and check pattern.
Adjust if necessary.
Note: If you are replacing the idler arm latch
bracket, use blue locktite to hold the bolts in
place. Tighten the bolts to 8 -- 10 Nm
(6 -- 8 ft lb).

3-- 18

800/810 MM337 (8--97)

SWEEPING
POWER THROWt
The Power Throwt loads the hopper with debris
picked up by the main brush.
Check the brush daily for wear or damage.
Remove any string or wire tangled on the main
brush, main brush drive hub, or main brush idler
hub.
The Power Throwt brush should clear the floor
by 7 to 13 mm (0.25 to 0.50 in). Adjust the floor
clearance with the adjusting bolt located under the
seat on the Power Throwt cross-tube. Turn the
bolt clockwise to increase the floor clearance, and
counter-clockwise to decrease the floor clearance.

08583

TO REPLACE POWER THROWt BRUSH
1. Set the machine parking brake and open the
right main brush door.
2. Raise the hopper and secure with the
hopper prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
3. Lower the Power Throwt.
4. Shut off the engine.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
5. Remove the hex screw holding the idler
plate of the Power Throwt to the brush
torque tube. Remove the brush idler plate.
6. Pull the Power Throwt
plug.

brush off the drive

7. Slide the new brush on the drive end of the
Power Throwt.
8. Slide the brush idler plate plug onto the
brush.
9. Reinstall the brush idler plate and hex screw.
10. Lower the hopper and operate the machine,
checking for proper operation.

800/810 MM337 (8--97)

08584

3-- 19

SWEEPING
TO REPLACE POWER THROWt BRUSH
IDLER BEARINGS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Set the machine parking brake and remove
the Power Throwt brush and idler plate.
See TO REPLACE POWER THROWt
BRUSH instructions in this section.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Remove the M6 hex screw holding the
plastic idler plug on the idler shaft. Pull the
plug off the idler shaft. Retain the square
key.
3. Remove the two M6 hex screws holding the
bearing cup to the idler arm. Remove the
bearing cup assembly.
4. Remove the first snap ring from the shaft.
5. Press the bearing nearest the key way off
the shaft.
6. Press the second bearing off the shaft.
7. Press both the new bearings on the shaft.
Be careful not to damage the snap rings
when pressing the bearings on.
8. Reinstall the bearing cup assembly to brush
arm using the two M6 hex screws. Tighten
to 8 -- 10 Nm (5 -- 7 ft lb).
9. Reinstall the snap ring that was removed in
step 4.
10. Reinstall the idler plug to shaft using M6 hex
screw. Tighten to 8 -- 10 Nm (5 -- 7 ft lb).
11. Reinstall the idler plate back on the
machine.
12. Reinstall the brush, lower the hopper, and
operate the machine. Check for proper
brush operation.

3-- 20

800/810 MM337 (8--97)

SWEEPING
SIDE BRUSH
The side brush sweeps debris along edges into
the path of the main brush.
Check the brush daily for wear or damage.
Remove any string or wire found tangled on the
side brush or side brush drive hub.
Check the side brush pattern daily. One-half of the
side brush bristles should contact the floor when
the brush is in motion. Adjust the side brush
pattern by the side brush down pressure knob.
Turn the knob counter-clockwise to increase the
brush contact with the sweeping surface, and
clockwise to decrease the brush contact with the
sweeping surface.
The side brush should be replaced when it no
longer sweeps effectively for your application. A
guideline length is when the remaining bristles
measure 50 mm (2 in) in length. You may change
the side brush sooner if you are sweeping light
litter, or wear the bristles shorter if you are
sweeping heavy debris.

TO REPLACE SIDE BRUSH
1. Make sure the hopper has been emptied of
all debris.
2. Set the parking brake, Raise the hopper and
engage the prop arm.
3. Shut off the engine.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
4. Pull the hair pin and cable out of the hole in
the end of the side brush retaining clevis pin.
Remove the clevis pin from the side brush
hub.

08466

5. Slide the side brush off the side brush drive
shaft.
6. Remove the five hex screws holding the
drive adaptor to the brush. Remove the drive
adaptor and install it on the new brush.
7. Slide the new side brush on the side brush
drive shaft.

800/810 MM337 (8--97)

3-- 21

SWEEPING
8. Insert the side brush clevis pin through the
side brush hub and shaft. Reinstall the hair
pin and cable back into the hole in the end of
the clevis pin.
9. Secure the pin by clipping the pin keeper
over the end of the pin.
10. Disengage the hopper prop arm and lower
the hopper.
11. Adjust the side brush pattern with the side
brush down pressure knob.

TO ADJUST SIDE BRUSH TIP ANGLE
1. Raise the hopper and engage the prop arm.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
2. Remove the M10 hex screw holding the side
brush lift cable to the lift arms.
3. Carefully lower side brush down onto the
side brush lift stop.
4. Make sure the side brush is down in the
sweep mode.
5. Locate the M10 threaded rod with two M10
jam nuts in the upper center of the side
brush motor mount bracket.
6. Loosen the rear jam nut and tighten the front
one. This will flatten out the brush pattern on
a worn brush and help maintain proper
sweeping performance.
7. Reconnect the side brush cable to the lift
arms using the M10 hex screw and washer.
Tighten to 52 -- 67 Nm (39 -- 51 ft lb).
8. Disengage prop arm, lower hopper and
check side brush for proper operation.

3-- 22

800/810 MM337 (8--97)

SWEEPING
TO ADJUST SIDE BRUSH RIDE HEIGHT
1. Raise the hopper and engage prop arm.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
2. Remove the M10 hex screw holding the side
brush lift cable to the lift arms.
3. Carefully lower side brush down onto the
side brush lift stop.
4. Make sure the side brush is down in the
sweep mode.
5. Loosen the two M8 hex screws holding the
side brush cable lift bracket to the side of the
side brush motor mount bracket.
6. Adjust the side brush to the desired height of
approximately 0.50 in from lower edge of
bumper with the side brush in the raised
position. Tighten the hex screws to
18 -- 24 Nm (15 -- 20 ft lb).
7. Reconnect the hopper up side brush cable
to the lift arms. using the M10 hex screw
and washer. Tighten to 52 -- 67 Nm
(39 -- 51 ft lb).
8. Disengage prop arm, lower hopper and
check side brush for proper operation.

800/810 MM337 (8--97)

3-- 23

SWEEPING
SKIRTS AND SEALS
The hopper lip skirts are located on the bottom
rear of the hopper. The skirts float over debris and
help deflect that debris into the hopper. The top
skirt is segmented.
Check the hopper lip skirts for wear or damage
daily.
Replace the hopper lip skirts when they no longer
touch the floor.

08491

TO REPLACE HOPPER LIP SKIRTS
1. Make sure the hopper has been emptied of
all debris.
2. Set the parking brake, Raise the hopper and
engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
3. Shut off the engine.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
4. Remove the hopper lip retaining strip
mounting bolts.
5. Remove the hopper lip retaining strip, the
hopper lip, and the back-up strip.
6. Thread the retaining strip mounting bolts
through the retaining strip, the new hopper
lip, the back-up strip, and into the hopper.
7. Tighten the mounting bolts to 8 -- 14 Nm
(6 -- 10 ft lb).
8. Start the engine.
9. Raise the hopper, disengage the hopper
prop arm, and lower the hopper.
10. Operate the machine and check for proper
operation.

3-- 24

800/810 MM337 (8--97)

SWEEPING
BRUSH COMPARTMENT SKIRTS
The brush compartment skirts are located on the
bottom of each of the two main brush doors and
around the ends of the brush on the main frame.
The inside brush door skirt should touch the floor,
and the outside brush door skirt should clear the
floor by 5 mm (0.25 in).
Check the skirts for wear or damage and
adjustment daily.
NOTE: The brush door skirts have slotted holes to
allow for a ground clearance adjustment. The door
must be closed for proper adjustment.
NOTE: Tire pressure will affect skirt clearances.

TO REPLACE AND ADJUST BRUSH DOOR
SKIRTS
1. Park the machine on a smooth, level
surface.
2. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
3. Open the main brush doors.
4. Remove the four hex screws holding the
brush door skirts and retainer to the brush
door.
5. Remove the skirt retaining strip and both
door skirts.
6. Discard the worn or damaged skirts.
7. Reinstall new skirts, skirt retainer, and M8
hex screws. Snug hex screws only at this
time.
8. Close the brush door and adjust skirt to
desired height 5 mm (0.25 in) off the floor.
9. Open the brush door and tighten M8 hex
screws to 8 -- 14 Nm (6 -- 10 ft lb)
10. Repeat this on the other brush door.

800/810 MM337 (8--97)

3-- 25

SWEEPING
REAR SKIRTS
The two rear skirts are located on the bottom rear
of the main brush compartment. The vertical skirt
should clear the floor up to 19 mm (0.75 in). The
recirculation skirt is self-adjusting.
Check the skirts for wear or damage and
adjustment daily.
NOTE: Tire pressure will affect skirt clearances.

TO REPLACE AND ADJUST THE REAR SKIRT
1. Park the machine on a smooth, level
surface.
2. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
3. Open the main brush doors.
4. Remove the main brush. See TO REPLACE
MAIN BRUSH instructions in this section.
5. Remove the five M8 hex screws and nyloc
nuts holding the skirt retainer channel to the
machine. Remove the skirt and retainer from
the machine.
6. Discard the old skirt. Position the new skirt
in place on the machine frame.
7. Thread the five hex screws through the
retaining channel, the rear skirt, and the
machine frame. Reuse the five nyloc nuts.
Leave loose for now.
NOTE: Make sure to reinstall the static chain on
the right hand skirt mounting hardware.
8. Slide the rear floor skirt up or down so that
the skirt clears the floor by 19 mm (0.75 in).
9. Tighten the rear floor skirt mounting bolts to
8 -- 14 Nm (6 -- 10 ft lb).
10. Reinstall the main brush. See TO REPLACE
MAIN BRUSH instructions in this section.
11. Close the brush doors and operate the
machine. Check for proper rear skirt
operation.

3-- 26

up to 19 mm
(up to 0.75 in)

800/810 MM337 (8--97)

SWEEPING
TO REPLACE AND ADJUST THE REAR
DEFLECTOR SKIRT
1. Park the machine on a smooth, level
surface.
2. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
3. Open the main brush doors.
4. Remove the main brush. See TO REPLACE
MAIN BRUSH instructions in this section.
5. Remove the four M8 hex screws and nyloc
nuts holding the deflector skirt retainer strap
to the deflector plate on the machine.
Remove the skirt and retainer from the
machine.
6. Discard the old skirt. Position the new
deflector skirt and old retainer strap in place
on the deflector plate on the machine.
7. Thread the four hex screws through the
retaining strap, the deflector skirt, and the
deflector plate. Reuse the four nyloc nuts.
Leave loose for now.
8. Adjust the recirculation flap high enough in
the slots so it can pivot back freely without
hitting the floor.
9. Tighten the brush deflector blade mounting
bolts to 8 -- 14 Nm (6 -- 10 ft lb).
10. Make sure the deflector spring moves the
recirculation flap freely into position.
11. Make sure to clear any build up of dirt or
debris from between the recirculation flap
mounting bracket and the brush wrap frame.
12. After a period of time the recirculation flap
will tend to curl down. When this happens
remove it, turn it end for end and upside
down, and reinstall. This will help maintain
proper sweeping performance.
13. Reinstall the main brush. See TO REPLACE
MAIN BRUSH instructions in this section.
14. Close the brush doors and operate the
machine. Check for proper deflector skirt
operation.

800/810 MM337 (8--97)

3-- 27

SWEEPING
BRUSH DOOR SEALS
The brush door seals are located on both main
brush doors and on corresponding portions of the
main frame.
Check the seals for wear or damage every
100 hours of operation.

08495

HOPPER SEALS
The hopper seals are located on the top and side
portions of the machine frame that contact the
hopper.
Check the seals for wear or damage every
100 hours of operation.

08496

3-- 28

800/810 MM337 (8--97)

SWEEPING
TO REPLACE HOPPER WHEEL POCKET
SEALS
1. Park the machine on a smooth, level
surface.
2. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
3. Raise hopper and engage hopper prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
4. Remove main brush. See TO REPLACE
MAIN BRUSH instructions in this section.
5. Remove six M6 hex screws and five plastic
rivets holding the four retainers and brush
compartment seal to the machine frame.
6. Remove and discard the old brush
compartment seal.
NOTE: The Power Throwt brush must be
removed on the model 810 to remove this seal.
See TO REPLACE POWER THROW BRUSH
instructions in this section.
7. Position the new brush compartment seal on
the machine frame.
8. Align holes on new skirt with holes in
retainers and frame.
9. Install and tighten the six M6 hex screws
and nyloc nuts to 8 -- 10 Nm (6 -- 8 ft lb).
10. Push the five plastic rivets in by hand.
NOTE: The plastic rivets may need to be replaced
if they were damaged during removal.
11. Repeat this procedure on the other side.

800/810 MM337 (8--97)

3-- 29

SWEEPING
HOPPER DOOR SEALS
The hopper door seals are located on the hopper
door. They seal the hopper when the hopper door
is closed.
Check the seals for wear or damage every
100 hours of operation.

08497

HOPPER SIDE SKIRT
The hopper side skirt is located on the left side of
the hopper.
Check the hopper side skirt for wear or damage
daily.

08492

HOPPER DUST SEAL
The hopper dust seal is located inside the hopper.
It seals the hopper filter compartment.
Check the seal for wear or damage every
100 hours of operation.

08498

HOPPER COVER SEAL
The hopper cover seals are located on the inside
of the hopper cover. They seal the hopper filter
compartment.
Check the seal for wear or damage every
100 hours of operation.

3-- 30

800/810 MM337 (8--97)

SWEEPING
HOPPER LIFT ARMS
The hopper lift arms lift and lower the hopper
assembly. They are held in place by pins and
fiberglide bearings in the ends of the lift arms.

TO REMOVE HOPPER LIFT ARM
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Remove debris hopper. See TO REMOVE
HOPPER instructions in this section.
2. Make sure the lift arms are in the down
position.
3. Trace the hydraulic hoses leading from the
hopper roll out cylinders and hopper dump
door cylinders back to the control valve.
4. Remove and plug these hoses at the control
valve .
Note: Observe hydraulic cleanliness requirements
when opening hydraulic lines.
5. Remove the pins connecting the black pivot
link to the lower lift arm bar.
6. Remove the pin connecting the hopper lift
arm to the hopper lift cylinder.
7. Remove the two M10 hex screws from the
hopper lift arm upper pins.
8. Lift arms must now be lifted with a chain or
cable so the pins can be removed.
9. Once the pins are removed the lift arm
assembly can be lifted out of the machine.

800/810 MM337 (8--97)

3-- 31

SWEEPING
TO INSTALL HOPPER LIFT ARM
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Position the lift arm assembly back into the
machine.
2. Align the upper holes in lift arm with the
upper holes in main frame towers. Install
pins and M10 hex screws. Hand tighten the
hardware.
3. Align the holes in lower lift arm bar with the
lower holes black pivot link. Install pins and
M10 hex screws. Tighten to 37 -- 48 Nm
(26 -- 34 ft lb).
4. Align the hole in the lift cylinder clevis with
the holes in cylinder lift ears on hopper arm.
Install pin and M10 hex screw. Tighten to
37 -- 48 Nm (26 -- 34 ft lb).
5. Reconnect roll out and dump door hydraulic
hoses to control valve. See schematic in the
HYDRAULICS section of this manual.
6. Reinstall debris hopper. See TO INSTALL
HOPPER instructions in this section.

3-- 32

800/810 MM337 (8--97)

SWEEPING
HOPPER VACUUM FAN SEAL
The hopper vacuum fan seal is mounted on the
vacuum fan inlet bracket.
Check the seal for wear or damage every
100 hours of operation.

VACUUM FAN
The vacuum fan is hydraulically driven. It pulls air
from the main brush area and through the hopper
filters. There is no vacuum when the hopper is in
the raised position.

TO REPLACE VACUUM FAN IMPELLER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Dump the machine debris hopper.
2. Set the machine parking brake.
3. Raise the hopper, engage the hopper prop
arm, and lower the hopper.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
4. Shut off the engine.
5. Open the engine cover and side door.
NOTE: The vacuum fan must be removed from
the machine to replace the hydraulic motor.
6. Remove the vacuum hose and bracket from
the front of vacuum fan housing.

800/810 MM337 (8--97)

3-- 33

SWEEPING
7. Disconnect the wires leading to the
thermo sentryt
8. Disconnect and plug the three hydraulic
hoses at the vacuum fan motor.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
9. Remove the two M10 hex screws, washers
and rubber isolators holding the vacuum fan
housing to the machine frame.
10. Remove solenoid valve mounting bracket
and rubber isolator from top of vacuum fan
housing.
11. Tip the vacuum fan assembly forward and
remove it from the machine.
12. Remove the six 0.31 in. hex screws holding
the front housing to rear housing.
NOTE: Mark the orientation of the outer fan
housing to the inner housing for proper
re--assembly.
13. Remove the crown nut from the impeller
shaft. Slide the impeller off the shaft.
(Remove and save key and any shims on
shaft under impeller.)
14. Turn the housing over and reinstall the
shims, key, fan impeller, and crown nut.
Tighten the crown nut to 34 -- 47 Nm
(25 -- 35 ft lb).
NOTE: Use blue loctite 242 on shaft threads.
NOTE: Be sure key is in shaft. Super gluing key
helps keep key in place.
NOTE: Make sure the impeller spins freely before
continuing with the assembly.
15. Reinstall the front housing on the rear
housing. Reinstall 0.31 in. hex screws and
tighten to 22 -- 27 Nm (16 -- 20 ft lb).
NOTE: Tennant part no. 57543 plastic shims must
be used for proper fan to housing clearance.
Remove the shims through the fan intake after
tightening screws.

3-- 34

800/810 MM337 (8--97)

SWEEPING
16. Reinstall the vacuum fan assembly into the
machine. Tighten the M10 hex screws to
37 -- 48 Nm (26 -- 34 ft lb).
17. Reinstall the solenoid mount bracket and
isolator to the top of fan assembly.
18. Reconnect the hydraulic hoses to the
vacuum fan motor. See schematic in
HYDRAULICS section.
19. Reinstall the vacuum hose and mounting
bracket to the front of vacuum fan. Tighten
the two M8 hex screws to 18 -- 24 Nm
(13 -- 18 ft lb).
20. Reconnect the electrical harness to the
thermo sentryt. See schematic in
HYDRAULICS section.
21. Start the machine and operate the vacuum
fan. Check for leaks and proper operation.

800/810 MM337 (8--97)

3-- 35

SWEEPING
MACHINE TROUBLESHOOTING

Problem

Cause

Remedy

Excessive dusting

Brush skirts and dust seals worn,
damaged, out of adjustment

Replace or adjust brush skirts or
dust seals

Hopper dust filter clogged

Shake and/or clean or replace
dust filter Also check operation
and adjustment of shaker
assembly

Main brush operating Power
Throwt speed

Operate main brush in Normal
speed

Vacuum hose damaged

Replace vacuum hose

Vacuum fan seal (vacuum fan inlet Replace seal
bracket) damaged

Poor sweeping
p g
performance
f

3-- 36

Vacuum fan failure

Contact TENNANT service
personnel

Hopper door partially or
completely closed

Open the hopper door

Thermo Sentryt tripped

Reset Thermo Sentryt

Fabric presceen missing on dust
filters

Clean filter elements and install
fabric prescreen

Hopper cover not sealing

Repair/replace hopper cover seal,
also check adjustment on hopper
cover latch and hinge.

Brush bristles worn

Replace brushes

Main and side brushes not
adjusted properly

Adjust main and side brushes

Debris caught in main brush drive
mechanism

Free drive mechanism of debris

Main brush drive failure

Contact TENNANT service
personnel

Side brush drive failure

Contact TENNANT service
personnel

Hopper full

Empty hopper

Hopper floor skirts worn or
damaged

Replace floor skirts

Hopper door partially or
completely open

Close the hopper door

Wrong sweeping brush

Contact TENNANT representative
for recommendations

800/810 MM337 (8--97)

ELECTRICAL
CONTENTS
Page
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . 4--3
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--3
TO REPLACE BATTERY ON LPG
MACHINE AND GAS/DIESEL
Serial # 002075 and up . . . . . . . . 4--4
TO REPLACE BATTERY ON GAS /
DIESEL MACHINE Serial # 002074
and down . . . . . . . . . . . . . . . . . . . . 4--5
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . 4--6
TO REPLACE INSTRUMENT PANEL . 4--6
TO DISASSEMBLE INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 4--7
TO REASSEMBLE INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 4--8
TO REPLACE MACHINE RELAY . . . . . 4--9
TO REPLACE MACHINE CIRCUIT
BREAKER . . . . . . . . . . . . . . . . . . . . . 4--10
TO REPLACE GOVERNOR
CONTROL BOX . . . . . . . . . . . . . . . . 4--11
Electrical Schematic 800--810 G/LPG
(LSG ENGINE) . . . . . . . . . . . . . . . . . . . . 4--12
Wire Harnesses Group 800--810 G/LPG
(LSG ENGINE) . . . . . . . . . . . . . . . . . . . . 4--20
Electrical Schematic 800--810 G/LPG
(LRG ENGINE) . . . . . . . . . . . . . . . . . . . 4--32
Wire Harnesses Group 800--810 G/LPG
(LRG ENGINE) . . . . . . . . . . . . . . . . . . . 4--40
Electrical Schematic 800--810 D
(PERKINS 200 SERIES ENGINE) . . . 4--52
Wire Harnesses Group 800--810 D
(PERKINS 200 SERIES ENGINE) . . . 4--58
Electrical Schematic 800--810 D
(PERKINS 700 SERIES ENGINE) . . . 4--68

800/810 MM337 (6--01)

Page
TROUBLESHOOTING . . . . . . . . . . . . . . . . 4--74
ENGINE RUN . . . . . . . . . . . . . . . . . . . . . 4--75
SHAKER . . 4--76
SHAKER FAILURE . . . . . . . . . . . . . 4--77
VAC FAN . . 4--80
VACUUM FAN FAILURE . . . . . . . . 4--81
MAIN BRUSH . . . . . . . . . . . . . . . . . . . . . 4--86
MAIN BRUSH FAILURE . . . . . . . . . 4--87
SIDE BRUSH . . . . . . . . . . . . . . . . . . . . . 4--89
SIDE BRUSH FAILURE . . . . . . . . . 4--90
HOPPER ROLL OUT . . . . . . . . . . . . . . 4--91
HOPPER ROLLOUT FAILURE . . . 4--92
HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . 4--93
HEADLIGHT FAILURE . . . . . . . . . . 4--94
WARNING LIGHT . . . . . . . . . . . . . . . . . 4--97
WARNING LIGHT FAILURE . . . . . 4--98
CLOGGED FILTER INDICATOR
CIRCUIT . . . . . . . . . . . . . . . . . . . . . 4--101
CLOGGED FILTER INDICATOR . 4--102
HOPPER DOOR CIRCUIT . . . . . . . . 4--103
HOPPER DOOR INDICATOR . . . 4--104
DOWN FORCE . . . . . . . . . . . . . . . . . . 4--105
DOWN FORCE CIRCUIT . . . . . . . 4--106
FUEL SENDER CIRCUIT
(GAS AND DIESEL MACHINES) 4--107
FUEL INDICATOR
(GAS AND DIESEL MACHINES) 4--108
COOLANT SENDER CIRCUIT . . . . . 4--109
COOLANT TEMPERATURE . . . . 4--110
LOW LP CIRCUIT
(L.P. MACHINES ONLY) . . . . . . . . 4--111
LOW L.P. CIRCUIT
(L.P. MACHINES ONLY) . . . . . . . . 4--112
ALTERNATOR FAULT . . . . . . . . . . . . 4--113
ALTERNATOR . . . . . . . . . . . . . . . . 4--114
HOURMETER CIRCUIT . . . . . . . . . . . 4--115
HOURMETER WON’T WORK . . 4--116
POWER UP CIRCUIT . . . . . . . . . . . . . 4--117
POWER UP TESTING . . . . . . . . . 4--118
800/810 RELAY AND CIRCUIT
BREAKER LOCATION . . . . . . . . . 4--121

4-- 1

ELECTRICAL

4-- 2

800/810 MM337 (8--97)

ELECTRICAL
ELECTRICAL SYSTEM
The machine electrical system consists of the
battery, alternator, and related components. This
section includes information on these components
and their troubleshooting.

BATTERY
The battery used in the machine is a low
maintenance battery. It has been constructed with
special materials and has extra electrolyte to
reduce or eliminate maintenance. Its design
reduces electrolyte loss and contamination. Do
not add water, remove the battery vent plugs, or
check the battery specific gravity. For specific
instructions, see the battery label.
Do not allow the battery to remain in discharged
condition for any time. Do not operate the
machine if the battery is in poor condition or
discharged beyond 80%, specific gravity below
1.120.
Periodically clean the top surface of the batteries
and the terminals, and check for loose
connections. Use a strong solution of baking soda
and water. Brush the solution sparingly over the
battery tops, terminals, and cable clamps. Do not
allow any baking soda solution to enter the
batteries. Use a wire brush to clean the terminal
posts and the cable connectors. After cleaning,
apply a coating of clear battery post protectant to
the terminals and the cable connectors. Keep the
tops of the batteries clean and dry.
Keep all metallic objects off the top of the
batteries, which may cause a short circuit.
Replace any worn or damaged wires.
The electrolyte level in regular non sealed
batteries can be checked. The level must always
be above the battery plates. Never add acid to the
batteries, only distilled water. Keep the battery
caps on the batteries always except when adding
water or taking hydrometer readings.
FOR SAFETY: When Servicing Machine, Avoid
Contact With Battery Acid.

800/810 MM337 (8--97)

4-- 3

ELECTRICAL
Using a hydrometer to measure the specific
gravity is a way to determine the charge level and
condition of the batteries. If one or more of the
battery cells test lower than the other battery cells
(0.050 or more), the cell is damaged, shorted, or
is about to fail.
NOTE: Do not take readings immediately after
adding distilled water. If the water and acid are not
thoroughly mixed, the readings may not be
accurate. Check the hydrometer readings against
the following chart to determine the remaining
battery charge level:
04380

SPECIFIC GRAVITY
at 27_ C (80_ F)
1.260 -- 1.280
1.230 -- 1.250
1.200 -- 1.220
1.170 -- 1.190
1.110 -- 1.160

BATTERY
CHARGE
100% Charged
75% Charged
50% Charged
25% Charged
Discharged

NOTE: If the readings are taken when the battery
electrolyte is any temperature other than 27_ C
(80_ F), the reading must be temperature
corrected. Add or subtract to the specific gravity
reading 0.004, 4 points, for each 6_ C
(10_ F)above or below 27_ C (80_ F).
TO REPLACE BATTERY ON LPG MACHINE
AND GAS/DIESEL Serial # 002075 and up
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Lift the engine cover and open the side door.
2. Disconnect the negative then the positive
battery cables.
3. Remove the small battery hold down bracket
from machine.
4. Tilt the battery towards you and lift it up and
out.
5. Clean the old cables and the posts on the
new battery.
6. Lift the new battery up and onto the battery
tray.
7. Reinstall the small battery hold down
bracket.
8. Reconnect the positive then the negative
battery cables.
4-- 4

800/810 MM337 (8--97)

ELECTRICAL
TO REPLACE BATTERY ON GAS / DIESEL
MACHINE Serial # 002074 and down
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Open the battery access door located at the
right rear of the machine.
2. Disconnect the negative then the positive
battery cables.
3. Remove the battery hold down bracket from
the machine.
4. Slide the battery towards you and lift it out.
5. Clean the old cables and the posts on the
new battery.
6. Lift the new battery up and slide it into the
battery tray.
7. Reinstall the battery hold down bracket.
8. Reconnect the positive then the negative
battery cables.
9. Close the battery access door.

800/810 MM337 (8--97)

4-- 5

ELECTRICAL
INSTRUMENT PANEL
The instrument panel consists of a circuit board, a
touch panel, and a water/dust resistant plastic
enclosure. The touch panel controls various
machine functions, while its indicator lights keep
the operator informed on machine performance.
TO REPLACE INSTRUMENT PANEL
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Remove the battery cables from the battery.
2. Remove the three plastic knobs from the
valve handles.
3. Place the steering wheel in lowest position.
4. Remove the eight M6 pan head screws from
the dash panel.
5. Pull the dash panel towards you until it
clears the valve handles.
6. Loosen the allen head screw in center of
instrument panel wire harness plug. Unplug
the harness from the panel.

08475

7. Remove the four M5 hex screws holding the
instrument panel to the dash panel. Remove
the instrument panel from the machine and
repair or replace it.
8. Position the new instrument panel back on
the dash panel. Reinstall the four M5 hex
screws and washers. Lightly hand tighten
this hardware.
9. Push the main harness plug back into the
instrument panel receptacle.

08475

NOTE:The slot in the instrument panel receptacle
must line up with the notch on main harness plug.
Lightly hand tighten the allen head screw.
10. Reinstall the dash panel on the machine
using the eight M6 pan head screws.
Tighten to 8 -- 10 Nm (5 -- 6 ft lb).
11. Reinstall the three plastic knobs on valve
handles. Hand tighten.
12. Reconnect the battery cables.
13. Start the machine and check for proper
operation of the instrument panel.
4-- 6

800/810 MM337 (8--97)

ELECTRICAL
TO DISASSEMBLE INSTRUMENT PANEL
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Remove the instrument panel from the
machine. See TO REPLACE INSTRUMENT
PANEL instructions in this section.
2. Place the instrument panel face down and
remove the twelve larger pan head screws.
3. The touch panel case can now be separated
from outer case and new o-ring gasket
installed if necessary.
4. To disassemble the touch panel case further,
remove the four smaller pan head screws
from the center of case box.
5. Remove the case box from the circuit board
touch panel assembly.
6. The o-ring and connector gaskets can now
be replaced in the case box if necessary.
7. Remove the eight smaller pan head screws,
unplug the flat connector and ground strap.
Remove the touch panel from the circuit
board.
8. Any burned-out lamps can now be changed
by turning them 1/4 turn counterclockwise
and lifting them straight out.
9. To replace the hour meter, unplug the two
wires and remove the two pan head screws.

800/810 MM337 (8--97)

4-- 7

ELECTRICAL
TO REASSEMBLE INSTRUMENT PANEL
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Position the circuit board over the touch
panel.
2. Feed the flat connector from the panel
through the slot in the board. Plug the
connector in and reconnect the ground
strap.
3. Reinstall the eight smaller pan head screws
and lightly hand tighten.
4. Turn the circuit board assembly over and
place it back in the case box.
5. Reinstall the four smaller pan head screws
in the center of the case box.
6. Reinstall the touch panel case onto the outer
case.
7. Reinstall the twelve pan head screws and
lightly hand tighten.
8. The instrument panel is now ready to be
reinstalled in machine. See TO REPLACE
INSTRUMENT PANEL instructions in this
section.

4-- 8

800/810 MM337 (8--97)

ELECTRICAL
TO REPLACE MACHINE RELAY
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Make sure the hopper has been emptied of
all debris.
2. Set the parking brake, Raise the hopper and
engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
3. Remove the battery cables from the battery.
4. Go in machine under the hopper by the dust
shield. Lift the dust shield and prop it out of
the way.
5. Remove the four M6 nyloc nuts and washers
holding the plastic relay cover in place. Pull
the cover back far enough to allow access to
the relays.
6. Locate the relay that needs replacing.
Un--plug the main electrical harness from
that relay.
7. Remove the M6 nyloc nut holding the relay
to the relay plate. Remove and discard the
relay.
8. Position the new relay on the threaded stud
on the relay plate. Reinstall the M6 nyloc nut
and hand tighten.
9. Plug the main harness into the new relay.
See electrical schematic in this section.
10. Reinstall the plastic relay cover. Hand
tighten the four M6 nuts and washers.
11. Drop the dust shield back in place.
12. Reconnect the battery cables.
13. Disengage the prop arm, lower the hopper
and operate the machine. Check the new
relay for proper operation.

800/810 MM337 (8--97)

4-- 9

ELECTRICAL
TO REPLACE MACHINE CIRCUIT BREAKER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Remove the battery cables from the battery.
2. Go in the machine operators compartment
and locate the removable circuit breaker
plate.
3. Remove the six M6 screws holding the
removable circuit breaker panel to the
machine. Pull the panel back far enough to
allow access to the wires on the circuit
breakers.
4. Locate the circuit breaker that needs to be
replaced. Remove the wires leading to that
circuit breaker.
5. The round, metal lock ring, that is holding
the circuit breaker to the panel, must be
removed.
NOTE: A new lock ring is provided with the new
circuit breaker in case the old one is damaged
during the removal procedure.
6. Pull the old circuit breaker out of the hole
and discard it. Retain the clear rubber boot.
NOTE: Re--use the clear rubber boot on the new
circuit breaker.
7. Position the new circuit breaker in the panel.
NOTE: The circuit breaker is ”D” shaped and will
only go in the hole one way.
8. Install the lock ring on the new circuit
breaker. Push it down all the way to the
panel.
9. Reconnect the wires to the new circuit
breaker. See electrical schematic in this
section.
10. Reinstall the circuit breaker plate to the
machine. Tighten the six M6 screws to
8 -- 10 Nm (5 -- 6 ft lb).
11. Reconnect the battery cables and start the
machine, checking for proper circuit breaker
operation.

4-- 10

800/810 MM337 (8--97)

ELECTRICAL
TO REPLACE GOVERNOR CONTROL BOX
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Make sure the hopper has been emptied of
all debris.
2. Set the parking brake, Raise the hopper and
engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
3. Remove the battery cables from the battery.
4. Go in machine under the hopper by the dust
shield. Lift the dust shield and prop it out of
the way.
5. Remove the four M6 nyloc nuts and washers
holding the plastic relay cover in place. Pull
the cover back far enough to allow access to
the governor control box.
6. Unplug the governor control box from the
main electrical harness.
7. Remove the hex screws holding the
governor control box to the plastic relay
panel. Remove the governor control box
from the machine.
8. Position the new governor control box on the
plastic relay panel. Hand tighten the hex
screws.
9. Plug the new governor control box into the
main harness. See electrical schematic in
this section.
10. Reinstall the plastic relay cover. Hand
tighten the four M6 nuts and washers.
11. Drop the dust shield back in place.
12. Reconnect the battery cables.
13. Disengage the prop arm, lower the hopper
and operate the machine. Check the new
governor control box for proper operation.

800/810 MM337 (8--97)

4-- 11

4-- 12

19

17

50

IGNITION
SWITCH

ACC

30

BATT.

1H/RED

1A/RED

1E/RED

1G/RED

1D/RED

1C/RED

1/RED

S--10

IGN.

20/BLU

NOT USED

90/ORA

START

10/GRY

2.5A

CB--3

15A

CB--2

15A

CB--1

M1

OUT

15A

B

87

30

L2

18/ORA

D

85

M3

23/GRY

10C/GRY

18C/ORA

2/ORA

GND ALTERNATOR

M3

S--3

C

86

MTR

L.H. SHAKER

MTR

R.H. SHAKER

TO EIP

E

6/GRN

NEUTRAL START
SWITCH OPTION
12/BRN
12A/BRN

12/BRN

M1

M1

13DDD/BLK

55A MAX.
CHARGE

13A/BLK

13X/BLK

HORN

13/BLK
12V
540 C.C.A.

STARTER RELAY COIL

STARTER RELAY COIL

13EEE/BLK

13III/BLK

HORN BUTTON
PB--1
5/PUR

STARTER MOTOR

SWITCHED POWER
TO EIP

30B/GRY

UNSWITCHED POWER

87

30A/GRY

MTR

30/GRY

30

3/BLU

M4

TO EIP

CB--4

SENSE

TO IGNITION
COIL

A

1B/RED

22/YEL

11/PUR

4/YEL

STARTER RELAY

BATTERY

ELECTRICAL
Electrical Schematic 800--810 G/LPG (LSG ENGINE)

1

2

3

4

800/810 MM337 (6--01)

800/810 MM337 (NIL)

ACC
LINE

A

90/ORA

SWITCH

IGNITION

FROM

RED/BLU

10A/GRY

NOT
USED

3
18D/ORA

BATT.

IGN.
COIL

18B/ORA

18J/ORA

IGN.

YEL.

GRN

ST.

DEC.
BOX

CONTROL

GOVERNOR

ELECTRONIC

DEC.

RESISTOR
WIRE
RED/GRN

RED

WHT

A

GRD.

+

M2

B

72/GRY

--

85

86

D

F

G

84/GRN

86/PUR

83/BRN

E

BLK/GRN

PUR

ORA

MODULE

IGN.

FORD

THROTTLE
ACTUATOR

DIST.

85/BLU

G

H

--

+

GROUND
LINE

SEPARATE

13E/BLK

CAB
OPTION

13EE/BLK

1

TO ELECTRONIC
F
INSTRUMENT PANEL

C

72A/GRY

18H/ORA

72B/GRY

4

20A/BLU

ELECTRICAL

Electrical Schematic 800--810 G/LPG (LSG ENGINE)

2

4-- 13

4-- 14
25/
BRN

2/ORA

23E/GRY

5

4

3

PANEL

24

2

15

22

23

12

ELECTRONIC
7
INSTRUMENT

18 13

85/
BLU

FILTER
INDICATOR
LIGHT

20

HEADLIGHT RELAY
85
86 60/GRN
23G/GRY
M6

23F/GRY

19

23D/GRY

23C/GRY

WARNING LIGHT
85
86 75/BRN
M7

6

21

1

11

14

17

83/
BRN

16

24A/PUR

HOPPER
THERMAL SW. FAN RELAY
S--2
86
24/PUR 85
M5

6/GRN

E

FROM
IGNITION
SWITCH

D

FROM
ALTERNATOR

SHAKER RELAY
85
86 29/GRN
M4

23B/GRY

23A/GRY

23/GRY

C

SWITCHED POWER

F

39/GRY

38/PUR

G

N.C.
S--4
13FFF/BLK

13DDD/BLK

HOPPER DIFFERENTIAL
PRESSURE SWITCH

COOLANT TEMP SE--2
SENDER

FUEL SENDER SE--1

13U/BLK

16/GRN

15/BLU

(L.P. ONLY)
13R/BLK

44/GRY

115/ORA

N.C.

N.O. S--6

N. O.

FILTER
S--21 INDICATOR
SWITCH

C

OIL
PRESSURE
SWITCH

LOW L.P. FUEL

CHASSIS
GROUND

S--5
N.C.H.O.

GROUND
LINE

13X/BLK

13B/BLK

13S/BLK

13T/BLK

13M/BLK

HYDRAULIC
FLUID
FILTER

L.P. GND.

SEPARATE

PRESSURE
SETTING
CLOSES AT
20” H O
2

CLOSES AT
225 F

13HH/BLK FULL=90
EMPTY=0

C
N.O.
HOPPER DOOR SWITCH
13CCC/BLK13BBB/BLK13AAA/BLK
39A/GRY
13BB/BLK
S--13
M. BRUSH HYD.
40/YEL
PRESSURE SWITCH 13MMM/BLK
S--14

38A/PUR

43/BLU

42/ORA

FROM ELECTRONIC
GOVERNOR CONTROL

ELECTRICAL
Electrical Schematic 800--810 G/LPG (LSG ENGINE)

1

800/810 MM337 (6--01)

800/810 MM337 (6--01)

15 AMP

CB--5

S--18

S--16

30

M6
62/YEL

93/ORA

76/ORA

96/ORA

GRY/
BLK

80/BLU

79/
YEL

YEL

BLU

RED
GRN
BLK
GRY

93B/ORA

93A/ORA

89A/BRN

88/GRN
91A/GRY

87/PUR

62C/YEL

62A/YEL

A/C CLUTCH

13AA/BLK

89/BRN

62D/YEL

91/GRY

62E/YEL

RUN LHT L.H.

13JJ/
TAIL LHT L.H. BLK

TAIL LHT R.H.

13II/
BLK

13AAA/BLK
CURB
LIGHT
62H/YEL

13BBB/BLK

R.H.
HEADLIGHT
62F/YEL
L.H.
HEADLIGHT
62G/YEL

RUN LHT R.H.

13TT/BLK

13NNN/BLK

13SS/BLK

13DD/BLK

GROUND
LINE

13KK/BLK 13L/BLK

13FF/BLK

13GG/BLK

13BB/BLK

13NN/BLK

BACK--UP
LIGHT 13QQ/BLK

BACK--UP ALARM UNIT

FLASHING
LIGHT

ROTATING
LIGHT

DOME LIGHT

WINDSHIELD
WIPER MTR

CAB
ENVIRONMENTAL
FAN CONTROL

MTR

MTR

FLASHER
94/YEL

76B/ORA

76A/ORA

SP3

SP2

OFF SP1

FAN SW

S--15

62B/YEL

S--9

S--17

96A/ORA

96B/ORA

DIRECTIONAL
SWITCH

77/GRY

87

YEL
BRN
”L”
”X”
FLASHER
BLU
”P”

74G/PUR

M7 87

FOOT
SWITCH

30

30 M2 87

BRAKE
SWITCH

74F/PUR

74D/PUR

74B/PUR

74A/PUR

74/PUR

9/ORA

THERMO
SWITCH

S--11

SEPARATE

HEADLIGHT
OPTION

BACK--UP
LIGHT
OPTION

SEPARATE

WARNING
LIGHT
OPTION

CAB
OPTION

AIR
CONDITIONER
OPTION

1

1F/RED

CB--8
1G/RED
30 AMP

B UNSWITCHED POWER

OFF
ON

ELECTRICAL

Electrical Schematic 800--810 G/LPG (LSG ENGINE)

4-- 15

4-- 16

20A/BLU

ACC
LINE

15 AMP

CB--6

21D/ORA

21C/ORA

21B/ORA

21A/ORA

21/ORA
M8

S--1

87

86

MAIN/FRONT
BRUSH

30

85

C

28B/BRN

27/YEL

37/YEL

B

A

7/PUR

28/BRN

28A/BRN

30

85

85

M9

M10

30

30

87

86

86

87

87

M5

31A/GRY

31B/GRY

19/GRY

19C/GRY

810 ONLY

31/GRY

32/GRN

N. O.

S--12
VAC FAN
SHUT OFF

LITTER
BRUSH
SV--2

MOV

MOV

13Y/BLK

13G/BLK

13C/BLK

13F/BLK

13W/BLK

MAIN
BRUSH
SV--1 13ZZ/BLK

FR. BRUSH
LIFT
SV--5

MOV

MOV

FAN
SV--6

13V/BLK

GROUND
LINE

ELECTRICAL
Electrical Schematic 800--810 G/LPG (LSG ENGINE)

1

2

3

800/810 MM337 (6--01)

800/810 MM337 (6--01)

20B/BLU

POWER RELAY

MOTOR

CIRCUIT BREAKER

PERMANENT MAGNET

JACK--FEM. SOCKET

PLUG--MALE PIN

PUSHBUTTON

VOLTMETER

FUSE

MTR

CB

PM

J

P

PB

VM

FU

21R/ORA

M

15 AMP

CB--7

NOV

N.C.

N.O.

C

GND

ACC

S

SV

HM

LEGEND

METAL OXIDE VARISTOR

NORMALLY CLOSED

NORMALLY OPEN

COMMON

GROUND CHASSIS

ACCESSORY

SWITCH

SOLENOID VALVE

HOURMETER

33D/GRN

33C/GRN

30

86
M11

87

85

26/PUR

35/YEL

33/GRN

26A/PUR

26B/PUR

33B/GRN

33A/GRN

R.H. SIDE BRUSH

2

NC

S--7

19A/GRY

NC

MOV

MOV

C

13KKK/BLK

L.H. SIDE
BRUSH LIFT
SV--10

L.H. SIDE
BRUSH
SV--8
13P/BLK

13VV/BLK

R.H. SIDE
BRUSH LIFT
SV--9
13I/BLK

R.H. SIDE
BRUSH
SV--3
13N/BLK

S--8
L.H. SIDE BRUSH

MOV

MOV

MOV

1

C

19B/GRY

M. BRUSH
LIFT
SV--4
13D/BLK

ELECTRICAL

Electrical Schematic 800--810 G/LPG (LSG ENGINE)

3

4-- 17

4-- 18

START

BATT.

74B/PUR

UNSWITCHED
POWER

23C/GRY

SWITCHED
POWER

IGN.

ACC 20/BLU

19

17

50

IGNITION
SWITCH
S--10

30

M6

STD.
SHAKER
RELAY
85
86
M4

30

18Q/ORA

87

29/GRN

TO RFS
CIRCUITRY
BOX

H

18P/ORA

20A/BLU

15A

CB--4

5
3

15

19

62/YEL

20

85

62A/YEL

62B/YEL

24

2

22

16

6

(RFS OPTION) 12
FOR STANDARD
23
EIP WIRING

ELECTRONIC 4
INSTRUMENT
7
PANEL

18 13

18H/ORA

18C/ORA

21

1

11

14

17

18/ORA

86
6/GRN
E

38B/PUR

TO EIP

J

TO RFS
CIRCUITRY
BOX

CURB LIGHT
13AM/BLK

13AP/BLK
R.H. SHAKER
MOTOR OVERRIDE

62H/YEL

L.H. HEADLIGHT

13AN/BLK

R.H. HEADLIGHT
62G/YEL

62F/YEL

HOPPER DIFFERENTIAL
PRESSURE SWITCH #1
N.C. S--4
38/PUR
38A/PUR
13AC/BLK 13AB/BLK
C
N.O.
HOPPER DOOR SWITCH
13AQ/BLK
39/GRY 39A/GRY
S--13

M3

K

K

13AQ/BLK

13BB/BLK

13X/BLK

GROUND
LINE

PRESSURE
SETTING
CLOSES AT
20”
2 HO

ELECTRICAL
Electrical Schematic 800--810 G/LPG (LSG ENGINE)

800/810 MM337 (6--01)

800/810 MM337 (6--01)

RFS OPTION

15A

11/PUR
87

11B/PUR

11C/PUR

11F/PUR

11E/PUR

11G/PUR

MTR

LH SHAKER
MOTOR

MTR

RH SHAKER
MOTOR

LH SHAKER
RFS CONTROL
85
86
M20

30/GRY

102/GRY

YEL
J2--F

BLU
J2--E

30

M20
87

M19
87
30
101B/ORA

M17
87

J1--E

J1--D

J2--H

BLK

M18
87

30

RFS
CIRCUITRY
BOX

POSITIVE
HERE = CLOSE

30

102B/GRY

86
13AJ/BLK

13AG/BLK SEPARATE

LH SHAKER
RFS CONTROL

RH SHAKER
RFS CONTROL

LH SHAKER
MOTOR OVERRIDE

RH SHAKER
MOTOR OVERRIDE

NOT
USED

NOT
USED

P2--H

13AS/BLK

13AR/BLK

SHAKER
MOTORS
VOLT 13.6
HP .04
13AK/BLK AMP 4.5

13AH/BLK

13AF/BLK

HOPPER DIFFERENTIAL
PRESSURE SWITCH #2
PRESSURE
PUR 38C/PUR N.C. S--22 13AD/BLK SETTING
CLOSES AT
C
J1--B P1--B
N.O.
6.5” H O
2
13AE/BLK
GRN
J1--F P1--F
FROM HOPPER
VANE
MOTORS
DIFFERENTIAL
MAX. 3.0
PRESSURE
AMPS
SWITCH #1
TAN NOT
USED
J1--C
38B/PUR
J

102A/GRY

101A/ORA

P2--C J2--C

108/GRN GRY

P2--B J2--B

107/BRN WHT

RED
P2--A J2--A

18Q/ORA ORA
P1--A J1--A

106/BRN BRN
P2--G J2--G

104/BLU
P2--E
RH VANE
ACTUATOR MOTOR
105/YEL
MTR
P2--F

M17

L.H. SHAKER
MOTOR OVERRIDE
85
86 13AL/BLK
M18

85

POSITIVE
HERE = CLOSE

30C/GRY

30A/GRY 30B/GRY

LH VANE
ACTUATOR MOTOR
103/GRN PNK
MTR
P2--D J2--D

30

101/ORA

M4

RH SHAKER
RFS CONTROL
85
86
M19

H

FROM CB--4
CONTROL
POWER -- FROM
KEY SWITCH

UNSWITCHED
POWER
CB--2
1D/RED
11B/PUR 11A/PUR

ELECTRICAL

Electrical Schematic 800--810 G/LPG (LSG ENGINE)

09918

4-- 19

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

1
43/BLU

115/ORA
HYD.
FILTER
INDICATOR
SWITCH
(OPTION)

WATER
TEMPERATURE
SENDER
44/GRY
13M/BLK

AB

93/ORA
74A/PUR

TO
ENGINE
13/BLK

L.P.
SWITCH

10/GRY
NEUTRAL
START
OPTION

ABC

F

BATTERY
LOCATION

12/BRN

10A/GRY
18B/ORA

F D

D

AB

12/YEL
1H/RED
1G/RED
1D/RED
1A/RED

AB

STARTER
1/RED
TO
BATTERY
TAIL LIGHT/ACC. HARNESS

ALTERNATOR

OIL
PRESSURE
SWITCH

AB

BA

13II/BLK

13A/BLK
G

COIL

REV.
SWITCH
(OPTION)

89/BRN
62D/YEL

G

ABC

RED
BLACK

16/GRN
13B/BLK
15/BLU

72/GRY
90/ORA

IGNITION
MODULE

SEE
OPTIONS
BA

E

CBA

E C

B

B

33/GRN
19B/GRY

2

R.H. SIDE
BRUSH SWITCH

C

FUEL HARNESS

SEE
OPTIONS

BA

TO
STARTER
1/RED

13JJ/BLK
RED
91/GRY
62E/YEL
BLACK
13VVV/BLK
42A/ORA
FUEL
SENDER

MAIN/FRONT
BRUSH
SWITCH

FUEL PUMP

SOCKET
NO.

WIRE
NO.

COLOR

1
2
3

23A
16
38

4
5
6

39
43
24A

4-- 20

SOCKET
NO.

WIRE
NO.

COLOR

GRY
GRN
PUR

7
8
9

40
PLUG
PLUG

YEL

GRY
BLU
PUR

10
11
12

PLUG
6
44

GRN
GRY

SOCKET
NO.

WIRE
NO.

COLOR

13
14
15

42
2
15

ORA
ORA
BLU

16
17
18

29
83
85

GRN
BRN
BLU

SOCKET
NO.

WIRE
NO.

COLOR

19
20
21

75
60
25

BRN
GRN
BRN

22
23
24

13R
13T
13U

BLK
BLK
BLK

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

VAC FAN
SHUT OFF
SWITCH

B

27/YEL
13V/BLK

84/GRN

B

1

86/PUR
L.H. HEADLIGHT
5/PUR

62G/YEL
62H/YEL
13AAA/BLK

HORN

ACTUATOR
SOLENOID
BLOCK

24A/PUR
24/PUR
23B/GRY

13JJJ/BLK
13HHH/BLK
13UU/BLK
13RRR/BLK
13Z/BLK
13T/BLK
13S/BLK
13E/BLK
ENGINE
GROUND
HYD.
115/ORA
FILTER
23F/GRY
LIGHT
INDICATOR
(OPTION)

THERMO
SWITCH
CIRCUIT
BREAKERS
AND
RELAYS

HOPPER HARNESS

AB

AB

B

B

SEE CHART
A
13S/BLK

BA

BA

L.H.
SHAKER
MOTOR
38/PUR 30/ORA A B
B A

30A/ORA
30B/ORA
13III/BLK

AB

R.H.
SIDE BRUSH
LIFT
SV--9

62B/YEL
13BB/BLK
CD
13X/BLK
39/GRY
VIEW A--A
R.H.
SHAKER
MOTOR

A
62F/YEL
62G/YEL

LP
MAIN HARNESS
CONNECTOR

13BBB/BLK
13CC/BLK

38A/PUR
13FFF/BLK

HOPPER
DIFF.
SWITCH

H

62F/YEL
BA
13AAA/BLK
38A/PUR 30A/ORA
VIEW B--B

BA
13I/BLK
33B/GRN

4/YEL
5/PUR

13R/BLK

39A/GRY 13DDD/BLKA B
CD

30B/ORA
13EEE/BLK

GOVERNOR

2

HORN
SWITCH

13BBB/BLK

ABC
62A/YEL 13L/BLK
76/ORA
ABC
62C/YEL 13KK/BLK
76A/ORA
VIEW E--E

800/810 MM337 (6--01)

HOPPER
DOOR
SWITCH
(OPTION)

ABC

CBA
VIEW F--F

7/PUR
37/YEL
28/BRN

TO
MAIN
HARNESS

BA

H

AB

R.H. HEADLIGHT
13CCC/BLK
39A/GRY

AB
1H/RED
20/BLU
20A/BLU

17
AC
30
50 19

10/GRY
10A/GRY
90/ORA

VIEW H--H
KEY SWITCH

42/ORA
13HH/BLK
VIEW D--D
AB
42A/ORA
13VVV/BLK
VIEW C--C

4-- 21

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)
RELAYS

L.H.
SIDE BRUSH
HARNESS
(OPTION)

M3 ELECTRONIC
INSTRUMENT PANEL
M4 SHAKER MOTOR
M5 VAC FAN SOLENOID
M6 HEADLIGHTS
M7 ROTATING/FLASHING
LIGHTS
M8 HOPPER LIFT
M9 FRONT BRUSH
M10 MAIN BRUSH

M6

M3

M4

M5

I

I
AIR
CONDITIONER -PRESSURIZER
HARNESS
(OPTION)

M7

M8

M9

M10
18J/ORA

J

33D/GRN

J

18H/ORA
33C/GRN

M3

M4

M5

MAIN
HARNESS

23/GRY
30/ORA
28A/BRN
6/GRN
29/GRN
25/BRN

18C/ORA
23C/GRY
24/PUR
22/YEL
11/PUR
32/GRN
M6

M7

M8

30
M9

86

M10

74B/PUR
74/PUR
21A/ORA
21B/ORA 21C/ORA
13Y/BLK
75/BRN
27/YEL
13G/BLK
60/GRN

85

87A
87
85 COIL+
86 COIL -30 COMMON CONTACT
87 N.O. CONTACT
87A N.C. CONTACT

37/YEL
23G/GRY
23D/GRY
21/ORA
7/PUR
62/YEL
76/ORA
28B/BRN
31/GRY

19/GRY

SECTION I--I

VIEW J--J

4-- 22

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

CB--8
(OPTION)

CB--7
(OPTION)

1G/RED

DIRECTIONAL
HARNESS
(OPTION)

CB--6

20B/BLU
20A/BLU

CB--5

21D/ORA
CB--3
2.5 A

1E/RED

1E/RED
1F/RED

CB--4

74/PUR
74E/PUR
CB--2

18/ORA
74F/PUR

1D/RED
1C/RED

CB--1

11/PUR

22/YEL

20/BLU

1C/RED
4/YEL

74D/PUR

MAIN
HARNESS
CIRCUIT
BREAKERS
CB--1 HORN
CB--2 SHAKER MOTOR
CB--3 VAC FAN RELAY, SHAKER RELAY, WARNING
LIGHT & HEADLIGHT
CB--4 ELECTRONIC INSTRUMENT PANEL
CB--5 ROTATING LIGHT & BACK--UP ALARM
CB--6 HOPPER LIFT RELAY, FRONT/MAIN BRUSH
CB--7 LEFT HAND SIDE BRUSH
CB--8 CAB ACCESSORIES

800/810 MM337 (6--01)

4-- 23

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

10C/GRY
12B/BRN

REV/FLSH
LIGHT (ONLY)
OHG/CAB

NEUTRAL
START
HARNESS

10C/GRY
12B/BRN

10/GRY
12/BRN

TO MAIN
HARNESS

76C/ORA
13PPP/BLK
HYD.
PUMP

RED

89/BRN

AB

13PPP/BLK
76C/ORA

BA

REV/FLSH
LIGHT
HARNESS

13NNN/BLK
76A/ORA
TO TAIL LIGHT
HARNESS

REV/FLSH
LIGHT

TURN SIGNAL
HARNESS

13PPP/BLK
76C/ORA

1

FLASHER

B

B

R

P
X L

93A/ORA
93B/ORA
94/YEL

R

LIGHT

94/YEL
13QQ/BLK
13NN/BLK
Q

BA

BA

Q

BACKUP HORN

TAIL LIGHT/ACC. HARNESS

93B/ORA
13NN/BLK

RED
BLK

TO MAIN
HARNESS

N

P

RED
BA
P

AB

N

AB

93B/ORA
13NN/BLK

13NNN/BLK
76A/ORA
VIEW R--R

AB

AB
91A/GRY
89A/BRN

93/ORA
VIEW N--N

AB

AB

93A/ORA
13QQ/BLK

13PPP/BLK
76C/ORA

VIEW Q--Q

4-- 24

AB

91/GRY

91/GRY

93B/ORA

89/BRN

VIEW P--P

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)
88/GRN
88A/GRN
13WWW/BLK
13TTT/BLK

TURN LIGHTS
LEFT HAND
S.E. OPTION

TURN LIGHTS
LEFT HAND
88A/GRN
13TTT/BLK
13ZZZ/BLK

62G/YEL
13AAA/BLK

1

TURN SIGNAL HARNESS

13BBB/BLK
FLASHER
80/BLU
79/YEL
74G/ORA

P
X

L

L.H.
HEADLIGHT
REF. ONLY

TO MAIN
HARNESS
13YYY/BLK
13YYY/BLK
13ZZZ/BLK

L

L

M

M
TO MAIN
HARNESS
TURN LIGHTS
RIGHT HAND
77/GRY
74F/PUR
74G/PUR

87A/PUR
HOPPER HARNESS

BRAKE
SWITCH

13SSS/BLK
13WWW/BLK

62H/YEL
13AA/BLK
SIDE BRUSH
LIGHT

88/GRN
79/YEL 87/PUR
14 7
2 8
36 9

800/810 MM337 (6--01)

13SSS/BLK

BLU
GRY/BLK
GRY
3 69

91A/GRY

89A/BRN
77/GRY
80/BLU
VIEW L--L

87A/PUR
87/PUR

TURN LIGHTS
RIGHT HAND
S.E. OPTION

BLK

14 7
YEL
GRN

RED

VIEW M--M

4-- 25

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

COMPRESSOR

CLUTCH

BLUE
BLOWER
SWITCH
B C
L
N
M
HEATER FAN,
PRESSURIZER AND
A/C FAN

RED/GRY

ORANGE
RED
YELLOW

ORANGE

M2

30
85 87A 86
87

18J/ORA
96/ORA

M11

BLOWER
MOTOR

1

21R/ORA
33D/GRN

9/ORA
13EE/BLK

PRESSURE
SWITCH

30
85 87A 86
87

BLACK
BLUE
THERMOSTAT

2

BLACK

35/YEL
26/PUR

WHITE
WHITE

WIPERS
SWITCH

WHITE
BLACK
DOME
LIGHT

4-- 26

WIPER
MOTOR

RED
BLACK

BLACK

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

13P/BLK
13VV/BLK
ENGINE
GROUND
BA

AB

26B/PUR
13P/BLK

1G/RED

TO
MAIN
HARNESS

13DD/BLK
96B/ORA
A/C HARNESS

96A/ORA
13SS/BLK
9/ORA

CB--8
30 AMP

CB--7

21R/ORA

LH SIDE
BRUSH SWITCH
TO
MAIN
HARNESS
35/YEL

GROUND

13VV/BLK
13KKK/BLK

TO
MAIN
HARNESS

18H/ORA

18J/ORA

LH SIDE BRUSH HARNESS

WHITE
BLACK

BA

2

AB

BLACK
RED/GRY

BA

1

AB

L.H.
SIDE BRUSH
LIFT
SV--10

13Q/BLK

M11

33C/GRN

33D/GRN

AB

BA

M12
26A/PUR
13KKK/BLK

LH SIDE
BRUSH
SV--8

800/810 MM337 (6--01)

4-- 27

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

18P/ORA

18/ORA

18Q/ORA
CB--4

20/BLU

1
11A/PUR

11/PUR

11B/PUR
CB--2

1C/RED
1D/RED

MAIN HARNESS

AB

A

AB

B

BA

BA

B

A

RFS OPTION

2

HARNESS ROUTING

108
103

4-- 28

105
104

P--2

38C

F E D

106

13AE

18Q
A B C

107

H G F E

13AF

A B C D

11G

NOT
USED
NOT
USED

NOT
USED
P--1

M20

102B/GRY
108/GRN

101B/ORA
107/BRN

30
85 87A 86

30
85 87A 86

M19

M18

87

87

11F/PUR
13AS/BLK

11E/PUR
13AR/BLK

102A/GRY
13AL/BLK
30
85 87A 86 M17
87
30C/GRY
13AK/BLK

101A/ORA
13AJ/BLK
30
85 87A 86
87
30B/GRY
13AH/BLK

VIEW C--C
800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

L.H. HEADLIGHT
GRN
WHT

104/BLU
103/GRN

62H/YEL

L.H.
VANE
MOTOR

11B/PUR
11C/PUR
102/GRY

RFS
CIRCUITRY
BOX
C

1

P--2

J--2

P--1

J--1

13AP/BLK
13AQ/BLK

L.H.
SHAKER
MOTOR

11C/PUR
11D/PUR
101/ORA

M--20
M--19

R.H.
SHAKER
MOTOR

M--18
M--17
C

106/BRN
105/YEL

13AD/BLK
13AE/BLK
38B/PUR
38C/PUR

GRN
WHT

R.H.
VANE
MOTOR

HOPPER
DIFF.
SWITCH--2

2

62G/YEL
62H/YEL
13AN/BLK

62F/YEL
62G/YEL

13AC/BLK
13AD/BLK

13AM/BLK

BA
HOPPER
DOOR
SWITCH
(OPTION)
39A/GRY 13AM/BLK
C D

800/810 MM337 (6--01)

R.H. HEADLIGHT

13AN/BLK

13AQ/BLK
39A/GRY

AB

62F/YEL
13AB/BLK
B A
30A/GRY
38A/PUR
VIEW B--B

13AP/BLK

38A/PUR
38B/PUR

AB

HOPPER
DIFF.
SWITCH--1

SIDE BRUSH
LIGHT

38/PUR
30/GRY
B A

39/GRY

C D

AB

62B/YEL
13X/BLK

13BB/BLK

VIEW A--A

4-- 29

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

4-- 30

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LSG ENGINE)

800/810 MM337 (6--01)

4-- 31

4-- 32

2.5A

CB--3

15A

CB--2

15A

CB--1

M1

1B/RED

X

X

X

X

X

X
START
17/ORA

17

IGN.

N/U
RUN/
ACC 20/BLU

19

10/GRY

SENSE

OUT

50

IGNITION SWITCHS--10
( X INDICATES A CLOSED CONTACT )

30

22/YEL

11/PUR

4/YEL

STARTER RELAY

OFF
PREHEAT
RUN START

BATT.

1H/RED

1A/RED

1E/RED

1G/RED

1D/RED

1C/RED

1/RED

30

30/GRY

M3
30

10C/GRY

C

S--3

MTR

L.H. SHAKER

MTR

R.H. SHAKER

12A/BRN

12/BRN

12/BRN

M1

M1

13DDD/BLK

55A MAX.
CHARGE

13A/BLK

13X/BLK

HORN

12V
540 C.C.A.

13/BLK

STARTER RELAY COIL

STARTER RELAY COIL

13EEE/BLK

13III/BLK

HORN BUTTON
PB--1
5/PUR

STARTER MOTOR

SWITCHED POWER
TO EIP

30B/GRY

30A/GRY

MTR

NEUTRAL START
SWITCH OPTION

TO EIP

D

23/GRY

2/ORA

GND ALTERNATOR

87

UNSWITCHED POWER

M4

ALTERNATOR
LIGHT 2

B

87

3/BLU

BATTERY

ELECTRICAL
Electrical Schematic 800--810 G/LPG (LRG ENGINE)

1

2

3

800/810 MM337 (6--01)

3

800/810 MM337 (6--01)
CRANK
POSITION
SENSOR

ELECTRONIC
COOLANT
TEMPERATURE
SENSOR

ACC
LINE

20A/BLU

2
18/ORA

2

1

M3

86

9

11
10

12

1

2

3

4

5

6

TAN/ORA

TAN/WHT

N/U

N/U

GRY/RED

GRY/RED

7

8

E

ELECTRONIC
GOVERNOR
CONTROL
BOX

18D/ORA

72/ORA

73//WHT

BLK

M2

G

H

F
B

E

85

87

A

D

C

84/GRN

86/PUR

IGNITION
COIL
MODULE

86

30

H

13E/BLK

GROUND
LINE

SEPARATE

THROTTLE
ACTUATOR

13AC/BLK

SPARK
PLUGS

CAB
OPTION

13EE/BLK

TO EIP

15A/BLU

FUEL PUMP
SV--14
14/YEL
13AB/BLK

85/BLU
83/BRN
F G
TO ELECTRONIC
INSTRUMENT PANEL

A

C

A

M12

TAN/WHT

TAN/ORA

85

18S/ORA

86

TO EIP
18T/ORA

ELECTRONIC
SPARK
CONTROL

6/GRN

RED/GRN

18J/ORA

85

YEL/BLK

18B/ORA

18H/ORA

18R/ORA

18C/ORA

FUEL
PUMP
RELAY

1

15A

CB--4

87A

ELECTRICAL

Electrical Schematic 800--810 G/LPG (LRG ENGINE)

4-- 33

4-- 34

6/GRN

E

FROM
IGNITION
SWITCH

1G/RED

30 AMP

CB--8

9/ORA

30 M2 87

20

HEADLIGHT RELAY
85
86
60/GRN
23G/GRY
M6

23F/GRY

19

WARNING LIGHT
85
86
75/BRN
M7

96/ORA

5

24

2

15

22

23

12

7

4

3

96A/ORA

96B/ORA

ELECTRONIC
INSTRUMENT
PANEL

18 13

85/
BLU

FILTER
INDICATOR
LIGHT

16

B UNSWITCHED POWER

23E/GRY

23D/GRY

23C/GRY

6

21

1

11

17
14

83/
BRN

SHAKER RELAY
85
86
29/GRN
M4

24A/PUR

25/
BRN

2/ORA

D

HOPPER
THERMAL SW.
FAN RELAY
S--2
86
23B/GRY
24/PUR 85
M5

23A/GRY

23/GRY

SWITCHED POWER
C

FROM
ALTERNATOR

F

N.O.
C

S--4
13FFF/BLK
13DDD/BLK

13X/BLK

OFF

OFF

ON

LOW L.P. FUEL

SP3

SP2
MTR

115/ORA
THERMO
S--11 SWITCH

SP1

13S/BLK

13T/BLK

13M/BLK

FILTER
INDICATOR
SWITCH

CAB
ENVIRONMENTAL
FAN CONTROL

A/C CLUTCH

N. O.

S--21

13DD/BLK

15A/BLU
G FROM ELECTRONIC
GOVERNOR CONTROL
15B/BLU
N.O. S--6
13B/BLK
C
N.C.
OIL
PRESSURE
SWITCH
CHASSIS
GROUND

(L.P. ONLY)
13R/BLK

S--5
N.C.H.O.

13U/BLK

16/GRN

15/BLU

44/GRY

HOPPER DOOR SWITCH
13CCC/BLK13BBB/BLK 13AAA/BLK 13BB/BLK
39A/GRY
S--13
M. BRUSH HYD.
40/YEL
PRESSURE SWITCH13MMM/BLK
S--14

38A/PUR

FAN SW

S--15

39/GRY

38/PUR

13HH/BLK

GROUND
LINE

HOPPER DIFFERENTIAL
PRESSURE SWITCH

SE--2

43/BLU
COOLANT TEMP
SENDER

FUEL SENDER SE--1

42/ORA

N.C.

G FROM ELECTRONIC
GOVERNOR CONTROL

AIR
CONDITIONER
OPTION

HYDRAULIC
FLUID
FILTER

L.P. GND.

SEPARATE

PRESSURE
SETTING
CLOSES AT
20” H
2 O

CLOSES AT
F
225

FULL=90
EMPTY=0

ELECTRICAL
Electrical Schematic 800--810 G/LPG (LRG ENGINE)

1

2

3

800/810 MM337 (6--01)

1F/RED

800/810 MM337 (6--01)

BRN
”X”

BRAKE
SWITCH

S--16

30

30

87

62/YEL

93/ORA

76/ORA

GRY/
BLK

80/BLU

79/
YEL

YEL

BLU

DIRECTIONAL
SWITCH

77/GRY

87

YEL

M6

FOOT
SWITCH

S--18

M7

”L”
FLASHER BLU
”P”

74G/PUR

74F/PUR

74D/PUR

74B/PUR

74A/PUR

74/PUR

2

15 AMP

CB--5

89A/BRN

91A/GRY

BLK
GRY

88/GRN

GRN

RED

87/PUR

89/BRN

62D/YEL

91/GRY

62E/YEL

RUN LHT L.H.

RUN LHT R.H.

62H/YEL

TAIL LHT L.H.

TAIL LHT R.H.

13TT/BLK

13NNN/BLK

13SS/BLK

13JJ/
BLK

13L/BLK

GROUND
LINE

13KK/BLK

13FF/BLK

13GG/BLK

13BB/BLK

13NN/BLK

BACK--UP
LIGHT 13QQ/BLK

13II/
BLK

13AA/BLK

62A/YEL

62C/YEL

13AAA/BLK

L.H.
HEADLIGHT
62G/YEL
CURB
LIGHT

13BBB/BLK

62F/YEL

R.H.
HEADLIGHT

BACK--UP ALARM UNIT

94/YEL

FLASHING
LIGHT

ROTATING
LIGHT

DOME LIGHT

62B/YEL

93B/ORA

FLASHER
93A/ORA

76B/ORA

76A/ORA

MTR

WINDSHIELD
WIPER MTR

SEPARATE

HEADLIGHT
OPTION

BACK--UP
LIGHT
OPTION

SEPARATE

WARNING
LIGHT
OPTION

CAB
OPTION

1

S--9

S--17

ELECTRICAL

Electrical Schematic 800--810 G/LPG (LRG ENGINE)

3

4-- 35

4-- 36

20A/BLU

ACC
LINE

15 AMP

CB--6

21D/ORA

21C/ORA

21B/ORA

21A/ORA

21/ORA

87

86

C

28B/BRN

27/YEL

S--1
MAIN/FRONT
BRUSH

M8

30

85

37/YEL

B

A

7/PUR

28/BRN

28A/BRN

30

85

85

M9

M10

30

30

87

86

86

87

87

M5

19/GRY

31/GRY

19C/GRY

810 ONLY

31A/GRY

31B/GRY

32/GRN

N. O.

S--12
VAC FAN
SHUT OFF

MOV

MOV

MOV

MOV

MAIN
BRUSH
SV--1

FR. BRUSH
LIFT
SV--5

LITTER
BRUSH
SV--2

FAN
SV--6

13ZZ/BLK

13Y/BLK

13G/BLK

13C/BLK

13F/BLK

13W/BLK

13V/BLK

GROUND
LINE

ELECTRICAL
Electrical Schematic 800--810 G/LPG (LRG ENGINE)
1

2

3

800/810 MM337 (6--01)

800/810 MM337 (6--01)

20B/BLU

21R/ORA

POWER RELAY
M
MTR MOTOR
CIRCUIT BREAKER
CB
PERMANENT MAGNET
PM
JACK--FEM. SOCKET
J
PLUG--MALE PIN
P
PUSHBUTTON
PB
VOLTMETER
VM
FU
FUSE

15 AMP

CB--7

LEGEND
HM
SV
S
ACC
GND
C
N.O.
N.C.
NOV

HOURMETER
SOLENOID VALVE
SWITCH
ACCESSORY
GROUND CHASSIS
COMMON
NORMALLY OPEN
NORMALLY CLOSED
METAL OXIDE VARISTOR

33D/GRN

33C/GRN

30

86
M11

87

85

NC

26/PUR

35/YEL

33/GRN

2

C

26A/PUR

26B/PUR

33B/GRN

33A/GRN

MOV

MOV

MOV

NC

MOV

MOV

C

13N/BLK

13D/BLK

13P/BLK

13KKK/BLK

L.H. SIDE
BRUSH LIFT
SV--10

L.H. SIDE
BRUSH
SV--8

13VV/BLK

R.H. SIDE
BRUSH LIFT
SV--9
13I/BLK

R.H. SIDE
BRUSH
SV--3

S--8
L.H. SIDE BRUSH

19A/GRY

1

S--7
R.H. SIDE BRUSH

19B/GRY

M. BRUSH
LIFT
SV--4

ELECTRICAL

Electrical Schematic 800--810 G/LPG (LRG ENGINE)

3

4-- 37

4-- 38

1D/RED

15A

CB--2

UNSWITCHED
POWER

M6
87

11/PUR

29/GRN

TO RFS
CIRCUITRY
BOX

STD.
SHAKER
RELAY
85
86
M4

30

3

M4
30

62/YEL

2

20

30/GRY

86

39/GRY

38/PUR

M3

13AN/BLK

62H/YEL

L.H. SHAKER
MOTOR OVERRIDE
85
86 13AL/BLK
M18

R.H. SHAKER
MOTOR OVERRIDE
85
86 13AJ/BLK
M17

13AP/BLK

L.H. HEADLIGHT

62G/YEL

30C/GRY

CURB LIGHT
13AM/BLK

13AQ/BLK

38B/PUR

R.H. HEADLIGHT

62F/YEL

GROUND
LINE

K

K

13AG/BLK

13AQ/BLK

13BB/BLK

SEPARATE

TO RFS
J CIRCUITRY
BOX
HOPPER DIFFERENTIAL
PRESSURE SWITCH #1
PRESSURE
N.C.
S--4
13X/BLK SETTING
13AU/BLK 13AT/BLK
CLOSES
AT
N.O. C
20” H2 O

E TO EIP

S--13
HOPPER DOOR SWITCH

39A/GRY

38A/PUR

6/GRN

30A/GRY 30B/GRY

62A/YEL

62B/YEL

24

15

19

4
ELECTRONIC
INSTRUMENT 7
1
PANEL
21
12
(RFS OPTION)
FOR
STANDARD
23
6
EIP WIRING
16
22

11

5

18H/ORA

18C/ORA 85

18 13

18/ORA

17
14

87

18Q/ORA
H

18P/ORA

20A/BLU

15A

CB--4

11B/PUR 11A/PUR

23C/GRY

UNSWITCHED
POWER

74B/PUR

IGN.

20/BLU

START

SWITCHED
POWER

IGNITION
SWITCH
S--10

ACC

19

17

BATT.
30
50

ELECTRICAL
Electrical Schematic 800--810 G/LPG (LRG ENGINE)

1

2

800/810 MM337 (6--01)

800/810 MM337 (6--01)

RFS OPTION

2

11B/PUR

11C/PUR

11F/PUR

11E/PUR

11G/PUR

MTR

LH SHAKER
MOTOR

MTR

RH SHAKER
MOTOR

LH SHAKER
RFS CONTROL
85
86
M20

RH SHAKER
RFS CONTROL
85
86
M19

H

FROM CB--4
CONTROL
POWER -- FROM
KEY SWITCH

102/GRY

101/ORA

102B/GRY

101B/ORA

102A/GRY

101A/ORA

108/GRN
GRY
P2--C J2--C

107/BRN
WHT
P2--B J2--B

RED
P2--A J2--A

18Q/ORA
ORA
P1--A J1--A

30

30

30

30

M20

M19

M18

M17

RFS
CIRCUITRY
BOX

YEL POSITIVE
J2--F HERE = CLOSE

106/BRN
BRN
P2--G J2--G

RH VANE
ACTUATOR MOTOR
105/YEL
MTR
P2--F

104/BLU
BLU
P2--E J2--E

103/GRN PNK POSITIVE
P2--D J2--D HERE = CLOSE

87

87

87

87

J1--E

J1--D

J2--H

J1--C

TAN

J1--F

J1--B

PUR

13AE/BLK

38B/PUR

LH SHAKER
RFS CONTROL

RH SHAKER
RFS CONTROL

LH SHAKER
MOTOR OVERRIDE

13AS/BLK

13AR/BLK

13AK/BLK

13AH/BLK

13AF/BLK

J

FROM HOPPER
DIFFERENTIAL
PRESSURE
SWITCH #1

RH SHAKER
MOTOR OVERRIDE

NOT
USED

NOT
USED

BLK
P2--H

NOT
USED

P1--F

GRN

HOPPER DIFFERENTIAL
PRESSURE SWITCH #2
N.C.
S--22
38C/PUR
13AD/BLK
N.O.
C
P1--B

SHAKER
MOTORS
VOLT 13.6
HP .04
AMP 4.5

VANE
MOTORS
MAX. 3.0
AMPS

PRESSURE
SETTING
CLOSES AT
6.5” H O
2

1

MTR

LH VANE
ACTUATOR MOTOR

ELECTRICAL

Electrical Schematic 800--810 G/LPG (LRG ENGINE)

10502

4-- 39

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

1

86/PUR

WATER
TEMPERATURE
SENDER
REV.
SWITCH
(OPTION)

89/BRN
62D/YEL

BA

13JJ/BLK

IGNITION
COIL
AB

RED
BLACK

AB

15B/BLU
13B/BLK
16/GRN
OIL
PRESSURE
SWITCH

72/GRY
73/WHT

ABC

HYD.
FILTER
INDICATOR
SWITCH
(OPTION)

43/BLU

AB
CARBURETOR
ACTUATOR
TO
BATTERY
LOCATION ENGINE
13/BLK

44/GRY
13M/BLK

93/ORA
74A/PUR
10/GRY
NEUTRAL
START
OPTION

12/YEL
1H/RED
1G/RED
1D/RED
1A/RED

84/GRN

AB

115/ORA

L.P.
SWITCH

E

E

F

F

12/BRN
FORD ENGINE HARNESS

TO
STARTER
1/RED

STARTER

33/GRN
19B/GRY

C

AB
SEE
OPTIONS

CBA

B D

B

B
13II/BLK

14C/YEL

13PP/BLK

B

AB

91/GRY
62E/YEL

D

BA
FUEL HARNESS

BA

SEE
OPTIONS

RED
BLACK

A C

ABC

A

AB

1/RED
TO
BATTERY
TAIL LIGHT/ACC. HARNESS

13AB/BLK
14/YEL

2

R.H. SIDE
BRUSH SWITCH

BA
BA

FUEL PUMP

NOT USED
ON GAS/LPG
MODELS

14C/YEL

FUEL
SENDER

BA

13VVV/BLK
42A/ORA

13PP/BLK

NOT USED
ON GAS/LPG
MODELS

FUEL PUMP

VIEW A--A
ABC
SOCKET WIRE
NO.
NO.

COLOR SOCKET WIRE
NO.
NO.

COLOR SOCKET WIRE
NO.
NO.

COLOR SOCKET WIRE
NO.
NO.

COLOR

YEL

1
2
3

23A
16
38

GRY
GRN
PUR

7
8
9

40
PLUG
PLUG

4
5
6

39
43
24A

GRY
BLU
PUR

10
11
12

PLUG
6
44

4-- 40

GRN
GRY

13
14
15

42
2
15

ORA
ORA
BLU

19
20
21

75
60
25

BRN
GRN
BRN

16
17
18

29
83
85

GRN
BRN
BLU

22
23
24

13R
13T
13U

BLK
BLK
BLK

62A/YEL 13L/BLK
76/ORA
ABC
62C/YEL 13KK/BLK
76A/ORA
VIEW B--B

800/810 MM337 (6--01)

ELECTRICAL

B

27/YEL
13V/BLK

1

B

Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

VAC FAN
SHUT OFF
SWITCH

ALTERNATOR
G
13A/BLK

5/PUR

L.H. HEADLIGHT
62G/YEL
62H/YEL
13AAA/BLK

HORN

G13MMM/BLK
24A/PUR
24/PUR

13KKK/BLK
13HHH/BLK
13AC/BLK
13UU/BLK
13RRR/BLK
13Z/BLK
13T/BLK
13S/BLK
13E/BLK

THERMO
SWITCH

23B/GRY

CIRCUIT
BREAKERS
AND
RELAYS
GOVERNOR

13BBB/BLK

115/ORA
23F/GRY
23B/GRY
13I/BLK
33B/GRN

2
4/YEL
5/PUR

HORN
SWITCH

13AAA/BLK
62F/YEL
39A/GRY 38A/PUR

R.H.
SIDE BRUSH
LIFT
SV--9

J EDB
CA

BA J

K EC
DBA

BA K

13S/BLK

13R/BLK
H

CBA

ABC

H

HOPPER
DOOR
SWITCH
(OPTION)

BA

7/PUR
37/YEL
28/BRN

EDCBA
BA
13BB/BLK
39/GRY 38/PUR 62B/YEL
VIEW K--K
R.H.
SHAKER
MOTOR

13BBB/BLK

38A/PUR
13FFF/BLK

HOPPER
DIFF.
SWITCH

30/ORA

13X/BLK

62F/YEL
62G/YEL

MAIN HARNESS

13CC/BLK
AB

LP
CONNECTOR

L.H.
SHAKER
MOTOR

30A/ORA
30B/ORA
13III/BLK

AB

SEE CHART

13CCC/BLK
39A/GRY

R.H. HEADLIGHT

AB

FROM
17/ORA
MAIN
HARNESS 1H/RED
20/BLU
10/GRY

EDCBA

30A/ORA
BA

VIEW J--J

HYD.
FILTER
LIGHT
INDICATOR
(OPTION)

MAIN/FRONT
BRUSH
SWITCH

13DDD/BLK

30B/ORA
13EEE/BLK

HOPPER HARNESS

ENGINE
GROUND

SOLENOID
BLOCK

BA

TO
ENGINE
13/BLK

17

AC
30
50 19

VIEW H--H
KEY SWITCH

800/810 MM337 (6--01)

42/ORA
13HH/BLK
VIEW C--C
AB

18B/ORA

13AC/BLK
VIEW E--E

RED/GRNBLK

42A/ORA
13VVV/BLK
VIEW D--D

VIEW F--F

4-- 41

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)
RELAYS
M3 ELECTRONIC INSTRUMENT PANEL
M4 SHAKER MOTOR
M5 VAC FAN SOLENOID
M6 HEADLIGHTS
M7 ROTATING/FLASHING LIGHTS
M8 HOPPER LIFT
M9 FRONT BRUSH
M10 MAIN BRUSH
M12 FUEL PUMP

M5

M6

L.H.
SIDE BRUSH
HARNESS
(OPTION)
M12

M3

L

M4

L
AIR
CONDITIONER -PRESSURIZER
HARNESS
(OPTION)

M7

M8

M9

M10
18J/ORA

M

33D/GRN

M

18H/ORA
33C/GRN

MAIN
HARNESS
M12

M3

30

M4

14/YEL
23/GRY
30/ORA
15A/BLU
6/GRN
29/GRN

86

85

17/ORA

87A
87
85 COIL+
86 COIL -30 COMMON CONTACT
87 N.O. CONTACT
87A N.C. CONTACT

18S/ORA
18R/ORA
23C/GRY
18T/ORA
22/YEL
11/PUR

SECTION L--L
M5

M6

M7

M8

M9

M10

21C/ORA
28A/BRN
74B/PUR
74/PUR
21A/ORA
21B/ORA
13Y/BLK
25/BRN
75/BRN
60/GRN
27/YEL
13G/BLK

37/YEL
23E/GRY
24/PUR
23D/GRY
21/ORA
7/PUR
28B/BRN
31/GRY
62/YEL
32/GRN
76/ORA

19/GRY

VIEW M--M

4-- 42

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

CB--8
(OPTION)

1G/RED

CB--7
(OPTION)
DIRECTIONAL
HARNESS
(OPTION)

CB--6

20B/BLU
20A/BLU

CB--5

21D/ORA
CB--3
2.5 A

1E/RED

1E/RED
1F/RED

CB--4

18/ORA

74/PUR
74E/PUR
CB--2

1D/RED
1C/RED
11/PUR

22/YEL

20A/BLU
20/BLU

74F/PUR
CB--1

1C/RED
4/YEL

74D/PUR

MAIN
HARNESS
CIRCUIT
BREAKERS
CB--1 HORN
CB--2 SHAKER MOTOR
CB--3 VAC FAN RELAY, SHAKER RELAY, WARNING
LIGHT & HEADLIGHT
CB--4 ELECTRONIC INSTRUMENT PANEL
CB--5 ROTATING LIGHT & BACK--UP ALARM
CB--6 HOPPER LIFT RELAY, FRONT/MAIN BRUSH
CB--7 LEFT HAND SIDE BRUSH
CB--8 CAB ACCESSORIES

800/810 MM337 (6--01)

4-- 43

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

10C/GRY
12B/BRN

REV/FLSH
LIGHT (ONLY)
OHG/CAB
76C/ORA
13PPP/BLK

NEUTRAL
START
HARNESS

10C/GRY
12B/BRN

10/GRY
12/BRN

FROM MAIN
HARNESS

HYD.
PUMP

REV/FLSH
LIGHT
HARNESS

RED

AB

BA

13PPP/BLK
76C/ORA

89/BRN

REV/FLSH
LIGHT

13NNN/BLK
76A/ORA

FROM TAIL LIGHT
HARNESS

DIRECTIONAL HARNESS

13PPP/BLK
76C/ORA

BACK--UP
ALARM
HARNESS

1

FLASHER

B

B

P

P
X L

93A/ORA
93B/ORA
94/YEL

P

LIGHT

94/YEL
13NN/BLK
13QQ/BLK
Q

BA

BA

Q

BACKUP/HORN

93B/ORA
TAIL LIGHT/ACC. HARNESS 13NN/BLK

RED

FROM MAIN
HARNESS

BLK

2

S

R
91/GRY

BA

AB

RED

S

R

AB

AB
AB

93B/ORA

AB

13NNN/BLK
13NN/BLK
76A/ORA
93A/ORA 13QQ/BLK 13PPP/BLK
76C/ORA
VIEW P--P
VIEW Q--Q
93/ORA

AB
91A/GRY
VIEW S--S

4-- 44

89A/BRN

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

TURN LIGHTS
LEFT HAND
S.E. OPTION

88/GRN
88A/GRN
13WWW/BLK
13TTT/BLK

TURN LIGHTS
LEFT HAND
88A/GRN
13TTT/BLK
13ZZZ/BLK
62G/YEL
62H/YEL
13AAA/BLK
13BBB/BLK

1

FLASHER
80/BLU
79/YEL
74G/ORA

P
X

L

L.H.
HEADLIGHT
REF. ONLY
88/GRN
79/YEL 87/PUR

FROM
HOPPER
HARNESS

14 7
2 8
36 9

13YYY/BLK
T

13YYY/BLK
13ZZZ/BLK

T

89A/BRN
77/GRY
80/BLU
VIEW T--T
GRY/BLK

U

91A/GRY

U

BLU

3 69

2

GRY
BLK

14 7
FROM MAIN
HARNESS
TURN LIGHTS
RIGHT HAND

77/GRY
74F/PUR
74G/PUR
BRAKE
SWITCH

YEL

RED

GRN
VIEW U--U

87A/PUR

HOPPER HARNESS

13SSS/BLK
13WWW/BLK

62H/YEL
13AA/BLK
SIDE BRUSH
LIGHT

87A/PUR
87/PUR

TURN LIGHTS
RIGHT HAND
S.E. OPTION

13SSS/BLK

AB
93B/ORA

91/GRY
VIEW R--R

800/810 MM337 (6--01)

89/BRN

4-- 45

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

COMPRESSOR

CLUTCH

BLUE
BLOWER
SWITCH
B C
L
N
M

RED/GRY

ORANGE
RED
YELLOW

HEATER FAN,
PRESSURIZER AND

PRESSURE
SWITCH
BLOWER
MOTOR

1

A/C FAN

2

BLACK
ORANGE
9/ORA
13EE/BLK

M2

30
85 87A 86
87

21R/ORA
33D/GRN

M11

18J/ORA

30
85 87A 86
87

35/YEL
96/ORA

BLUE
THERMOSTAT

BLACK

26/PUR

WHITE
WHITE
WIPERS
SWITCH

WHITE
BLACK
DOME
LIGHT

4-- 46

WIPER
MOTOR

RED
BLACK

BLACK

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

13P/BLK
13VV/BLK
ENGINE
GROUND
BA

AB

26B/PUR
13P/BLK

FROM
MAIN
HARNESS

96A/ORA
13SS/BLK

9/ORA

CB--8
30 AMP

CB--7

21R/ORA

LH SIDE BRUSH HARNESS

1F/RED
1G/RED

13DD/BLK
96B/ORA

A/C HARNESS

WHITE
BLACK

BA

2

AB

BLACK
RED/GRY

BA

1

AB

L.H.
SIDE BRUSH
LIFT
SV--10

LH SIDE
BRUSH SWITCH
FROM
MAIN
HARNESS
35/YEL

GROUND

13VV/BLK
13KKK/BLK

FROM
MAIN
HARNESS

18H/ORA

18J/ORA

13Q/BLK

M11

33C/GRN

33D/GRN

AB

BA

M12

26A/PUR
13KKK/BLK

LH SIDE
BRUSH
SV--8

800/810 MM337 (6--01)

4-- 47

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

18/ORA

18P/ORA
18Q/ORA

CB--4

20/BLU

1

20A/BLU
11/PUR

11A/PUR
11B/PUR

CB--2

1C/RED
1D/RED

MAIN HARNESS
J EDB
CA

BA J

K EDCBA

BA K

2

RFS OPTION
HARNESS ROUTING

13AF

11G

13AE

18Q

105
NOT
USED

F E D

38C

104
P--2

4-- 48

106
A B C

103

H G F E

108

A B C D

107

NOT
USED
NOT
USED

P--1

102B/GRY
108/GRN
30
M20 85 87A 86
87
11F/PUR
13AS/BLK

101B/ORA
107/BRN
30
M19 85 87A 86
87
11E/PUR
13AR/BLK

102A/GRY
13AL/BLK
30
M18 85 87A 86
87
30C/GRY
13AK/BLK

BA

HOPPER
DOOR
SWITCH
(OPTION)

101A/ORA
13AJ/BLK
30
M17 85 87A 86
87
30B/GRY
13AH/BLK

VIEW V--V
800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

L.H. HEADLIGHT
104/BLU
103/GRN

GRN
WHT
L.H.
VANE
MOTOR

62H/YEL
13AP/BLK
13AQ/BLK
BA

11B/PUR
11C/PUR
102/GRY

1

V

P--2

P--1

J--2

RFS
CIRCUITRY
BOX

13AT/BLK 62F/YEL
L.H.
SHAKER
MOTOR

13DDD/BLK

30A/ORA

EDCBA
39A/GRY 38A/PUR
VIEW J--J

J--1

11C/PUR
11D/PUR
101/ORA

M--20
M--19

R.H.
SHAKER
MOTOR

M--18

BA
13BB/BLK
62B/YEL
30/ORA

13X/BLK

EDCBA
M--17
V

106/BRN
105/YEL

13AD/BLK
13AE/BLK
38B/PUR
38C/PUR

39/GRY 38/PUR

GRN
WHT
R.H.
VANE
MOTOR

HOPPER
DIFF.
SWITCH--2

2

VIEW K--K

62G/YEL
62H/YEL
13AN/BLK

62F/YEL
62G/YEL

13AD/BLK
13AU/BLK

13AM/BLK
13AN/BLK

AB

HOPPER
DIFF.
SWITCH--1

38A/PUR
38B/PUR

800/810 MM337 (6--01)

13AQ/BLK
39A/GRY

13AP/BLK
R.H. HEADLIGHT

SIDE BRUSH
LIGHT

4-- 49

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

P

MAIN
HARNESS

B

1A/RED
1B/RED
1B/RED
L2

2/ORA

S
E
EXC
13A/BLK
13MMM/BLK
STANDARD
ALTERNATOR
VIEW G--G

ELECTRONIC
GOVERNOR
CONTROL

13U/BLK

N

A

A

D

D

MAIN
HARNESS

N

4-- 50

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 G/LPG (LRG ENGINE)

GND.

REL.

+B

IND.

(NOT USED)

13A/BLK
MAIN

13MMM/BLK

HARNESS
1B/RED
1A/RED
1B/RED
2/ORA

S.E.
ALTERNATOR
VIEW G--G

72/GRY

13E/BLK
18D/ORA

73/WHT

A

D

E

H

86/PUR
84/GRN

85/BLU

83/BRN

VIEW N--N
ELECTRONIC
GOVERNOR
CONTROL

800/810 MM337 (6--01)

4-- 51

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 200 SERIES ENGINE)

1

2
3
4

5

4-- 52

800/810 MM337 (6--01)

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 200 SERIES ENGINE)

1

2

3
4

5

800/810 MM337 (6--01)

4-- 53

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 200 SERIES ENGINE)

1

2

3

4-- 54

800/810 MM337 (6--01)

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 200 SERIES ENGINE)

1

2

3

800/810 MM337 (6--01)

4-- 55

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 200 SERIES ENGINE)

1

2

3
4-- 56

800/810 MM337 (6--01)

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 200 SERIES ENGINE)

1

2

3

800/810 MM337 (6--01)

4-- 57

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

1

4-- 58

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

1

800/810 MM337 (6--01)

4-- 59

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

4-- 60

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

800/810 MM337 (6--01)

4-- 61

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

4-- 62

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

800/810 MM337 (6--01)

4-- 63

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

1

4-- 64

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

1

800/810 MM337 (6--01)

4-- 65

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

1
2

4-- 66

800/810 MM337 (6--01)

ELECTRICAL
Wire Harnesses Group 800--810 D (PERKINS 200 SERIES ENGINE)

1
2

800/810 MM337 (6--01)

4-- 67

4-- 68

40 AMP

FU -- 1

2.5A

CB--3

15A

15A
CB--2

CB--1

M1

X

X

X

X

X

X

10/GRY

36A/ORA

36/ORA

START

IGN.

RUN/
ACC 20/BLU

19

17

50

87

M4
30

3/BLU

15A

30
23A/GRY

30/ORA

4/YEL

L2

18/ORA

10C/GRY

D

S--3

18E/ORA

2/ORA

MTR

L.H. SHAKER

MTR

R.H. SHAKER

85

M3

12A/BRN

86

E

M1

M1

6/GRN

12/BRN

12/BRN

13DDD/BLK

12V
540 C.C.A.

55A MAX.
CHARGE

13AA/BLK

13G/BLK

HORN

13/BLK

TO EIP

STARTER RELAY COIL

STARTER RELAY COIL

13EEE/BLK

13III/BLK

HORN BUTTON
PB--1
5/PUR

STARTER MOTOR

SWITCHED POWER
TO EIP
PAGE 2

30B/ORA

30A/ORA

MTR

NEUTRAL START
SWITCH OPTION

C

GND ALTERNATOR

TO EIP

CB--4

SENSE

1B/RED

OUT

87

M3

UNSWITCHED POWER
PAGE 2

1J/RED

22/YEL

B

11/PUR

STARTER RELAY

S--10 IGNITION SWITCH
( X INDICATES ACLOSED CONTACT )

30

OFF
PREHEAT
RUN START

BATT.

1A/RED

1B/RED

1H/RED

1E/RED

1G/RED

1D/RED

1C/RED

1/RED

BATTERY

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 700 SERIES ENGINE)

1

2

3

4

5
6

800/810 MM337 (6--01)

6

800/810 MM337 (6--01)

5

ACC
LINE
SEE

20A/BLU

2
18D/ORA

10/GRY

18C/ORA

36C/ORA

36B/ORA

48/PUR

18A/ORA

85
M11

85

87A

87

85

30

M2

M13

86

30

86

87

87A

J

G

C

D

H

85/BLU

H

E

F

15A/BLU

14/
YEL 14A/YEL

84/ORA

TO INSTRUMENT
PANEL

13D/BLK

13AB/BLK

CAB
OPTION

13EE/BLK

GROUND
LINE
SEE

13JJJ/BLK

G
TO OIL
PRESSURE
SWITCH

13N/BLK

13M/BLK

13?/BLK

13AC/BLK

GLOW PLUGS

GOVERNOR ACTUATOR

FUEL PUMP
SV--1

GLOW
INDICATOR

45/GRY

14C/YEL

F

B
86/PUR

GLOW PLUG CURRENT
DRAW: 28 AMPS MAX.

TO INSTRUMENT
PANEL

83/BRN

A

72A/ORA

72B/ORA

ENGINE SPEED MAGNETIC PICK--UP

86

1

GOVERNOR CONTROLLER72/ORA

18B/ORA 18J/ORA

ELECTRICAL

Electrical Schematic 800--810 D (PERKINS 700 SERIES ENGINE)

3

4

4-- 69

4-- 70

B

1G/RED

23E/GRY

23D/GRY

23B/GRY

23F/GRY

23/GRY

23A/GRY

6/GRN

FROM
IGNITION
SWITCH
E

2/ORA

FROM
ALTERNATOR
D

20

HEADLIGHT RELAY
86 60/GRN
23C/GRY 85
M6

9/ORA

30 AMP

CB--11

1CA/RED

30 AMP

CB--10
30 AMP

M11
30 87

19

WARNING LIGHT
85
86 75/BRN
M7

23E/GRY

17
5
3

85/BLU

24

2

15

23

96A/ORA

96/ORA

15 AMP

CB--8

S--413FFF/BLK 13DDD/BLK
C

13X/BLK

109/GRN
107/YEL

N.C.

N.O. S--6

115/ORA

97A/PUR

97/PUR

WIPER MOTOR
MTR13CG/BLK
99/BLU

CONDENSER FAN

DOME LAMP
DOME LAMP SWITCH
13CH/BLK
INTERNAL

WIPER SWITCH

13CA/BLK

BLOWER MOTOR
MTR13CJ/BLK 18 AMPS

FILTER
S--21 INDICATOR
SWITCH
N. O.

FROM M2
FUEL PUMP G

M. BRUSH HYD.
PRESSURE SWITCH

OIL
PRESSURE
SWITCH

110/BLU

C

15A/BLU
F
15B/BLU

S--14

13B/BLK
CHASSIS
GROUND
CAB BLOWER
RESISTOR

16/GRN

15/BLU

40/YEL

S--13

HYDRAULIC
FLUID
FILTER

13B/BLK

FROM FUEL
LOCK OFF
SOLENOID

SEPARATE

13A/BLK

13X/BLK

PRESSURE
SETTING
CLOSES AT
20” H O
2

CLOSES AT
225F

GROUND
LINE
13L/BLK FULL=90
EMPTY=0

HOPPER DIFFERENTIAL
PRESSURE SWITCH

HIGH/LOW
(A/C ONLY)
THERMOSTAT(A/C) PRESSURE
(A/C ONLY)
86 13CB/BLK
102/BRN
103/PUR
104/YEL 85
M13

HIGH

38A/PUR

N.C.

COOLANT TEMP
SENDER
SE--2

FUEL SENDER
SE--1

N.O.
HOPPER DOOR SWITCH
39/GRY 39A/GRY
13CCC/BLK
13BBB/BLK13AAA/BLK 13BB/BLK

38/PUR

MEDIUM108/ORA

LOW

FAN SWITCH

42/ORA
TO GOVERNOR CONTROLLER
43/BLU

FILTER INDICATOR LIGHT

16

6

SHAKER RELAY
85
86 29/GRN
M4

24/PUR

18

H

4
ELECTRONIC
1
INSTRUMENT
PANEL
7

11

13
14

J
83/BRN

HOPPER
FAN RELAY
THERMAL SW.
25/
86
BRN
24A/PUR85
M5
21

S--2

SWITCHED POWER
C

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 700 SERIES ENGINE)

1

2

3

4

800/810 MM337 (6--01)

4

3

800/810 MM337 (6--01)

BRN
”X”

BRAKE
SWITCH

S--16

30

M6

93/ORA

76/ORA

62/YEL

80/BLU

79/
YEL

YEL

GRY

BLK

RED
GRN

GRY/
BLK

BLU

DIRECTIONAL
SWITCH

77/GRY

87

FOOT
SWITCH

S--18

M7 87

YEL
”L”
FLASHER BLU
”P”

74G/PUR

74F/PUR

74L/PUR

74/PUR

74D/PUR

30

FLASHER

89A/BRN

88/GRN
91A/GRY

87/PUR

89/BRN

62D/YEL

91/GRY

62E/YEL

RUN LHT L.H.

TAIL LHT L.H.

TAIL LHT R.H.

13AA/BLK
RUN LHT R.H.

13AAA/BLK
CURB
LIGHT
62H/YEL

62B/YEL

62C/YEL

13BBB/BLK

L.H.
HEADLIGHT
62G/YEL

62A/YEL

13TT/BLK

13NNN/BLK

13JJ/
BLK

SEPARATE

HEADLIGHT
OPTION

BACK--UP
LIGHT
OPTION

SEPARATE

WARNING
LIGHT
OPTION

CAB
OPTION

GROUND
LINE

13KK/BLK 13K/BLK

13II/
BLK

13FF/BLK

13GG/BLK

13H/BLK

13NN/BLK

BACK--UP
LIGHT 13QQ/BLK

BACK--UP ALARM UNIT

94/YEL

FLASHING
LIGHT

ROTATING
LIGHT

COMPRESSOR CLUTCH
106C/BRN
GROUND 3.5 AMPS

R.H.
HEADLIGHT
62F/YEL

93B/ORA

93A/ORA

76B/ORA

76A/ORA

MTR13CC/BLK 5.5 AMPS

CONDENSER FAN
MTR13CD/BLK 5.5 AMPS
106B/BRN

106A/BRN

2

74A/PUR

M13
30 87

1

1F/RED

CB--5
74B/PUR
15 AMP

105/BRN

ELECTRICAL

Electrical Schematic 800--810 D (PERKINS 700 SERIES ENGINE)

4-- 71

4-- 72

20A/BLU

ACC
LINE

CB--6
21D/ORA
15 AMP

21C/ORA

21B/ORA

21A/ORA

21/ORA
M8

S--1

87

86

MAIN/FRONT
BRUSH

30

85

C

28B/BRN

27/YEL

37/YEL

B

A

7/PUR

28/BRN

28A/BRN

30

85

85

M9

M10

30

30

87

86

86

87

87

M5

31A/GRY

31B/GRY

19/GRY

19C/GRY

810 ONLY

31/GRY

32/GRN

N. O.

S--12
VAC FAN
SHUT OFF

MOV

MOV

MOV

MOV

MAIN
BRUSH
SV--1

FR. BRUSH
LIFT
SV--5

LITTER
BRUSH
SV--2

FAN
SV--6

13ZZ/BLK

13Y/BLK

13G/BLK

13C/BLK

13F/BLK

13W/BLK

13V/BLK

GROUND
LINE

ELECTRICAL
Electrical Schematic 800--810 D (PERKINS 700 SERIES ENGINE)
1

2

3

800/810 MM337 (6--01)

800/810 MM337 (6--01)

20B/BLU

POWER RELAY

MOTOR

CIRCUIT BREAKER

PERMANENT MAGNET

JACK--FEM. SOCKET

PLUG--MALE PIN

PUSHBUTTON

VOLTMETER

FUSE

MTR

CB

PM

J

P

PB

VM

FU

15 AMP

21R/ORA

M

CB--7

NOV

N.C.

N.O.

C

GND

ACC

S

SV

HM

LEGEND

METAL OXIDE VARISTOR

NORMALLY CLOSED

NORMALLY OPEN

COMMON

GROUND CHASSIS

ACCESSORY

SWITCH

SOLENOID VALVE

HOURMETER

33D/GRN

33C/GRN

30

86
M12

87

85

26/PUR

35/YEL

33/GRN

26A/PUR

26B/PUR

33B/GRN

33A/GRN

R.H. SIDE BRUSH

2

NC

S--7

19A/GRY

NC

MOV

MOV

C

S--8

MOV

MOV

MOV

13N/BLK

13P/BLK
L.H. SIDE
BRUSH LIFT
SV--10
13KKK/BLK

L.H. SIDE
BRUSH
SV--8

13VV/BLK

L.H. SIDE BRUSH

R.H. SIDE
BRUSH LIFT
SV--9
13I/BLK

R.H. SIDE
BRUSH
SV--3

13D/BLK

1

C

19B/GRY

M. BRUSH
LIFT
SV--4

ELECTRICAL

Electrical Schematic 800--810 D (PERKINS 700 SERIES ENGINE)

3

4-- 73

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.

4-- 74

800/810 MM337 (8--97)

ELECTRICAL
ENGINE RUN
BATTERY
CB-- 3 22/YEL
87
30
2.5A ALTERNATOR
M3
GND
OUT

1E/RED
1A/RED
1H/RED

BATT.
30 50
START

13/BLK

1B/RED SENSE

13A/BLK 55A MAX.
CHARGE

L2

2/ORA

17
19 N/U

23/GRY
18/ORA

90/
ORA

ACC 20/BLU

12V
540 C.C.A.

CB-- 4 18C/ORA 85
86
M3
15A

IGNITION
SWITCH
S-- 10

IGN.
DEC.
ST.
GRD.

6/GRN

FORD
IGN.
MODULE

- +

ORA

- DIST.

RESISTOR
BLK/GRN
WIRE
RED/GRN
DEC. YEL. 72/GRY
72A/GRY
72B/GRY

IGN.
COIL
BATT.

PUR

GRN

18B/ORA

+

18D/ORA
ELECTRONIC
GOVERNOR
CONTROL
BOX

86/PUR
84/GRN
THROTTLE
ACTUATOR

B
A

G H
C D E F
13E/BLK
85/BLU

83/BRN
42/ORA
43/BLU
17
14
11

23A/GRY

18 13

SEPARATE

FUEL SENDER

SE-- 1

COOLANT TEMP SE-- 2
SENDER

13HH/BLK FULL=90
EMPTY=0
CLOSES AT
225 F

5

1

CIRCUIT

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

BOARD

15

15/BLU

2

16/GRN

N.O.
N.C.

OIL
PRESSURE
SWITCH
C
S-- 6

13B/BLK

4-- 75

ELECTRICAL
SHAKER
BATTERY

13/BLK
12V
540 C.C.A.

1D/RED

CB-- 2

87

11/PUR

15A

SHAKER

30

30/GRY

30A/GRY

M4
30B/ GRY

1E/RED

CB-- 3

22/YEL

87

2.5A

M
M

13III/
BLK
13X/BLK
13EEE/
BLK

30
M3

BATT.
30 50
START

23/GRY

17
18/ORA

19 N/U
ACC 20/BLU

CB-- 4
15A

85
18C/ORA

M3

86

IGNITION
SWITCH
S-- 10
6/GRN

11
23A/GRY

23C/GRY

1

SHAKER RELAY
86
85
M4
29/GRN

23

13T/BLK

16
CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

4-- 76

800/810 MM337 (8--97)

ELECTRICAL
SHAKER FAILURE
ACTIVATING THE SHAKER SWITCH TURNS ON A 45 SECOND TIMER.
THIS MAY CAUSE AN INCORRECT READING.
TEST ASSUMES SHAKER TIMER IS ACTIVE UNLESS KEY IS OFF.
TURN KEY ON

RESETTING SWITCH WILL BE NECESSARY.
YES

YES

DOES
SHAKER PANEL
LIGHT COME ON?

> 8.5 AMPS

REPLACE MOTOR

TEST
TOUCH PANEL
PLUG 2 -PIN 3 TO 7

LED BURNT OUT

CHECK AMP DRAW

>100 τ

REPLACE
TOUCH PANEL

REPLACE
CIRCUIT BOARD

IF NECESSARY

NO

SEE POWER UP
TESTING

NO

<100 τ

CHECK &
RESET CB2

DOES THE PANEL
LIGHT FOR
4 SEC.?

O AMPS

YES

CHECK VOLTAGE
AT MOTOR

NO

30A GRY
TO 13III BLK
30B GRY
TO 13EEE BLK
(= BATTERY VOLTAGE)

CONT. NEXT PAGE
REPLACE MOTOR

800/810 MM337 (8--97)

4-- 77

ELECTRICAL

CHECK VOLTAGE
BATT +
TO 13III BLK
BATT +
TO 13EEE BLK
AND 13X BLK

YES

REMOVE M4 RELAY

NO

(BATTERY VOLTAGE)

NO

NO VOLTAGE
1D RED OR
11 PUR

CHECK VOLTAGE
11 PUR
TO BATT. NEG.

REPLACE
13III BLK,
13EEE BLK
OR 13X BLK

YES

CHECK VOLTAGE
AT CB 2
BATTERY VOLTAGE
(BOTH SIDES)
1D RED ONLY
TO BATT. NEG.

CHECK VOLTAGE
AT M4

BATTERY
VOLTAGE
1D RED &
11 PUR
REPAIR OR
REPLACE

0 VOLTS

23C GRAY / BATT -BATTERY
VOLTAGE

REPAIR OR
REPLACE

REPLACE CB 2

1D RED

KEY OFF

REPLACE
11 PURPLE

MOTOR
OPERATES

REPLACE M4 WITH
KNOWN
GOOD RELAY

23C GRAY

NOT
OPERATING

NO

REPLACE M4

CHECK
CONTINUITY
30 GRY / 30A GRY
OR 30B GRY
YES

REPAIR
CONNECTION
REPLACE WIRE

CONT. NEXT PAGE

4-- 78

800/810 MM337 (8--97)

ELECTRICAL

INSERT TEST HARNESS

SWITCH ON

KEY OFF
0 VOLTS

CHECK VOLTAGE
ACROSS PLUG 1
P--16 / P--23

BATTERY

SWITCH OFF

VOLTAGE
REMOVE M4 RELAY

CHECK CONTINUITY

LET COOL 3 MIN.

NO

> 1 MEG

THEN SWITCH ON

OF 29 GREEN

CHECK RESISTANCE
PLUG 1 P16 -- P23

REPAIR OR REPLACE
29 GREEN

800/810 MM337 (8--97)

REPLACE BOARD

4-- 79

ELECTRICAL
VAC FAN
BATTERY

CB-- 3 22/YEL
2.5A

1E/RED

87

30

13/BLK

12V
540 C.C.A.

23/GRY

M3

BATT.
30 50
START
17
18/ORA

19 N/U

CB-- 4 18C/ORA 85
86
M3
15A

ACC 20/BLU

6/GRN

IGNITION
SWITCH
S-- 10

23/GRY
6/GRN
11

23A/GRY

HOPPER
THERMAL SW.FAN RELAY
25/
23B/GRY
24/PUR 85 M5 86 BRN
S-- 2

1
21

24A/PUR 6

S-- 5

23

13T/BLK

CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

21D/ORA
CB-- 6
20A/BLU
15 AMP

21/ORA
21A/ORA

85

M8

86

30 87

S-- 12
HOPPER LIFT

27/YEL
28B/BRN
28A/BRN 30

N
M5

32/GRN

O

FAN
SV-- 6

13V/BLK
13W/BLK

87
MOV

4-- 80

800/810 MM337 (8--97)

ELECTRICAL
VACUUM FAN FAILURE
TEST ASSUMES VAC FAN SWITCH IS ACTIVATED UNLESS KEY IS OFF.
RESETTING SWITCH WILL BE NECESSARY.

TURN KEY ON
YES

YES

DOES VAC FAN PANEL

DOES THE PANEL
LIGHT FOR
4 SEC.?

NO

SEE POWER UP

NO

LIGHT COME ON?

TESTING

<100 τ

TEST TOUCH PANEL

>100 τ

PLUG 2 -- PIN 4 TO 7

UNPLUG M10 RELAY
(REMOVE BRUSHES
FROM CIRCUIT)
UNPLUG M12 RELAY
(REMOVE HOPPER
ROLL--OUT FROM
CIRCUIT)

LED BURNT OUT
REPLACE
CIRCUIT BOARD

REPLACE TOUCH PANEL

CHECK & RESET CB6
IF NECESSARY

CONT. NEXT PAGE

800/810 MM337 (8--97)

4-- 81

ELECTRICAL

BY--PASS
MOTOR
OFF

YES

TEST FOR MAGNETISM

THERMAL SENSOR &
LIFT ARM SWITCH

MOTOR
RUNS

RESET OR REPLACE
NO

THERMAL SENSOR

AT SV--6

OR LIFT ARM SWITCH
REMOVE M5 RELAY

CHECK VOLTAGE

CHECK

NO

YES

24 PUR TO BATT. NEG.

HYDRAULICS

YES

CHECK VOLTAGE

NO

23B GRY TO BATT. NEG.

REPAIR OR REPLACE

REPAIR OR REPLACE

24 PURPLE

23B GRAY

CONT. NEXT PAGE

4-- 82

800/810 MM337 (8--97)

ELECTRICAL

NO

REPLACE M8 WITH
KNOWN
GOOD RELAY

CHECK VOLTAGE
YES
AT M5 RELAY
28A BRN
TO BATT. NEG.

REPLACE M5 WITH
NOT
KNOWN
OPERATING
GOOD RELAY

MOTOR
OPERATES

MOTOR
OPERATES

NOT
OPERATING

REPLACE M8

CHECK VOLTAGE
AT CB 6
NO VOLTAGE
BATTERY VOLTAGE
20A BLU ONLY
20A BLUE OR (BOTH SIDES)
TO BATT. NEG.
21D ORA

REPLACE M5

BATTERY
VOLTAGE
20A BLUE &
21D ORA
REPAIR OR
REPLACE

NO

CHECK VOLTAGE
YES
AT M8
21 ORA
TO BATT. NEG.
21A ORA
TO BATT. NEG.

REPAIR OR
REPLACE
21D ORA, 21 ORA
OR 21A ORA

NO

REPAIR OR
REPLACE
27 YEL OR 13V BLK

800/810 MM337 (8--97)

REPLACE CB 6

REMOVE M8

20A BLUE

CHECK VOLTAGE
AT M8
21 ORA TO 27 YEL

CONT. NEXT PAGE

YES

REPAIR OR
REPLACE
28B BRN OR
28A BRN

4-- 83

ELECTRICAL

CHECK VOLTAGE

0 VOLTS

AT SV--6

YES

32 GRN / 13W BLK
(= BATTERY VOLTAGE)

(BATTERY VOLTAGE)
NO

CHECK VOLTAGE

OUT

CHECK SV--6 COIL
7 +/-- 2 OHMS

BATT + TO 13W/BLK

IN

YES

REPLACE COIL

REPLACE 13W/BLK

SV--6

REPAIR OR REPLACE
32 GREEN
CONT. NEXT PAGE

4-- 84

800/810 MM337 (8--97)

ELECTRICAL

INSERT TEST HARNESS

CHECK VOLTAGE
O VOLTS

ACROSS PLUG 1
P--21 / P--23

KEY OFF
BATTERY
VOLTAGE

SWITCH OFF

REMOVE M5 RELAY

NO

LET COOL 3 MIN.

CHECK
< 1 MEG

CONTINUITY OF
25 BRN

> 1 MEG

CHECK
RESISTANCE
PLUG 1 P21 -- P23

REPAIR OR
REPLACE

CHECK

25 BRN

HYDRAULICS

800/810 MM337 (8--97)

THEN SWITCH ON

REPLACE BOARD

4-- 85

ELECTRICAL
MAIN BRUSH
BATTERY

13/BLK
12V
540 C.C.A.

BATT.
30 50
START
17
19 N/U
ACC 20/BLU
IGNITION
SWITCH
S-- 10

21D/ORA
CB-- 6

20A/BLU
21/ORA
15 AMP
21A/ORA

85

M8

86

30 87

S-- 12
HOPPER LIFT

27/YEL

N

28B/BRN

MAIN/FRONT
BRUSH
S-- 1

13V/BLK

O

C

B
37/YEL
21C/ORA

86
85
M10
30 87

13Y/BLK

19/GRY

MAIN
BRUSH
SV-- 1

13Z/BLK
MOV

19A/GRY
M. BRUSH
LIFT
SV-- 4

4-- 86

13D/BLK
MOV

800/810 MM337 (8--97)

ELECTRICAL
MAIN BRUSH FAILURE
(VAC FAN WORKS)
TEST ASSUMES MAIN BRUSH SWITCH IS ACTIVATED UNLESS KEY IS OFF.
RESETTING SWITCH WILL BE NECESSARY.
TURN KEY ON
YES

TEST
FOR MAGNETISM
AT SV--1

NO

YES

SEE HYDRAULICS

CHECK VOLTAGE
AT S--1

NO

28B BRN
TO BATT NEG.
REMOVE M10

NO

YES

CHECK VOLTAGE
AT M10
37 YEL
TO BATT. NEG.

CHECK VOLTAGE
AT S--1

REPAIR OR
REPLACE

YES

28B BROWN

NO

CHECK VOLTAGE

YES

21C ORA
TO BATT NEG.

37 YEL
TO BATT. NEG.
NO

REPAIR OR
REPLACE

REPAIR OR
REPLACE

37 YELLOW

NO

CHECK VOLTAGE
21C ORA
TO 13Y BLK

21C ORANGE

YES

REPLACE S--1

REPAIR OR
REPLACE

BRUSH SWITCH

13Y BLK

CONT. NEXT PAGE

800/810 MM337 (8--97)

4-- 87

ELECTRICAL

REPLACE M10 WITH
MOTOR
KNOWN
OPERATES
GOOD RELAY
OPERATING
NOT

CHECK VOLTAGE
AT SV--1

0 VOLTS

REPLACE M10
YES

19 GRY TO 13Z BLK
(= BATTERY VOLTAGE)

NO

CHECK VOLTAGE

CHECK SV--1 COIL

YES

OUT

7 +/-- 2 OHMS

BATT + TO 13Z/BLK

IN

REPAIR OR
REPLACE
13Z BLK

REPAIR OR
REPLACE
19 GRAY

REPLACE COIL
SV --1

CHECK
HYDRAULICS

4-- 88

800/810 MM337 (8--97)

ELECTRICAL
SIDE BRUSH
BATTERY

13/BLK
12V
540 C.C.A.

BATT.
30 50
START
17
19 N/U
ACC 20/BLU
IGNITION
SWITCH
S-- 10

21D/ORA
CB-- 6
20A/BLU
21/ORA
15 AMP

85

M8

86

30 87

21A/ORA

S-- 12
HOPPER LIFT

27/YEL

N

28B/BRN

MAIN/FRONT
BRUSH
S-- 1

13V/BLK

O

C

B
37/YEL

86
85
M10
30 87

21C/ORA

13Y/BLK
19/GRY
19A/GRY

19B/GRY
S-- 7
R.H. SIDE BRUSH
33/GRN
C

R.H. SIDE
BRUSH
SV-- 3

13N/BLK

NC
MOV

800/810 MM337 (8--97)

4-- 89

ELECTRICAL
SIDE BRUSH FAILURE
(MAIN BRUSH WORKS)
TEST ASSUMES SIDE BRUSH LEVER IS ENGAGED.

TURN KEY ON
YES

TEST FOR MAGNETISM

NO

AT SV--3

YES

SEE HYDRAULICS

NO

CHECK VOLTAGE

CHECK VOLTAGE
AT S--7
19B/GRY TO BATT NEG.

NO

REPAIR OR REPLACE

YES

33 GRN TO BATT NEG.

REPLACE S--7

0 VOLTS

SIDE BR. SWITCH

19B GRY OR 19A GRY

CHECK VOLTAGE
AT SV--3

YES

33 GRN TO 13N BLK
(= BATTERY VOLTAGE)

NO

CHECK VOLTAGE

OUT

BATT + TO 13N BLK
YES

CHECK SV--3 COIL
7 +/-- 2 OHMS
IN

REPLACE COIL

REPLACE 13N BLK

SV --3

4-- 90

REPAIR OR REPLACE

CHECK

33 GREEN

HYDRAULICS

800/810 MM337 (8--97)

ELECTRICAL
HOPPER ROLL OUT

12V
540 C.C.A.

BATTERY

13/BLK

BATT.
30 50
START
17
19 N/U
ACC 20/BLU
IGNITION
SWITCH
S-- 10

21J/ORA

85

21G/ORA

M
12

86
67/PUR

21H/ORA
87A
87

66/BRN

S-- 22 HOPPER ROLL OUT
13GGG/BLK
N O
67A/PUR
SV-- 7 HOPPER ROLL OUT
MOV

13H/BLK

30

21D/ORA

20A/BLU
CB-- 6
15 AMP
21/ORA

800/810 MM337 (8--97)

4-- 91

ELECTRICAL
HOPPER ROLLOUT FAILURE
(NO REDUCED CYLINDER SPEED)
(HOPPER IS FULLY RAISED AND ROLLED OUT)

TURN KEY ON
NO

TEST FOR MAGNETISM

YES

AT SV--7

NO

SEE HYDRAULICS

NO

CHECK VOLTAGE
AT SV--7
66 BRN TO BATT. NEG.

CHECK CONTINUITY
OF S--22
HOPPER ROLL OUT
SWITCH

YES

REPLACE
S--22

REPLACE OR REPLACE

REPLACE

SV--7 OR CHECK VALVE

M12 RELAY

4-- 92

YES

800/810 MM337 (8--97)

ELECTRICAL
HEADLIGHT
BATTERY

13/BLK
12V
540 C.C.A.

1G/RED
1E/RED

CB-- 3 22/YEL
2.5A

1H/RED

87

30
M3

23/GRY

BATT.
30 50

START

17
18/ORA

19 N/U
ACC 20/BLU

CB-- 4
15A

18C/ORA 85

M3

86

IGNITION
SWITCH
S-- 10

6/GRN

11

23A/GRY

1

13T/BLK

23
CIRCUIT
BOARD

23E/GRY

HEADLIGHT RELAY
85
86
M6
60/GRN

20
ELECTRONIC
INSTRUMENT
PANEL

30 M6 87
1F/RED CB-- 5 74B/PUR
62/YEL
15 AMP

HEADLIGHT R.H.
62B/YEL

62F/YEL
62G/YEL
HEADLIGHT L.H.

800/810 MM337 (8--97)

13BBB
13BB
13AAA

4-- 93

ELECTRICAL
HEADLIGHT FAILURE
TEST ASSUMES HEADLIGHT SWITCH IS ACTIVATED UNLESS KEY IS OFF.
RESETTING SWITCH WILL BE NECESSARY.
TURN KEY ON
YES

YES

DOES HEADLIGHT
NO
PANEL LIGHT
COME ON?

<100 τ

CHECK &
RESET CB5

CHECK AMP DRAW

NO

SEE POWER UP
TESTING

TEST
TOUCH PANEL
PLUG 2 -PIN 2 TO 7

LED BURNT OUT

>100 τ

REPLACE

REPLACE
CIRCUIT BOARD

IF NECESSARY

> 8.5 AMPS

DOES THE PANEL
LIGHT FOR
4 SEC.?

TOUCH PANEL

O AMPS

( 10 +/-- 1 AMP )

CHECK
AND REPAIR
SHORTED WIRE

YES

CHECK VOLTAGE
AT LIGHTS
62F YEL TO
13BBB BLK (RH)
62G YEL TO
13AAA BLK (LH)

NO

(BATTERY VOLTAGE)

REPLACE LIGHTS

4-- 94

CONT. NEXT PAGE

800/810 MM337 (8--97)

ELECTRICAL

CHECK VOLTAGE
YES BATT +
TO 13BBB BLK
& 13AAA BLK
REMOVE M6 RELAY

NO

(BATTERY VOLTAGE)

REPAIR OR
REPLACE
13BBB BLK OR
13AAA BLK

CHECK VOLTAGE
YES
AT M6
74B PUR
TO BATT. NEG.

CHECK VOLTAGE
NO VOLTAGE
AT CB 5
BATTERY VOLTAGE
1F RED OR (BOTH SIDES)
1F RED ONLY
74 PUR
TO BATT. NEG.

CHECK VOLTAGE
AT M6
23E GRY
TO BATT. NEG.

BATTERY
VOLTAGE
1F RED &
74 PUR
REPAIR OR
REPLACE

NO

0 VOLTS

BATTERY
VOLTAGE

REPAIR OR
REPLACE

REPLACE CB5

1F RED

23E GRAY
KEY OFF

REPAIR OR
REPLACE
74B PURPLE

LIGHTS
OPERATE

REPLACE M6 WITH
KNOWN
GOOD RELAY

NO
LIGHTS

NO

REPLACE M6

CHECK
CONTINUITY
62 YEL, 62B YEL,
62F YEL & 62G YEL
YES

REPAIR OR
REPLACE
YELLOW WIRES
CONT. NEXT PAGE

800/810 MM337 (8--97)

4-- 95

ELECTRICAL

INSERT TEST HARNESS

SWITCH ON

KEY OFF
0 VOLTS

CHECK VOLTAGE
ACROSS PLUG 1
P--20 / P--23

BATTERY

SWITCH OFF

VOLTAGE
REMOVE M6 RELAY

CHECK CONTINUITY

LET COOL 3 MIN.

NO

> 1 MEG

THEN SWITCH ON

OF 60 GREEN

CHECK RESISTANCE
PLUG 1 P20 -- P23

REPAIR OR REPLACE

REPLACE BOARD

60 GREEN

4-- 96

800/810 MM337 (8--97)

ELECTRICAL
WARNING LIGHT
BATTERY

13/BLK
12V
540 C.C.A.

1G/RED
CB-- 3 22/YEL
2.5A

1E/RED
1H/RED

87

30
M3

23/GRY

BATT.
30 50
START
17

18/ORA

19 N/U
ACC 20/BLU

CB-- 4
15A

86
18C/ORA 85
M3

IGNITION
SWITCH
S-- 10

6/GRN

11
23A/GRY

1

23

13T/BLK

CIRCUIT

23D/GRY

WARNING LIGHT
85
86
M7
75/BRN

BOARD

19
ELECTRONIC
INSTRUMENT
PANEL

1F/RED CB-- 5
15 AMP

800/810 MM337 (8--97)

74/PUR

30 M7 87

ROTATING LIGHT
76/ORA

76A/ORA
76B/ORA

13NNN
FLASHING LIGHT

13TT

4-- 97

ELECTRICAL
WARNING LIGHT FAILURE
TEST ASSUMES HAZARD LIGHT SWITCH IS ACTIVATED UNLESS KEY IS OFF.
RESETTING SWITCH WILL BE NECESSARY.
TURN KEY ON
YES

YES

DOES
WARNING LIGHT
PANEL LIGHT
COME ON?

TESTING

TEST
TOUCH PANEL
PLUG 2 -PIN 1 TO 7

LED BURNT OUT

>100 τ

REPLACE

REPLACE
CIRCUIT BOARD

IF NECESSARY

NO

SEE POWER UP

NO

<100 τ

CHECK &
RESET CB5

DOES THE PANEL
LIGHT FOR
4 SEC.?

TOUCH PANEL

> 8.5 AMPS CHECK AMP DRAW O AMPS
( 10 +/-- 1 AMP )

CHECK
AND REPAIR
SHORTED WIRE

YES

CHECK VOLTAGE
AT LIGHTS

NO

76A ORA TO
13NNN BLK (R)
76B ORA TO
13TT BLK (F)
(BATTERY VOLTAGE)

REPLACE LIGHTS

4-- 98

CONT. NEXT PAGE

800/810 MM337 (8--97)

ELECTRICAL

CHECK VOLTAGE
YES

(BATTERY VOLTAGE)

REMOVE M7 RELAY

NO

CHECK VOLTAGE
AT M7

NO

BATT +
TO 13NNN BLK
& 13TT BLK

REPAIR OR
REPLACE
13NNN BLK OR
13TT BLK

YES

74 PUR
TO BATT. NEG.

NO VOLTAGE
1F RED OR
74 PUR

CHECK VOLTAGE
AT CB 5
(BOTH SIDES)
TO BATT. NEG.

BATTERY VOLTAGE
1F RED ONLY

0 VOLTS

BATTERY
VOLTAGE

BATTERY
VOLTAGE
1F RED &
74 PUR
REPAIR OR
REPLACE

CHECK VOLTAGE
AT M7
23D GRY
TO BATT. NEG.

REPAIR OR
REPLACE

REPLACE CB5

1F RED

23D GRAY
KEY OFF

REPAIR OR
REPLACE
74 PURPLE

LIGHTS
OPERATE

REPLACE M7 WITH
KNOWN
GOOD RELAY

NO
LIGHTS

NO

REPLACE M7

CHECK
CONTINUITY
76 ORA, 76A ORA
OR 76B ORA
YES

REPAIR OR
REPLACE
ORANGE WIRES
CONT. NEXT PAGE

800/810 MM337 (8--97)

4-- 99

ELECTRICAL

INSERT TEST HARNESS

KEY OFF
0 VOLTS

CHECK VOLTAGE
ACROSS PLUG 1

BATTERY

P--19 / P--23

VOLTAGE

SWITCH OFF

REMOVE M7 RELAY

CHECK CONTINUITY

LET COOL 3 MIN.
THEN SWITCH ON

NO

OF 75 BROWN

> 1 MEG

CHECK RESISTANCE
PLUG 1 P19 -- P23

REPAIR OR REPLACE

REPLACE BOARD

75 BROWN

4-- 100

800/810 MM337 (8--97)

ELECTRICAL
CLOGGED FILTER INDICATOR CIRCUIT
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

CB-- 3 22/YEL
2.5A

87

30
M3

1H/RED
BATT.
30 50
START
17
18/ORA

19 N/U
ACC 20/BLU

CB-- 4

18C/ORA

15A
IGNITION
SWITCH
S-- 10

85

86
M3

6/GRN

23/GRY

38A/PUR
3
23A/GRY

11

38/PUR

N.C.
N.O.

13FFF/BLK
S-- 4

13X/BLK

C

HOPPER DIFFERENTIAL 13DDD/BLK
PRESSURE SWITCH

1

23

13T/BLK

CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

4-- 101

ELECTRICAL
CLOGGED FILTER INDICATOR
LIGHT WILL NOT COME ON
TURN KEY ON
YES

YES

JUMPER

NO LIGHT

ACROSS S--4

DOES
CLOGGED FILTER
PANEL LIGHT
COME ON?

DOES THE PANEL
LIGHT FOR
4 SEC.?

SEE POWER UP

NO

TESTING

REPLACE LAMP

LIGHT

NO

NO LIGHT

THEN RE--TEST

INSERT TEST HARNESS

CHECK VOLTAGE

TEST VACUUM
APPLY 11”
+/-- 1/2” VAC
TO SWITCH
DIAPHRAGM

0 VOLTS

PLUG 1 P1 -- P3

BATTERY
VOLTAGE

NO LIGHT

REPLACE
P.C. BOARD

LIGHT

CHECK
CONNECTIONS
& CONTINUITY OF

REPLACE SWITCH

38 PUR, 38A PUR,
13FFF BLK,
13DDD BLK
AND 13X BLK

REPLACE VACUUM

REPLACE BOARD

LINES

REPAIR OR
REPLACE

4-- 102

800/810 MM337 (8--97)

ELECTRICAL
HOPPER DOOR CIRCUIT
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

CB-- 3 22/YEL
2.5A

87

30
M3

1H/RED
BATT.
30 50
START
17
18/ORA

19 N/U
ACC 20/BLU

CB-- 4

18C/ORA 85

15A
IGNITION
SWITCH
S-- 10

M3

86

6/GRN

23/GRY

23A/GRY

39/GRY

11

4

1

39A/GRY

13CCC

13BB

S-- 13
HOPPER DOOR

23

13AAA

13BBB

13T/BLK

CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

4-- 103

ELECTRICAL
HOPPER DOOR INDICATOR
LIGHT WILL NOT COME ON

TURN KEY ON
YES

DOES THE PANEL
LIGHT FOR

NO

4 SEC.?

NO

NO LIGHT

DOES
HOPPER DOOR
PANEL LIGHT
COME ON?

REPLACE BULB

SEE POWER UP

YES

TESTING

JUMPER

OFF

AND RETEST

ON

ACROSS S--13
INSERT TEST HARNESS

REPLACE
P.C. BOARD

BATTERY
VOLTAGE

REPLACE BOARD

CHECK VOLTAGE

0 VOLTS

REPLACE SWITCH

PLUG 1 P1 -- P4

CHECK
CONNECTIONS
& CONTINUITY OF
39 GRAY / 13BB BLK

NO

REPAIR OR
REPLACE
WIRES AS NEEDED

4-- 104

800/810 MM337 (8--97)

ELECTRICAL
DOWN FORCE
LIGHT WILL NOT COME ON
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

CB-- 3 22/YEL
2.5A

87

30
M3

1H/RED
BATT.
30 50
START
17
19 N/U
ACC 20/BLU
IGNITION
SWITCH
S-- 10

18/ORA

CB-- 4 18C/ORA 85
86
M3
15A
6/GRN

23/GRY

23A/GRY

11
1

7

40/YEL

S-- 14

13MMM/BLK

DN. FORCE
23

13T/BLK

CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

4-- 105

ELECTRICAL
DOWN FORCE CIRCUIT
LIGHT WILL NOT COME ON

TURN KEY ON
YES

NO

NO LIGHT

DOES
DOWN FORCE
PANEL LIGHT
COME ON?

REPLACE BULB

DOES THE PANEL
LIGHT FOR
4 SEC.?

NO

SEE POWER UP

YES

TESTING

JUMPER

OFF

ON

ACROSS S--14

AND RETEST
INSERT TEST HARNESS

REPLACE
P.C. BOARD

BATTERY
VOLTAGE

REPLACE BOARD

CHECK VOLTAGE

REPLACE

0 VOLTS

PLUG 1 P1 -- P7

S--14 SWITCH

CHECK
CONNECTIONS
& CONTINUITY OF
40 YEL /
13MMM BLK

NO

REPAIR OR
REPLACE
WIRES AS NEEDED

4-- 106

800/810 MM337 (8--97)

ELECTRICAL
FUEL SENDER CIRCUIT
(GAS AND DIESEL MACHINES)
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

CB-- 3 22/YEL
2.5A

87

30
M3

1H/RED
BATT.
30 50
START
17
19 N/U
ACC 20/BLU
IGNITION
SWITCH
S-- 10

18/ORA

CB-- 4 18C/ORA 85
86
M3
15A
6/GRN

23/GRY

42/ORA

FUEL SENDER

SE-- 1

13HH/BLK
FULL=90
EMPTY=0

13
23A/GRY

11
1

13T/BLK

23
CIRCUIT

22

BOARD

13R/BLK

13S/BLK

(LP ONLY
ON GAS WILL TURN LIGHTS OFF)

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

4-- 107

ELECTRICAL
FUEL INDICATOR
(GAS AND DIESEL MACHINES)
TURN KEY ON
YES

BATTERY
VOLTAGE

NO LIGHTS

REMOVE
42 ORA WIRE
FROM
FUEL SENDER
= OPEN

CHECK VOLTAGE
AT SE--1
13HH BLK
TO BATT. +

GROUND 42 ORA

NO

SEE POWER UP

0 VOLTS

TESTING

REPAIR OR
REPLACE
13HH BLK

ALL LIGHTS ON

ALL LIGHTS OFF

DOES THE PANEL
LIGHT FOR
4 SEC.?

ALL LIGHTS ON

INSERT TEST HARNESS
INSERT TEST HARNESS

YES

REPLACE SE--1

CHECK
CONTINUITY

NO

42 ORA

CHECK
CONTINUITY

YES

REPLACE PANEL

P1--22
TO BATT. NEG.

REPAIR OR
REPLACE
42 ORA

NO

REPLACE PANEL

4-- 108

REMOVE JUMPER
13R BLK
FOR L.P. ONLY
SEE SCHEMATIC

800/810 MM337 (8--97)

ELECTRICAL
COOLANT SENDER CIRCUIT
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

CB-- 3 22/YEL
2.5A

87

30
M3

1H/RED
BATT.
30 50
START
17
19 N/U
ACC 20/BLU
IGNITION
SWITCH
S-- 10

18/ORA

CB-- 4 18C/ORA 85
86
M3
15A
6/GRN

23/GRY

43/BLU
5

23A/GRY

COOLANT TEMP
SENDER

SE-- 2
CLOSES AT
225 F

11
1

23

13T/BLK

CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

4-- 109

ELECTRICAL
COOLANT TEMPERATURE
LIGHT WILL NOT COME ON

TURN KEY ON
YES

NO

NO LIGHT

DOES
COOLANT TEMP.
PANEL LIGHT
COME ON?

REPLACE BULB

DOES THE PANEL
LIGHT FOR
4 SEC.?

NO

SEE POWER UP

YES

TESTING

OFF

JUMPER ACROSS

ON

SENSOR SE--2

AND RETEST
INSERT TEST HARNESS

REPLACE
P.C. BOARD

BATTERY
VOLTAGE

REPLACE BOARD

CHECK VOLTAGE

REPLACE

0 VOLTS

PLUG 1 P1 -- P5

SE--2 SENSOR

CHECK
CONTINUITY

NO

43 BLU

REPAIR OR
REPLACE
43 BLU

4-- 110

800/810 MM337 (8--97)

ELECTRICAL
LOW LP CIRCUIT (L.P. MACHINES ONLY)
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

CB-- 3 22/YEL
2.5A

87

30
M3

1H/RED
BATT.
30 50
START
17
18/ORA

19 N/U
ACC 20/BLU

CB-- 4
15A

IGNITION
SWITCH
S-- 10

86
18C/ORA 85
M3

6/GRN

23/GRY

23A/GRY

11

LOW L.P. FUEL

1

12

23
23

44/GRY
N.C.H.O.

CLOSED=FLASH
OPEN=ALL OFF
13M/BLK

S-- 5
13T/BLK

13R/BLK

13S/BLK

CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

4-- 111

ELECTRICAL
LOW L.P. CIRCUIT (L.P. MACHINES ONLY)
TURN KEY ON
DOES THE PANEL
LIGHT FOR
4 SEC.?

YES

NO

DOES
MORE THAN 2
FUEL LIGHT
SEGMENTS
COME ON?

NO

SEE POWER UP

YES

TESTING
INSERT TEST HARNESS

NO

CHECK VOLTAGE
AT S--5

YES

13M BLK TO BATT. +

CHECK
CONTINUITY
P1--22
TO BATT. NEG.

NO

YES

REPAIR OR
REPLACE

REMOVE 44 GRY
FROM S--5

13M BLK

= OPEN

2 FUEL
LIGHTS
FLASH

REPAIR OR
REPLACE

REPLACE PANEL

13R BLK
OR 13S BLK

GROUND 44 GRY NO FLASHING
FUEL LIGHTS
INSERT TEST HARNESS

YES

REPLACE S--5

REPLACE PANEL

CHECK
CONTINUITY
44 GRY

NO

REPAIR OR
REPLACE
44 GRY

4-- 112

800/810 MM337 (8--97)

ELECTRICAL
ALTERNATOR FAULT
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

1A/RED

CB-- 3 22/YEL
87
30
2.5A
M3
ALTERNATOR
GND
OUT
1B/RED SENSE

13A/BLK
55A MAX.
CHARGE

L2

1H/RED
BATT.
30 50
START
17
18/ORA

19 N/U
ACC 20/BLU

CB-- 4
15A

IGNITION
SWITCH
S-- 10

86
18C/ORA 85
M3

6/GRN
2/ORA
23/GRY

14
23A/GRY

11
1

23

13T/BLK

CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

4-- 113

ELECTRICAL
ALTERNATOR
(AFTER CHECKING THE BATTERY AND ITS CONNECTIONS)

TURN KEY ON

YES

DOES THE PANEL
LIGHT FOR

NO

4 SEC.?

NO
ALT. LIGHT

IS ALTERNATOR
LIGHT
ON CONSTANTLY?

YES

SEE POWER UP
TESTING

INSERT TEST HARNESS
& START ENGINE

REPLACE
P.C. BOARD

4-- 114

NO

REPLACE LAMP

LIGHT

AND RETEST

> 1 VOLT

CHECK VOLTAGE
ACROSS

0 VOLTS

PLUG 1 P1 -- P14

REPLACE
ALTERNATOR

RETEST BATTERY

800/810 MM337 (8--97)

ELECTRICAL
HOURMETER CIRCUIT
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

CB-- 3 22/YEL
2.5A

87

30
M3

1H/RED
BATT.
30 50
START
17
18/ORA

19 N/U
ACC 20/BLU

CB-- 4
15A

IGNITION
SWITCH
S-- 10

86
18C/ORA 85
M3

6/GRN

23/GRY

23A/GRY

11
1
CIRCUIT
BOARD

13T/BLK

23

15

15/BLU

ELECTRONIC 2
INSTRUMENT
PANEL

16/GRN

HM

800/810 MM337 (8--97)

N.O.
N.C.

OIL
PRESSURE
SWITCH

13B/BLK

C
S-- 6

4-- 115

ELECTRICAL
HOURMETER WON’T WORK
(THE HOURMETER RUNS WHEN THE ENGINE IS RUNNING ONLY,
NOTE: THIS TEST DOES NOT REQUIRE THE ENGINE TO RUN.)

TURN KEY ON
DOES THE PANEL
YES

LIGHT FOR

NO

4 SEC.?

0 VOLTS

CHECK VOLTAGE
AT S--6
13B BLK TO BATT. +

BATTERY

SEE POWER UP

VOLTAGE

TESTING

REMOVE 15 BLU FROM

REPAIR OR REPLACE

S--6 AND JUMPER

13B BLK

TO GROUND

NO

DOES HOURMETER
INDICATOR CLICK

YES

WITHIN 1 MINUTE
INSERT TEST HARNESS

NO

CHECK CONTINUITY

YES

REPLACE S--6

15 BLU

REPAIR OR REPLACE

REPLACE HOURMETER

15 BLU

AND RETEST

4-- 116

800/810 MM337 (8--97)

ELECTRICAL
POWER UP CIRCUIT
BATTERY

13/BLK
12V
540 C.C.A.

1E/RED

CB-- 3 22/YEL
2.5A

87

30
M3

1H/RED
BATT.
30 50
START
17
18/ORA

19 N/U
ACC 20/BLU

15A
IGNITION
SWITCH
S-- 10

85

CB-- 4

18C/ORA

86
M3

6/GRN

23/GRY

23A/GRY

11
1

23

13T/BLK

CIRCUIT
BOARD

ELECTRONIC
INSTRUMENT
PANEL

800/810 MM337 (8--97)

4-- 117

ELECTRICAL
POWER UP TESTING
TURN KEY ON
PANEL WARNING
LIGHTS ON
(4 SECONDS)

NO

CHECK BATTERY
VOLTAGE

RESET CB 3 & CB 4
IF NECESSARY
REMOVE M3 RELAY

NO

CHECK VOLTAGE
AT RELAY

YES

18C ORA
TO BATT. NEG.

CHECK VOLTAGE
AT CB 4
BATTERY VOLTAGE
20 BLU ONLY (BOTH SIDES)
TO BATT. NEG.

0 VOLTS
20 BLU &
18 ORA

BATTERY
VOLTAGE
20 BLU &
18 ORA
CHECK VOLTAGE
NO
AT S--10 KEY SWITCH
1H RED
TO BATT. NEG.

REPLACE CB 4

YES

REPAIR OR
REPLACE
1H RED

REPAIR OR
REPLACE
18 ORA

CHECK AND REPAIR
KEY SWITCH
OR 20 BLUE

4-- 118

CONT. NEXT PAGE

800/810 MM337 (8--97)

ELECTRICAL

BATTERY
VOLTAGE

CHECK VOLTAGE
22 YEL
TO BATT. NEG.

0 VOLTS

(=BATTERY VOLTAGE)

LIGHTS OFF REPLACE M3 WITH
KNOWN
GOOD RELAY

LIGHTS ON

REPLACE M3

NO VOLTAGE
1E RED OR
22 YEL

CHECK VOLTAGE
BATTERY
AT CB 3
VOLTAGE
(BOTH SIDES)
1E RED ONLY
TO BATT. NEG.
BATTERY
VOLTAGE
1E RED &
22 YEL

REPAIR OR
REPLACE

REPLACE CB 3

1E RED

CONT. NEXT PAGE
REPAIR OR
REPLACE
22 YELLOW

800/810 MM337 (8--97)

4-- 119

ELECTRICAL

INSERT TEST HARNESS

REPLACE BOARD

BATTERY

CHECK VOLTAGE

VOLTAGE

P1--23 TO BATT. +

BATTERY

CHECK VOLTAGE

VOLTAGE

P1--1 TO P1--23

0 VOLTS

REPAIR OR REPLACE

0 VOLTS

13T BLK OR 13 BLK

REPAIR OR REPLACE
23A GRAY

4-- 120

800/810 MM337 (8--97)

ELECTRICAL
800/810 RELAY AND CIRCUIT BREAKER
LOCATION

CB 6

CB 4
M3
CB 1
CB 3
M6

M5

M10

M3 -- INSTR. PANEL

CB 1 -- HORN

M4 -- SHAKER MOTOR

CB 2 -- SHAKER MOTOR

M5 -- VAC FAN SOL.

CB 3 -- VAC FAN RELAY

M6 -- HEADLIGHTS

CB 4 -- INSTR. PANEL

M7 -- FLASHING LIGHT

CB 5 -- FLASHING LIGHT

M8 -- HOPPER LIFT

CB 6 -- HOPPER LIFT & BRUSHES

M9 -- FRONT BRUSH

CB 7 -- AUX. SIDE BRUSH

M10 -- MAIN BRUSH

CB 8 -- CAB ACCY.

800/810 MM337 (8--97)

4-- 121

ELECTRICAL

4-- 122

800/810 MM337 (8--97)

HYDRAULICS
CONTENTS
Page
HYDRAULIC FLUID RESERVOIR . . . . . . . 5--3
TO DRAIN HYDRAULIC FLUID
RESERVOIR AND REPLACE
FILTER ELEMENT . . . . . . . . . . . . 5--4
TO FILL HYDRAULIC FLUID
RESERVOIR . . . . . . . . . . . . . . . . . . . . 5--4
HYDRAULIC FLUID . . . . . . . . . . . . . . . . 5--5
HYDRAULIC HOSES . . . . . . . . . . . . . . . 5--5
DIRECTIONAL CONTROL . . . . . . . . . . . . . 5--6
DIRECTIONAL PEDAL . . . . . . . . . . . . . . 5--6
TO REPLACE DIRECTIONAL PEDAL
CENTERING SPRING . . . . . . . . . . . 5--6
TO REPLACE DIRECTIONAL
CONTROL CABLE . . . . . . . . . . . . . . 5--8
TO ADJUST DIRECTIONAL
CONTROL . . . . . . . . . . . . . . . . . . . . . 5--11
HYDRAULIC COMPONENTS . . . . . . . . . . 5--12
TO REPLACE PROPEL PUMP . . . . . . 5--12
TO REPLACE ACCESSORY PUMP . 5--14
TO REPLACE HOPPER LIFT
CYLINDER . . . . . . . . . . . . . . . . . . . . 5--16
TO REPLACE STEERING
CYLINDER . . . . . . . . . . . . . . . . . . . . 5--18
TO REPLACE HOPPER ROLL OUT
CYLINDERS . . . . . . . . . . . . . . . . . . . 5--20
TO REPLACE HOPPER DUMP
DOOR CYLINDERS . . . . . . . . . . . . 5--22
TO REPLACE MAIN BRUSH LIFT
CYLINDER . . . . . . . . . . . . . . . . . . . . 5--24
TO REPLACE SIDE BRUSH LIFT
CYLINDER . . . . . . . . . . . . . . . . . . . . 5--26
TO REPLACE POWER THROWt
BRUSH LIFT CYLINDER . . . . . . . . 5--28
TO REPLACE SIDE BRUSH
SOLENOID VALVE . . . . . . . . . . . . . 5--30
TO REPLACE HYDRAULIC LIFT
VALVE . . . . . . . . . . . . . . . . . . . . . . . . 5--31
TO REPLACE HYDRAULIC
STEERING VALVE . . . . . . . . . . . . . 5--33
TO REPLACE HYDRAULIC
SOLENOID VALVE . . . . . . . . . . . . . 5--35
TO REPLACE SOLENOID VALVE
CARTRIDGE . . . . . . . . . . . . . . . . . . . 5--37
TO REPLACE ENGINE COOLING
FAN HYDRAULIC MOTOR . . . . . . 5--38
TO REPLACE REAR DRIVE
MOTOR . . . . . . . . . . . . . . . . . . . . . . . 5--40
TO REPLACE MAIN BRUSH
MOTOR . . . . . . . . . . . . . . . . . . . . . . . 5--42
TO REPLACE SIDE BRUSH
MOTOR . . . . . . . . . . . . . . . . . . . . . . . 5--44
TO REPLACE POWER THROWt
BRUSH MOTOR . . . . . . . . . . . . . . . 5--45

800/810 MM337 (6--01)

VACUUM FAN . . . . . . . . . . . . . . . . . . . . . . .
TO REPLACE VACUUM FAN
HYDRAULIC MOTOR . . . . . . . . . . .
Fig. 1 -- Hydraulic Schematic
800 G/LPG/D (for machines below
serial number 2300) . . . . . . . . . .
Fig. 2 -- Hydraulic Schematic
800 G/LPG/D (for machines serial
number 2300 and above) . . . . .
Fig. 3 -- Hydraulic Schematic
810 G/LPG/D (for machines below
serial number 2300) . . . . . . . . . .
Fig. 4 -- Hydraulic Schematic
810 G/LPG/D (for machines serial
number 2300 and above) . . . . .
Fig. 5 -- Hydraulic Hose Group
800 G/LPG/D (for machines below
serial number 2300) . . . . . . . . . .
Fig. 6 -- Hydraulic Hose Group
810 G/LPG/D (for machines below
serial number 2300) . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . .
800 MAIN -- LO SPD AND VAC FAN .
810 REAR BROOM AND VAC FAN . .
800 MAIN, S. BR. AND VAC FAN . . . .
810 ALL BROOMS AND VAC FAN . . .
800 / 810 HOPPER LOWER . . . . . . . .
800 / 810 HOPPER LIFT . . . . . . . . . . .
800 / 810 DOOR OPEN . . . . . . . . . . . .
800 / 810 DOOR CLOSE . . . . . . . . . . .
800 / 810 ROLL IN . . . . . . . . . . . . . . . . .
800 / 810 ROLL OUT . . . . . . . . . . . . . .
800 / 810 RIGHT TURN . . . . . . . . . . . .
800 / 810 LEFT TURN . . . . . . . . . . . . .
800/810 COOLANT FAN . . . . . . . . . . .
EATON REPAIR INFORMATION . . . . . . .

Page
5--47
5--47
5--50
5--52
5--54
5--56
5--58
5--59
5--61
5--62
5--63
5--64
5--65
5--66
5--67
5--68
5--69
5--70
5--71
5--72
5--73
5--74
5--75

5-- 1

HYDRAULICS

5-- 2

800/810 MM337 (8--97)

HYDRAULICS
HYDRAULIC FLUID RESERVOIR
The reservoir is located behind the operator seat.
Mounted on top of the reservoir is a filler cap with
a built-in breather. Replace the cap every 800
hours of operation.

08452

Check the hydraulic fluid level at operating
temperature every 100 hours of operation. Make
sure the hopper is down when checking hydraulic
fluid level. The sight gauge is marked with full, the
black line, and add, the red line, levels to indicate
the level of hydraulic fluid in the reservoir.
Lubricate the filler cap gasket with a film of
hydraulic fluid before putting the cap back on the
reservoir.
ATTENTION! Do not overfill the hydraulic fluid
reservoir or operate the machine with a low
level of hydraulic fluid in the reservoir.
Damage to the machine hydraulic system may
result.

08430

Drain and refill the hydraulic fluid reservoir with
new hydraulic fluid every 800 hours of operation.
The hydraulic fluid filter is located in the engine
compartment.
Replace the filter element every 800 hours of
operation.
The reservoir has a built-in strainer outlet that
filters hydraulic fluid before it enters the system.
Replace the strainer every 800 hours of operation.

08453

800/810 MM337 (8--97)

5-- 3

HYDRAULICS
TO DRAIN HYDRAULIC FLUID RESERVOIR
AND REPLACE FILTER ELEMENT
1. Stop the engine and set the parking brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
2. Wait for the hydraulic fluid to cool down.
3. Un-thread and discard the hydraulic fluid
filter element. Hydraulic fluid will drain
through the filter head. Discard the used
hydraulic fluid. Loosen the breather-filter
cap.

08453

NOTE: Be aware the hydraulic filter is lower than
the reservoir. All fluid will drain from the reservoir.
Discard all hydraulic fluid drained from the
system. The fluid may contain foreign material
harmful to the hydraulic system.
4. Apply a thin coat of hydraulic fluid to the seal
of the new hydraulic fluid filter element.
5. Thread and hand tighten the new hydraulic
fluid filter element on the filter head.
TO FILL HYDRAULIC FLUID RESERVOIR
1. Remove the reservoir breather-filler cap.
2. Pour new, approved hydraulic fluid through a
200 mesh screened funnel into the reservoir.
ATTENTION! Use only new, approved
hydraulic fluid to fill the hydraulic fluid
reservoir. Do not overfill!
3. Check the hydraulic fluid level in the
reservoir with the sight gauge.
4. Add hydraulic fluid until the level in the
reservoir is in between the full, black line
and the add, red line. Do not overfill!

08452

NOTE: Do not overfill the hydraulic fluid reservoir.
Hydraulic fluid expands as it reaches its normal
operating temperature. Always allow for
expansion when filling the reservoir.
5. Put the reservoir breather-filler cap on the
reservoir.
6. Start engine and operate all the hydraulic
components.
7. Recheck the hydraulic fluid level.
8. Check for any leaks.
5-- 4

08430

800/810 MM337 (8--97)

HYDRAULICS
HYDRAULIC FLUID
The quality and condition of the hydraulic fluid
play 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 fluids
available for different temperature ranges:
TENNANT part no.
65870--1
74217--1

Ambient Temperature
above 0_ C (32_ F)
below 0_ C (32_ F)

The higher temperature fluid has a higher
viscosity and should not be used at the lower
temperatures. Damage to the hydraulic pumps
may occur because of improper lubrication.
The lower temperature fluid is a thinner fluid for
colder temperatures.
If a locally-available hydraulic fluid is used, make
sure the specifications match TENNANT hydraulic
fluid specifications. Using substitute fluids can
cause premature failure of hydraulic components.
ATTENTION! Hydraulic components depend
on system hydraulic fluid for internal
lubrication. Malfunctions, accelerated wear,
and damage will result if dirt or other
contaminants enter the hydraulic system.

HYDRAULIC HOSES
Check the hydraulic hoses every 200 hours of
operation for wear or damage.
Fluid escaping at high pressure from a very small
hole can be almost invisible, and can cause
serious injuries.
See a doctor at once if injury results from
escaping hydraulic fluid. Serious infection or
reaction can develop if proper medical treatment
is not given immediately.
FOR SAFETY: When Servicing Machine, Use
Cardboard To Locate Leaking Hydraulic Fluid
Under Pressure.
00002

800/810 MM337 (8--97)

5-- 5

HYDRAULICS
DIRECTIONAL CONTROL
DIRECTIONAL PEDAL
The directional pedal controls the flow of hydraulic
fluid to the hydraulic propelling motor. The pedal
neutral position is the position in which the
propelling pump sends no hydraulic fluid to the
propelling motor. The machine should not move
when the pedal neutral position is adjusted
correctly. The pedal linkages should also be
adjusted whenever the reverse is faster or slower
than machine specification.

08467

TO REPLACE DIRECTIONAL PEDAL
CENTERING SPRING
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Remove the clevis pin holding the hopper up
speed cable to the right side lift arm.
3. Remove the rubber floor mat from machine
operator compartment.
4. Remove the seven M8 hex screws from the
directional pedal plate.
5. Lift the plate up and back so the directional
spring assembly is accessible.
6. Remove the M6 hex screw from the bracket
attaching the ball joint to the directional
pedal assembly.
7. Unscrew the spacer from threaded end of
the directional spring assembly and save.
8. Loosen the large jam nuts holding directional
spring assembly to the pedal plate. Drop the
directional spring assembly down, off the
pedal plate.

5-- 6

800/810 MM337 (8--97)

HYDRAULICS
9. Unscrew the directional spring assembly
from the directional control cable using the
flats located at the end of spring assembly.
NOTE: The cable may have to be held to keep it
from turning.
10. Thread a new directional spring assembly
back on the directional control cable.
11. Use the large jam nut to lock the directional
spring assembly in place.
12. Thread the spacer back on the end of the
cable.
13. Reconnect the spacer to the ball joint
bracket using the M6 hex screw. Tighten to
8 -- 10 Nm (5 -- 7 ft lb).
14. Position the directional cable assembly back
on the pedal plate. Hand tighten the large
jam nuts.
15. Place the pedal plate back down on floor of
the operators compartment. Reinstall the
seven M8 hex screws and tighten to
19 -- 24 Nm (15 -- 20 ft lb).
16. Reinstall the rubber floor mat.
17. Reconnect the hopper up speed cable to the
right hand lift arm.
18. Disengage the hopper prop arm and lower
the hopper. Lift the rear drive tire off the
ground and place jack stands under the
frame.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
19. Check the adjustment of the new directional
spring assembly by starting the machine and
checking the rear drive tire for any rotation.
If the tire is rotating in either direction see
TO ADJUST DIRECTIONAL CONTROL
instructions in this section.

800/810 MM337 (8--97)

5-- 7

HYDRAULICS
TO REPLACE DIRECTIONAL CONTROL
CABLE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Remove the clevis pin holding the hopper up
speed cable to the right side lift arm.
3. Remove the rubber floor mat from machine
operator compartment.
4. Remove the seven M8 hex screws from the
directional pedal plate.
5. Lift the plate up and back so the directional
spring assembly is accessible.
6. Remove the M6 hex screw from the bracket
attaching the ball joint to the directional
pedal assembly.
7. Unscrew the spacer from threaded end of
the directional spring assembly and save.
8. Loosen the large jam nuts holding directional
spring assembly to the pedal plate. Drop the
directional spring assembly down, off the
pedal plate.
9. Unscrew the directional spring assembly
from the directional control cable using the
flats located at the end of spring assembly.
NOTE: The cable may have to be held to keep it
from turning.
10. Open the engine cover and side door.
Locate the propel pump under the radiator/
fan shroud assembly.

5-- 8

800/810 MM337 (8--97)

HYDRAULICS
11. Remove the nyloc nut holding the ball
joint/directional cable to the propel pump
directional arm. Remove the ball joint and
jam nut from the cable.
12. Loosen the two large jam nuts on the control
cable. Remove the cable from the bracket.
13. Remove any clamps or ties holding the
control cable to the machine frame.
Carefully remove the cable from the
machine.
14. Reinstall jam nut and ball joint on the new
directional control cable.
15. Install the new control cable in the machine.
Use the same route as the old cable.
16. Reinstall any clamps or ties used to secure
the old cable.
17. Reinstall the M6 nyloc nut on the ball joint.
18. Place the cable assembly in the slot on the
mount bracket. Hand tighten the large jam
nuts.
NOTE: Try to position the new control cable as
close as possible to the position of the old cable.
19. Thread the old directional spring assembly
on the new directional control cable at the
other end of the cable in the operators
compartment.
20. Use the large jam nut to lock the directional
spring assembly in place.
21. Thread the spacer back on the end of the
cable.

800/810 MM337 (8--97)

5-- 9

HYDRAULICS
22. Reconnect the spacer to the ball joint
bracket using the M6 hex screw. Tighten to
8 -- 10 Nm (5 -- 7 ft lb).
23. Position the directional cable assembly back
on the pedal plate. Hand tighten the large
jam nuts.
24. Place the pedal plate back down on floor of
the operators compartment. Reinstall the
seven M8 hex screws and tighten to
19 -- 24 Nm (15 -- 20 ft lb).
25. Reinstall the rubber floor mat.
26. Reconnect the hopper up speed cable to the
right hand lift arm.
27. Close the engine cover and side door.
28. Disengage the hopper prop arm and lower
the hopper. Lift the rear drive tire off the
ground and place jack stands under the
frame.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
29. Check the adjustment of the new directional
spring assembly by starting the machine and
checking the rear drive tire for any rotation.
If the tire is rotating in either direction see
TO ADJUST DIRECTIONAL CONTROL
instructions in this section.

5-- 10

800/810 MM337 (8--97)

HYDRAULICS
TO ADJUST DIRECTIONAL CONTROL
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Lift the rear drive tire off the ground and
place jack stands under the frame.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Check the neutral centering of the pump by
starting the machine and observing the rear
tire for any rotation. If the tire is rotating in
either direction, shut off the engine.
3. Open the engine cover and side door.
Locate the propel pump under the radiator/
fan shroud assembly.
4. Remove the nyloc nut holding the ball
joint/directional cable to the propel pump
directional arm. Lift the ball joint up out of
the arm.
5. Start the engine. With the ball joint
disconnected from arm the pump should
automatically be in neutral.
6. Shut off the engine. Loosen the jam nut
locking the ball joint to control cable. Turn
the ball joint until it lines up with the hole in
the pumps directional arm.
7. Reinstall M6 nyloc nut to ball joint. Hand
tighten.
8. Check neutral centering of pump by starting
machine and observing rear tire for any
rotation. If pump still is not centered, repeat
steps 4 -- 7.
9. The large jam nuts on the control cable can
be loosened and repositioned for more
adjustment.
10. Remove the jack stands and lower the
machine. Operate the machine and check
for proper pedal centering.

800/810 MM337 (8--97)

5-- 11

HYDRAULICS
HYDRAULIC COMPONENTS

TO REPLACE PROPEL PUMP
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Lift the rear drive tire off the ground and
place jack stands under the frame.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Open the engine cover and side door.
3. Remove the muffler and tail pipe.
4. Disconnect the directional control cable from
the propel pump.
5. Remove the two 0.375 in. hex screws
holding accessory pump to propel pump.
6. Pull the accessory pump back and out of the
propel pump. Leave the hydraulic hoses
hooked up to the accessory pump.
NOTE: Be careful not to lose or damage the
o--ring on the accessory pump.
7. Position the accessory pump and control
cable bracket up and out of the way to ease
removal of the propel pump.
NOTE: Mark the hoses that are connected to the
propel pump with tape or some other marking
device to make sure they are returned to the
correct fitting.
8. Remove and plug the hydraulic hoses
leading to the propel pump.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
9. Remove the two M12 hex screws holding
the propel pump to the flywheel housing.

5-- 12

800/810 MM337 (8--97)

HYDRAULICS
10. Pull the propel pump back and out of the
flywheel coupling. The pump must be
dropped down and out of the machine
between engine the cradle and rear frame.
11. Install the fittings from old pump into the new
pump.
NOTE: Make sure to install the fittings in the
same orientation as they were removed.
12. Put a small amount of grease on splines of
the new pump.
13. Position the new pump in machine. The new
pump must be brought under machine and
up between the rear frame and engine
cradle.
14. Line up the splines on pump shaft with the
splines in the flywheel coupling. Push the
pump in and reinstall the two M12 hex
screws. Tighten to 64 -- 83 Nm
(50 -- 60 ft lb).
15. Reconnect the hydraulic hoses to the new
propel pump. See the schematic in this
section.
16. Reinstall the accessory pump and control
cable mount bracket to the rear of the
propel pump.
NOTE: Be sure the o-ring is in place on the
accessory pump.
17. Reinstall the two 0.375 in. hex screws.
Tighten to 36 -- 47 Nm (27 -- 35 ft lb).
18. Reconnect the directional control cable to
the propel pump.
19. Reinstall the muffler and tail pipe.
20. Start machine and check for any leaks at the
propel pump. Close the engine cover and
side door.
21. Observe the rear tire for any rotation. If the
tire is rotating in either direction see TO
ADJUST DIRECTIONAL CONTROL
instructions in this section.

800/810 MM337 (8--97)

5-- 13

HYDRAULICS
TO REPLACE ACCESSORY PUMP
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Lift the rear drive tire off the ground and
place jack stands under the frame.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Open the engine cover and side door.
3. Remove the muffler and tail pipe.
NOTE: Mark the hoses that are connected to the
accessory pump with tape or some other marking
device to make sure they are returned to the
correct fitting.
4. Remove and plug hydraulic hoses leading to
the accessory pump.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
5. Remove the two 0.375 in. hex screws
holding the accessory pump to the propel
pump.
6. Place the control cable bracket up and out of
the way to ease the removal of the
accessory pump.
7. Pull the accessory pump back and out of the
propel pump. The accessory pump must be
dropped down and out of the machine
between the engine cradle and rear frame.
NOTE: Be careful not to lose or damage the
o--ring on the accessory pump.

5-- 14

800/810 MM337 (8--97)

HYDRAULICS
8. Remove the fittings from the old accessory
pump and install in the new or rebuilt pump.
NOTE: Make sure to install the fittings in the
same orientation as they were removed.
9. Put a small amount of grease on splines of
the new pump.
10. Position the new pump in machine. The new
pump must be brought under machine and
up between the rear frame and engine
cradle.
11. Reinstall the accessory pump and control
cable mount bracket to the rear of the
propel pump.
NOTE: Be sure the o-ring is in place on the
accessory pump.
12. Reinstall the two 0.375 in. hex screws.
Tighten to 36 -- 47 Nm (27 -- 35 ft lb).
13. Reconnect the hydraulic hoses to the new
accessory pump. See the schematic in this
section.
14. Reinstall the muffler and tail pipe.
15. Start machine and check for any leaks at the
propel pump. Close the engine cover and
side door.
16. Observe the rear tire for any rotation. If the
tire is rotating in either direction see TO
ADJUST DIRECTIONAL CONTROL
instructions in this section.

800/810 MM337 (8--97)

5-- 15

HYDRAULICS
TO REPLACE HOPPER LIFT CYLINDER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Remove the M10 hex screw holding the
clevis pin in upper rod end of the hopper lift
cylinder. Remove the pin.
NOTE: Mark the hoses that are connected to the
hopper lift cylinder with tape or some other
marking device to make sure they are returned to
the correct fitting.
3. Remove and plug the two hydraulic hoses
leading to the lift cylinder.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
4. Open the engine cover and side door.
5. Remove the inner snap ring from the clevis
pin on lower piston end of the lift cylinder.
6. Pull the pin out toward the engine.
7. The cylinder can now be removed out the
front of the machine.
8. If a new or rebuilt cylinder is going to be
installed, remove the fittings and rod end
clevis from the old cylinder.

5-- 16

800/810 MM337 (8--97)

HYDRAULICS
9. Reinstall the fittings and clevis on the new
cylinder.
NOTE: Make sure to install the fittings in the
same orientation as they were removed.
10. Position the new cylinder back in machine.
Reinstall the rear clevis pin and snap ring
first.
11. Align the upper clevis with hole in hopper
arm lift lug. Reinstall the clevis pin and M10
hex screw. Tighten to 52 -- 67 Nm
(40 -- 50 ft lb).
12. Reconnect the hydraulic hoses to the new
hopper lift cylinder. See the schematic in this
section.
13. Start the machine and lift the hopper. Check
for any leaks.
14. Close the engine cover and side door.
15. Disengage the prop arm and lower the
hopper. Operate the machine and check for
proper operation.

800/810 MM337 (8--97)

5-- 17

HYDRAULICS
TO REPLACE STEERING CYLINDER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Lift the rear drive tire off the ground and
place jack stands under the frame.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
3. Tilt the seat forward and remove both
access panels.
NOTE: Mark the hoses that are connected to the
steering cylinder with tape or some other marking
device to make sure they are returned to the
correct fitting.
4. Remove and plug the two hydraulic hoses
leading to the steering cylinder.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
5. Remove the two 0.75 in. hex screws and
nyloc nuts attaching the steering cylinder to
the machine frame and the rear drive
casting steering bracket.
6. The steering cylinder can now be removed
out the front of the machine.

5-- 18

800/810 MM337 (8--97)

HYDRAULICS
7. If a new or rebuilt cylinder is going to be
installed, remove the fittings and ball joint
ends from the old cylinder.
NOTE: Measure the ball joint center line distance
for proper installation on new cylinder.
8. Reinstall the fittings on the new cylinder.
NOTE: Make sure to install the fittings in the
same orientation as they were removed.
9. Position the new steering cylinder in the
machine. Reinstall two 0.75 in. hex screws
and nyloc nuts. Tighten to 290 -- 380 Nm
(215 -- 280 ft lb).
10. Reconnect the hydraulic hoses to the new
steering cylinder. See schematic in this
section.
11. Reinstall the two access panels. Tighten the
M6 pan head screws to 11 -- 14 Nm
(7 -- 10 ft lb).
12. Start the machine and turn the steering
wheel in both directions. Check for any leaks
and proper operation of the steering cylinder.
13. Remove the jack stands and lower the
machine.
14. Disengage the prop arm and lower the
hopper.

800/810 MM337 (8--97)

5-- 19

HYDRAULICS
TO REPLACE HOPPER ROLL OUT
CYLINDERS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Remove the two M8 hex screws holding
each fender to front bumper. Disengage the
prop arm and lower the hopper.
3. Open the hopper cover and remove the
eight M8 hex screws attaching the LH and
RH fenders to the hopper.
4. Open the front headlight panel and remove it
by spreading the fenders apart. Remove the
fenders from the machine.
NOTE: Mark the hoses that are connected to the
hopper roll out cylinder with tape or some other
marking device to make sure they are returned to
the correct fitting.
5. Remove and plug the two hydraulic hoses
leading to the hopper roll out cylinder.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
6. Remove the M6 hex screw from the pin in
the rod end clevis of the roll out cylinder.
Remove the pin.
7. Pull the hair pin out of cylinder piston end
clevis. Remove the pin. Remove the cylinder
from the machine lift arm.
8. If a new or rebuilt cylinder is going to be
installed, remove the fittings and clevis end
from the old cylinder.
NOTE: Measure the location of clevis on old
cylinder and install in same location on new
cylinder.

5-- 20

800/810 MM337 (8--97)

HYDRAULICS
9. Reinstall the fittings on the new cylinder.
NOTE: Make sure to install the fittings in the
same orientation as they were removed.
10. Position the new roll out cylinder on the
machine lift arm. Reinstall the upper clevis
pin and hair pin.
11. Reinstall the lower pin and M6 hex screw.
Tighten to 11 -- 14 Nm (7 -- 10 ft lb).
12. Reconnect the hydraulic hoses to the new
roll out cylinder. See the schematic in this
section.
13. Repeat steps 5 -- 12 on the other side of the
machine if replacing both the roll out
cylinders.
14. Reinstall the front panel and the RH and LH
fenders. Tighten the M8 hex screws to
18 -- 24 Nm (13 -- 18 ft lb).
15. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
16. Reinstall the two M8 hex screws in bottom of
each fender. Tighten to 18 -- 24 Nm
(13 -- 18 ft lb).
17. Disengage the prop arm and lower the
hopper.
18. Start the machine and roll the hopper in and
out a few times. Check for any leaks.

800/810 MM337 (8--97)

5-- 21

HYDRAULICS
TO REPLACE HOPPER DUMP DOOR
CYLINDERS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Remove the two M8 hex screws holding
each fender to front bumper. Disengage the
prop arm and lower the hopper.
3. Open the hopper cover and remove the
eight M8 hex screws attaching the LH and
RH fenders to the hopper.
4. Open the front headlight panel and remove it
by spreading the fenders apart. Remove the
fenders from the machine.
5. Start the engine and open the dump door.
NOTE: Remove only one cylinder at a time with
the dump door open.
6. Remove and plug the two hydraulic hoses
leading to the dump door cylinder.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
7. Remove the M8 hex screw holding the lower
cylinder clevis pin. Remove the pin.
8. Remove the cotter pin and clevis pin from
the rod end of dump door cylinder. Remove
the cylinder from the machine.
9. If a new or rebuilt cylinder is going to be
installed, remove the fittings from the old
cylinder.

5-- 22

800/810 MM337 (8--97)

HYDRAULICS
10. Reinstall the fittings on the new cylinder.
NOTE: Make sure to install the fittings in the
same orientation as they were removed.
11. Install cylinder back in the machine.
Reinstall both pins using the cotter pin and
M8 hex screw. Tighten the screw to
26 -- 34 Nm (19 -- 25 ft lb).
12. Reconnect the hydraulic hoses to the new
dump door cylinder. See the schematic in
this section.
13. Repeat steps 6 -- 12 on the other side of the
machine if replacing both cylinders.
14. Reinstall the front panel and the RH and LH
fenders. Tighten the M8 hex screws to
18 -- 24 Nm (13 -- 18 ft lb).
15. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
16. Reinstall the two M8 hex screws in bottom of
each fender. Tighten to 18 -- 24 Nm
(13 -- 18 ft lb).
17. Disengage the prop arm and lower the
hopper.
18. Start the machine and open the dump door
a few times. Check for any leaks.

800/810 MM337 (8--97)

5-- 23

HYDRAULICS
TO REPLACE MAIN BRUSH LIFT CYLINDER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Jack up the rear of the machine.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Open the engine cover and side door.
3. Remove the muffler and tail pipe.
4. Disconnect the main brush lift cable at the
cylinder bracket.
NOTE: Mark the hoses that are connected to the
lift cylinder with tape or some other marking
device to make sure they are returned to the
correct fitting.
5. Remove and plug the two hydraulic hoses
on the main brush lift cylinder.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
6. Remove the two large tension springs from
the white plastic retainer tubes.
NOTE: Make sure cylinder is all the way
retracted before removing springs.
7. Remove the cotter pin from the clevis
holding lift cylinder to the mount bracket.
The cylinder can now be removed from the
machine.
8. Remove one 0.50 in. hex nut from the
threaded rod holding plastic spring tubes to
the lift cylinder.

5-- 24

800/810 MM337 (8--97)

HYDRAULICS
9. Remove rod, plastic tubes, and cable
bracket from old cylinder and install on the
new cylinder. Hand tighten the 0.50 in. hex
nut. Use a small amount 242 blue loctite on
threads.
10. Remove the fittings from the old cylinder and
install in the new one.
NOTE: Remember to orientate the fittings as
close as possible to the way they came out.
11. Position the new lift cylinder assembly back
in machine from underneath. Install the
clevis and cotter pin.
12. Reconnect both tension springs to the
plastic spring tubes.
NOTE: Make sure cylinder is all the way retracted
before installing springs.
13. Reconnect the hydraulic hoses to the brush
lift cylinder. See the schematic in this
section.
14. Reconnect the main brush lift cable to the
cylinder bracket. Tighten the M8 hex bolt to
18 -- 24 Nm (13 -- 18 ft lb).
15. Reinstall the muffler and tail pipe.
16. Start engine and check for any leaks.

800/810 MM337 (8--97)

5-- 25

HYDRAULICS
TO REPLACE SIDE BRUSH LIFT CYLINDER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Turn off the engine and engage the parking
brake.
3. Remove the M10 hex screw holding the side
brush, hopper up, lift cable to the lift arm.
4. Let the side brush drop down on the stop.
5. Remove the M10 hex screw holding the side
brush lift cable to the side brush assembly.
NOTE: Mark the hoses at the lift cylinder so they
can be reinstalled to the correct port.
6. Disconnect and plug the two hydraulic hoses
leading to the side brush lift cylinder.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
7. Remove the M10 hex screw, nyloc nut and
spacer from the piston end of the side brush
lift cylinder at the upper frame bracket.
8. Remove the cotter pin from the 0.375 clevis
pin connecting the rod end of the side brush
lift cylinder to the pivot brackets.

5-- 26

800/810 MM337 (8--97)

HYDRAULICS
9. The side brush lift cylinder can now be
removed from the machine.
10. Remove the fittings from the old cylinder and
install into the new cylinder making sure to
keep the orientation the same.
NOTE: Remember to orientate the fittings as
close as possible to the way they came out.
11. Position the new cylinder back in the
machine, rod end first.
12. Reinstall the 0.375 clevis pin back through
the pivot plate and the hole in the end of the
cylinder rod. Reinstall the cotter pin.
13. Position the piston end of the cylinder back
into the upper frame bracket. Reinstall the
M10 hex screw, spacer, and nyloc nut.
Hand tighten.
14. Reconnect the two hydraulic hoses to the
cylinder. See schematic in this section.
15. Reconnect the side brush lift cable to the
side brush assembly. Tighten the M10 hex
screw to 37 -- 48 Nm (26 -- 34 ft lb).
16. Lift the side brush assembly up and
reconnect the side brush, hopper up, lift
cable to the lift arm. Tighten the M10 hex
screw to 37 -- 48 Nm (26 -- 34 ft lb).
17. Start the machine, lower hopper, and check
the side brush lift cylinder for any leaks and
proper operation.

800/810 MM337 (8--97)

5-- 27

HYDRAULICS
TO REPLACE POWER THROWt BRUSH LIFT
CYLINDER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Jack up the rear of the machine.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Open the engine cover and side door.
3. Remove the muffler and tail pipe.
4. Disconnect the POWER THROWt brush lift
cable at the cylinder bracket.
NOTE: Mark the hoses that are connected to the
lift cylinder with tape or some other marking
device to make sure they are returned to the
correct fitting.
5. Remove and plug the two hydraulic hoses
leading to the POWER THROWt brush lift
cylinder.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
6. Remove the two large tension springs from
the white plastic retainer tubes.
NOTE: Make sure cylinder is all the way
retracted before removing springs.
7. Remove the cotter pin from the clevis
holding lift cylinder to the mount bracket.
The cylinder can now be removed from the
machine.
8. Remove one 0.50 in. hex nut from the
threaded rod holding plastic spring tubes to
the lift cylinder.

5-- 28

800/810 MM337 (8--97)

HYDRAULICS
9. Remove rod, plastic tubes, and cable
bracket from old cylinder and install on the
new cylinder. Hand tighten the 0.50 in. hex
nut. Use a small amount 242 blue loctite on
threads.
10. Remove the fittings from the old cylinder and
install in the new one.
NOTE: Remember to orientate the fittings as
close as possible to the way they came out.
11. Position the new POWER THROWt lift
cylinder assembly back in machine from
underneath. Install the clevis and cotter pin.
12. Reconnect both tension springs to the
plastic spring tubes.
NOTE: Make sure cylinder is all the way retracted
before installing springs.
13. Reconnect the hydraulic hoses to the
POWER THROWt lift cylinder. See the
schematic in this section.
14. Reconnect the POWER THROWt brush lift
cable to the cylinder bracket. Tighten the M8
hex bolt to 18 -- 24 Nm (13 -- 18 ft lb).
15. Reinstall the muffler and tail pipe.
16. Start engine and check for any leaks.

800/810 MM337 (8--97)

5-- 29

HYDRAULICS
TO REPLACE SIDE BRUSH SOLENOID VALVE
1. Raise the hopper and the engage prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Turn off the engine and engage the parking
brake.
3. Lift the rubber dust flap located in front of
the driver’s compartment.
NOTE: Mark the hoses at the solenoid valve so
they can be reinstalled to the correct port.
4. Disconnect and plug the six hydraulic hoses
leading to the side brush solenoid valve.
5. Un-plug the solenoid valve cartridges from
the main electrical harness.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
6. Remove the two M6 hex screws, nyloc nuts
and rubber washers holding the solenoid
valve to the valve bracket. Remove the
valve from the machine.
7. Remove the fittings from the old valve and
install in the new valve. Make sure to keep
the orientation the same.
NOTE: Remember to orientate the fittings as
close as possible to the way they came out.
8. Position the new valve back in the machine.
Reinstall the two M6 hex screws and nyloc
nuts. Make sure that the rubber washers are
installed between valve and bracket. Hand
tighten the hex screws.
9. Reconnect the six hydraulic hoses to the
solenoid valve. See schematic in this
section.
10. Reconnect the main harness to the solenoid
valve. See schematic in the ELECTRICAL
section.
11. Drop rubber dust flap back in place.
12. Start the machine, lower hopper, and check
the side brush for proper operation.

5-- 30

800/810 MM337 (8--97)

HYDRAULICS
TO REPLACE HYDRAULIC LIFT VALVE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Turn off engine and engage the parking
brake.
08475

3. Remove the battery cables from the battery.
4. Remove the three plastic knobs from the
valve handles.
5. Put the steering wheel in the lowest position.
6. Remove the eight M6 pan head screws from
dash panel.
7. Pull the dash panel toward the steering
wheel until it clears the valve handles.

IN OUTPB
ACE
D
F

NOTE: Mark the hoses that are connected to the
valve with tape or some other marking device to
make sure they are returned to the correct fitting.
8. Remove and plug all the hoses connected to
valve.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
9. Remove one large clevis pin and three
smaller clevis pins attaching the valve
handles to valve and mount bracket.

OUT
A

PB
C

E

D
F

10. Remove the three M6 hex screws, washers,
isolators and steel sleeves holding the valve
and mount bracket to the machine frame.
Remove the valve out the front of of the
machine.
11. Remove the two M6 hex screws holding the
valve to the mount bracket. Remove the
mount bracket.

800/810 MM337 (8--97)

5-- 31

HYDRAULICS
12. Remove the fittings from the old cylinder and
install in the new one.
NOTE: Remember to orientate the fittings as
close as possible to the way they came out.
13. Reinstall the new valve on the valve bracket
using two M6 hex screws. Tighten to
8 -- 10 Nm (5 -- 7 ft lb).
14. Reinstall the valve and bracket back in the
machine through the front. Reinstall the
three M6 hex screws, washers, and rubber
isolators. Tighten to 8 -- 10 Nm (5 -- 7 ft lb).
NOTE: Make sure rubber ring is between valve
bracket and machine frame.
15. Reinstall the three valve handles using one
large clevis pin and three smaller ones.
16. Reconnect the hydraulic hoses to the control
valve. See schematic in this section.
17. Reinstall the dash panel on machine using
eight M6 pan head screws. Tighten to
8 -- 10 Nm (5 -- 7 ft lb).
18. Reinstall the three plastic knobs on the valve
handles. Lightly hand tighten.
19. Reconnect the battery cables.
20. Start machine and check the new valve for
leaks.

OUT

D

A

PB

C

E

F

5-- 32

800/810 MM337 (8--97)

HYDRAULICS
TO REPLACE HYDRAULIC STEERING VALVE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Turn off engine and engage the parking
brake.
3. Remove the rubber cap from center of the
steering wheel.
4. Remove the M12 hex nut holding the
steering wheel to the steering column.
5. Remove the steering wheel.
NOTE: A puller may be needed to remove the
steering wheel.
6. Lift the rubber dust flap located in front of
the driver’s compartment.
NOTE: Mark the hoses that are connected to the
steering valve with tape or some other marking
device to make sure they are returned to the
correct fitting.
7. Remove and plug the five hydraulic hoses
leading to the steering control motor.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
8. Remove the four M6 hex screws holding the
two steering bracket pivot bearing in place.
9. Slide the steering column, control motor, and
pivot bracket assembly down and out of the
machine.

800/810 MM337 (8--97)

5-- 33

HYDRAULICS
10. Remove the four 0.375 in. screws holding
the steering column and pivot bracket to the
control motor.
NOTE: There is two different length screws. Note
the location of each.
11. Remove the hydraulic fittings from the old
control motor and install in new or rebuilt
motor.
12. Reinstall the steering column and pivot
bracket to the new control motor using the
0.375 in. screws. Tighten to 18 -- 24 Nm
(13 -- 18 ft lb).
NOTE: Make sure to position the pivot bracket in
the same location as it was removed from the old
control motor.
13. Slide the steering column, control motor, and
pivot bracket assembly back in the machine.
14. Reinstall four M6 hex screws holding both
steering bracket pivot bearing in place.
Tighten to 8 -- 10 Nm (6 -- 8 ft lb).
15. Reconnect the hydraulic hoses to the new
steering control motor. See the schematic in
this section.
16. Drop the rubber dust flap back in place.
17. Reinstall steering wheel back on the steering
column. Tighten the M12 hex nut to
102 -- 132 Nm (75 -- 97 ft lb).
18. Reinstall the rubber cap on the steering
wheel.
19. Start the engine and check the steering
control motor for leaks.

5-- 34

800/810 MM337 (8--97)

HYDRAULICS
TO REPLACE HYDRAULIC SOLENOID VALVE

C4
C3

FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

C1
DR
M5

M4

M3

1. Raise the hopper and engage the prop arm.

T3
C2

M1

T2 SW T1
PM2

WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Turn off the engine and engage the parking
brake.
3. Remove the battery cables from the battery.
4. Open the engine cover and side door.

C4
C3
C1

5. Un-plug the four solenoid valve cartridges
from the main electrical harness.

DR
M5

NOTE: Mark the hoses that are connected to the
valve with tape or some other marking device to
make sure they are returned to the correct fitting.

M4

T3
C2

M1

P M2

T2 SW T1

6. Remove and plug the hoses connected to
the valve.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
7. Remove the two M6 hex screws holding the
upper valve mounting bracket to the
machine frame.
8. Remove the valve by lifting it up and out of
the lower bracket.
NOTE: Be careful not to lose two rubber isolator
strips.
9. Remove the three M8 flat head screws
holding the valve mounting plate to the
valve.

800/810 MM337 (8--97)

5-- 35

HYDRAULICS
10. Remove the fittings from the old valve and
install in the new one.
NOTE: Remember to orientate the fittings as
close as possible to the way they came out.
11. Reinstall the new valve on the old valve
plate using three M8 flat head screws.
Tighten to 18 -- 24 Nm (13 -- 18 ft lb).
12. Reinstall the valve and mount plate back on
the lower mount bracket.
NOTE: Make sure rubber isolator strips are in
place.
13. Reinstall the upper valve mount bracket
using two M6 hex screws. Tighten to
8 -- 10 Nm (5 -- 7 ft lb).

C4
C3

14. Reconnect the hydraulic hoses to the new
control valve. See schematic in this section.

C1
DR
M4

15. Plug the four solenoid valve cartridges back
into the main harness. See schematic in the
ELECTRICAL section.
16. Reconnect the battery cables.
17. Start the machine and check for leaks and
proper operation of the solenoid valve.

5-- 36

T3

M5

C2
M1
M3
T1
SW
P M2
T2

800/810 MM337 (8--97)

HYDRAULICS
TO REPLACE SOLENOID VALVE CARTRIDGE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Turn off the engine and engage the parking
brake.
2. Remove the battery cables from the battery.
3. Open the engine cover and side door.
4. Identify the cartridge to be removed from the
solenoid valve assembly. Unplug the
cartridge from the main harness.
5. Remove the hex nut and rubber o-ring from
cartridge stem.
6. Slide the electrical coil and rubber o-ring off
the cartridge stem.
NOTE: Hydraulic oil will run out of the valve when
cartridge is removed.
7. Loosen and unscrew the cartridge stem out
of the valve body.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
8. Install a new or rebuilt cartridge stem back in
the valve port. Hand tighten. Do not over
tighten.
NOTE: Make sure the new cartridge had an
o-ring installed and oiled before reinstalling.
9. Slip the o-ring and coil back over the stem.
10. Install the o-ring and hex nut on the stem.
Hand tighten. Do not over tighten.
NOTE: Do not over tighten, snug only.
11. Plug the coil back in the main harness. See
schematic in the ELECTRICAL section.
12. Reconnect the battery cables.
13. Start the machine and check the cartridge
for leaks and proper operation.

800/810 MM337 (8--97)

5-- 37

HYDRAULICS
TO REPLACE ENGINE COOLING FAN
HYDRAULIC MOTOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Turn off the engine and engage the parking
brake.
2. Remove the battery cables from the battery.
3. Open the engine cover and side door.
4. Remove the two springs and hooks holding
the fan screen guard to engine fan housing.
NOTE: Mark the hoses that are connected to the
fan motor with tape or some other marking device
to make sure they are returned to the correct
fitting.
5. Remove and plug the hoses connected to
cooling fan motor.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
6. Remove the four M6 hex screws and nyloc
nuts holding the fan motor mount channel to
fan housing. Remove the fan assembly from
the machine.
7. Remove the hex nut from the fan motor
shaft in center of the fan blade.
8. Remove the fan blade from the motor shaft.
NOTE: A puller must be used to remove the fan
blade from the tapered motor shaft.

5-- 38

800/810 MM337 (8--97)

HYDRAULICS
9. Remove the two M8 hex screws holding the
fan motor to the mount channel.
10. Remove fittings from old fan motor and
install in the new one.
NOTE: Remember to orientate the fittings as
close as possible to the way they came out.
11. Reinstall the new motor on the mount
channel using two M8 hex screws. Tighten
to 18 -- 24 Nm (13 --18 ft lb).
12. Reinstall the fan blade back on the fan
motor shaft.
NOTE: Make sure the key is in place on the
motor shaft.
13. Reinstall the hex nut on the fan motor shaft.
Tighten to 18 -- 24 Nm (13 -- 18 ft lb).
14. Reinstall the fan motor assembly back on
the fan housing. Use four M6 hex screws
and nyloc nuts. Tighten to 8 -- 10 Nm
(5 -- 7 ft lb).
15. Reconnect the hydraulic hoses to the fan
motor. See schematic in this section.
16. Reinstall the screen guard. Reinstall the
springs and hooks.
17. Reconnect the battery cables.
18. Start the machine and check the fan motor
for any leaks and proper operation.

800/810 MM337 (8--97)

5-- 39

HYDRAULICS
TO REPLACE REAR DRIVE MOTOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Engage the parking brake, block the front
tires.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Jack up the rear of machine. Use jack
stands to support the machine.
3. Remove the rear tire and wheel assembly.
4. Remove the cotter pin and slotted nut from
the drive motor.
5. Remove the drive hub from the motor. A
wheel puller may need to be used to break
the hub free from the motor shaft.
6. Remove and plug the hydraulic hoses from
the drive motor. Mark the hoses for proper
assembly orientation.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
7. Remove the four hex screws holding the
drive motor to the rear casting. Remove the
drive motor.
8. Rebuild or replace the drive motor. If you
replace the drive motor, remove the
hydraulic fittings from the old motor and
install in the new motor in the same
orientation.
9. Position the new or rebuilt motor on the rear
casting in the same orientation as it was
removed.
10. Install the four socket-head screws and
nyloc nuts. Torque nuts to 120 -- 157 Nm
(89 -- 116 ft lb).

5-- 40

800/810 MM337 (8--97)

HYDRAULICS
11. Reconnect the hydraulic hoses. Make sure
each hose is placed on the fitting it was
removed from.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
12. Place the drive hub on the tapered motor
shaft. Tighten slotted nut to 270 -- 340 Nm
(200 -- 250 ft lb). Install cotter pin.
NOTE: Make sure the square key is in place on
the motor shaft before installing the drive hub.
13. Install the rear tire and wheel assembly.
Tighten the six wheel nuts to 122 -- 142 Nm
(90 -- 105 ft lb).
14. Start the machine and run the propel circuit
in forward and reverse. Check for leaks and
proper operation.
15. Remove jack stands and lower machine.

800/810 MM337 (8--97)

5-- 41

HYDRAULICS
TO REPLACE MAIN BRUSH MOTOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Raise the hopper and engage the hopper
prop arm.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Remove the main brush from the machine.
See TO REPLACE MAIN BRUSH
instructions in this section.
3. Remove and plug the hydraulic hoses from
the brush motor.
Note: Observe hydraulic cleanliness requirements
when opening hydraulic lines.
4. Remove the cotter pin from the castle nut at
the end of brush drive plug.
5. Hold the brush drive plug and remove the
castle nut.
6. A puller must be used to remove the brush
drive plug from the tapered shaft on the
brush motor.
7. Remove four 0.375 in. hex screws from
main brush motor arm. Brush motor can now
be removed. (Note orientation of motor in
brush arm).
8. Remove hydraulic fittings from old motor.
9. Install new or rebuilt main brush motor back
in main brush arm. Tighten 0.375 in. hex
screws to 37 -- 47 Nm (27 -- 35 ft lb). Make
sure corners of brush motor line up with
slots in brush arm.
10. Reinstall hydraulic fittings in motor.
11. Reconnect hydraulic hoses to motor.
(See schematic in hydraulic section).

5-- 42

800/810 MM337 (8--97)

HYDRAULICS
12. Reinstall brush drive plug on tapered motor
shaft. (Make sure key is in place).
13. Reinstall castle nut and tighten to
40 -- 54 Nm (30 -- 40 ft lb). Continue to
tighten castle nut until it lines up with hole in
brush motor shaft. Install new cotter pin.
14. Reinstall main brush.
15. Lower the hopper, operate the main brush
and check for proper rotation and leaks.

800/810 MM337 (8--97)

5-- 43

HYDRAULICS
TO REPLACE SIDE BRUSH MOTOR
1. Remove the side brush. See TO REPLACE
SIDE BRUSH instructions in the
SWEEPING section.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
2. Remove and plug the hydraulic hoses from
the side brush motor.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.

08466

3. Remove the four 0.375 in. hex screws from
the bottom of the side brush motor. Remove
the side brush guard and the side brush
motor from the machine.
4. Remove the hydraulic fittings from the the
old motor.
5. Install new or rebuilt side brush motor and
side brush guard with .375 in. hex screws
tighten to 37 -- 47 Nm (27 -- 35 ft lb). Make
sure to install four 0.375 SAE flat washers
between motor and mount bracket.
6. Reinstall hydraulic fittings in motor.
7. Reconnect hydraulic hoses to motor.
(See schematic in HYDRAULICS section.)
8. Slide the side brush onto the side brush
drive shaft.
9. Insert the side brush clevis pin through the
side brush hub and shaft. Reinstall the hair
pin and cable back into the hole in the end of
the clevis pin.

5-- 44

800/810 MM337 (8--97)

HYDRAULICS
TO REPLACE POWER THROWt BRUSH
MOTOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Set the machine parking brake and remove
the Power Throwt brush and idler plate.
See TO REPLACE POWER THROWt
BRUSH instructions in the SWEEPING
section.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
2. Go into the main brush area and locate the
Power Throwt brush drive plug.
3. Remove the M6 hex screw on the end of the
plastic drive plug. Pull the drive plug off the
shaft. Retain the square key.
4. Remove and plug the two hydraulic hoses
on the brush motor.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
5. Remove the four 0.375 in. socket head
screws holding hydraulic motor to arm.
6. Remove the hydraulic motor and drive shaft
from the brush arm. Note the orientation of
the motor in the brush arm.
7. Drive the roll pin out of the shaft. Remove
the drive shaft from the motor.
8. Install the drive shaft and roll pin on new or
rebuilt hydraulic motor.
9. Remove the hydraulic fittings from the old
motor and reinstall in the new motor.
10. Reinstall new motor and drive shaft on brush
arm using four 0.375 in. socket head
screws. Tighten to 37 -- 40 Nm
(27 -- 30 ft lb). Note the orientation of the
motor in the brush arm.

800/810 MM337 (8--97)

5-- 45

HYDRAULICS
11. Reconnect the two hydraulic hoses to motor.
(See schematic in HYDRAULICS section.)
12. Reinstall brush drive plug. Tighten M6 hex
screw to 7 -- 10 Nm (5 -- 8 ft lb). Make sure
the square key is in place in the drive shaft.
13. Reinstall the Power Throwt brush and idler
plate. See TO REPLACE POWER
THROWt BRUSH instructions in the
SWEEPING section.

5-- 46

800/810 MM337 (8--97)

HYDRAULICS
VACUUM FAN
The vacuum fan is hydraulically driven. It pulls air
from the main brush area and through the hopper
filters. There is no vacuum when the hopper is in
the raised position.
TO REPLACE VACUUM FAN HYDRAULIC
MOTOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Dump the machine debris hopper.
2. Set the machine parking brake.
3. Raise the hopper, engage the hopper prop
arm, and lower the hopper.
WARNING: Raised Hopper May Fall.
Engage Hopper Support Bar.
4. Shut off the engine.
5. Open the engine cover and side door.
NOTE: The vacuum fan must be removed from
the machine to replace the hydraulic motor.
6. Remove the vacuum hose and bracket from
the front of vacuum fan housing.
7. Disconnect the wires leading to the Thermo
Sentryt
8. Disconnect and plug the three hydraulic
hoses at the vacuum fan motor.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
9. Remove the two M10 hex screws, washers,
and rubber isolators holding the vacuum fan
housing to the machine frame.

800/810 MM337 (8--97)

5-- 47

HYDRAULICS
10. Remove solenoid valve mounting bracket
and rubber isolator from top of vacuum fan
housing.
11. Tip the vacuum fan assembly forward and
remove it from the machine.
12. Remove the six 0.31 in. hex screws holding
the front housing to rear housing.
NOTE: Mark the orientation of the outer fan
housing to the inner housing for proper
re--assembly.
13. Remove the crown nut from the impeller
shaft. Slide the impeller off the shaft.
(Remove and save key and any shims on
shaft under impeller.)
14. Turn the housing over and remove the four
0.375 in. nyloc nuts and washers from the
motor mount plate. Remove the plate from
housing.
NOTE: Mark the orientation of the motor and
fittings before removal.
15. Remove the four 0.25 in. flat head screws
and nyloc nuts holding the motor to the
plate.
16. Install the new motor to the plate. Tighten
the four 0.25 in. flat head screws to
9 -- 13 Nm (7 -- 10 ft lb).
17. Remove the three hydraulic fittings from the
old motor. Install in the new motor.
NOTE: Make sure the fittings are positioned in the
same orientation as they were removed.
18. Reinstall the motor and mounting plate on
the rear housing. Tighten the 0.375 in. nyloc
nuts to 16 -- 22 Nm (12 -- 16 ft lb).
NOTE: Make sure the motor and fittings are
positioned in the same orientation as they were
removed.

5-- 48

800/810 MM337 (8--97)

HYDRAULICS
19. Turn the housing over and reinstall the
shims, key, fan impeller, and crown nut.
Tighten the crown nut to 34 -- 47 Nm
(25 -- 35 ft lb).
NOTE: Use blue loctite 242 on shaft threads.
NOTE: Be sure key is in shaft. Super gluing key
helps keep key in place.
NOTE: Make sure the impeller spins freely before
continuing with the assembly.
20. Reinstall the front housing on the rear
housing. Reinstall 0.31 in. hex screws and
tighten to 22 -- 27 Nm (16 -- 20 ft lb).
NOTE: Tennant part no. 57543 plastic shims must
be used for proper fan to housing clearance.
Remove the shims through the fan intake after
tightening screws.
21. Reinstall the vacuum fan assembly into the
machine. Tighten the M10 hex screws to
37 -- 48 Nm (26 -- 34 ft lb).
22. Reinstall the solenoid mount bracket and
isolator to the top of fan assembly.
23. Reconnect the hydraulic hoses to the
vacuum fan motor. See schematic in
HYDRAULICS section.
24. Reinstall the vacuum hose and mounting
bracket to the front of vacuum fan. Tighten
the two M8 hex screws to 18 -- 24 Nm
(13 -- 18 ft lb).
25. Reconnect the electrical harness to the
thermo sentryt. See schematic in
HYDRAULICS section.
26. Start the machine and operate the vacuum
fan. Check for leaks and proper operation.

800/810 MM337 (8--97)

5-- 49

HYDRAULICS
Fig. 1 -- Hydraulic Schematic 800 G/LPG/D
(for machines below serial number 2300)

1 2

5-- 50

3 45 6

800 MM337 (6--01)

Fig. 1 -- Hydraulic Schematic 800 G/LPG/D
(for machines below serial number 2300)

1 2

800 MM337 (6--01)

HYDRAULICS

3 45 6

5-- 51

HYDRAULICS
Fig. 2 -- Hydraulic Schematic 800 G/LPG/D
(for machines serial number 2300 and above)

1 2

5-- 52

3 4 5 6

800 MM337 (6--01)

HYDRAULICS
Fig. 2 -- Hydraulic Schematic 800 G/LPG/D
(for machines serial number 2300 and above)

1 2

3 4 5 6

09912 -- 800

800 MM337 (6--01)

5-- 53

HYDRAULICS
Fig. 3 -- Hydraulic Schematic 810 G/LPG/D
(for machines below serial number 2300)

1 2

5-- 54

3 45 6

800 MM337 (6--01)

Fig. 3 -- Hydraulic Schematic 810 G/LPG/D
(for machines below serial number 2300)

1 2

800 MM337 (6--01)

HYDRAULICS

3 45 6

5-- 55

HYDRAULICS
Fig. 4 -- Hydraulic Schematic 810 G/LPG/D
(for machines serial number 2300 and above)

1

2

5-- 56

3 4 5 6

800 MM337 (6--01)

HYDRAULICS
Fig. 4 -- Hydraulic Schematic 810 G/LPG/D
(for machines serial number 2300 and above)

1

2

3 4 5 6

09911 -- 810
800 MM337 (6--01)

5-- 57

HYDRAULICS
Fig. 5 -- Hydraulic Hose Group 800 G/LPG/D
(for machines below serial number 2300)

5-- 58

800 MM337 (6--01)

HYDRAULICS
Fig. 6 -- Hydraulic Hose Group 810 G/LPG/D
(for machines below serial number 2300)

800 MM337 (6--01)

5-- 59

HYDRAULICS

5-- 60

800 MM337 (6--01)

HYDRAULICS
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.

800/810 MM337 (8--97)

5-- 61

HYDRAULICS
800 MAIN -- LO SPD AND VAC FAN

1000 psi
6,900 kPa

SV6

VAC FAN

PB

OUT

DOOR

PRESSURE
ROLL

RETURN
SUCTION

LIFT

RV2
2000 psi
13800 kPa

IN
S-- 14
1900 psi
13200 kPa

1150 psi
8000 kPa

RV1
2200 psi
15000 kPa
P

500 psi
3500 kPa

SV4
C2

C1

DR
T3
SV1

SV3

M2

M4

T2

SV2
M1

500 psi
3500 kPa

M5

6.2 GPM @ 2400 RPM
23.5 LPM @ 2400 RPM

6.2 GPM @ 2400 RPM
23.5 LPM @ 2400 RPM

500 psi
3500 kPa

REAR LIFT

SV9

MAIN BROOM
R SIDE
BROOM

RV4
25 psi
170 kPa

STRN1
RV8
3 psi
20 kPa

L SIDE
BROOM

HTX1

FLTR1
RES1

5-- 62

800/810 MM337 (8--97)

HYDRAULICS
810 REAR BROOM AND VAC FAN

1000 psi
6900 kPa
SV6

VAC FAN

PB

OUT

DOOR

PRESSURE

ROLL

RETURN
SUCTION

LIFT

RV2
2000 psi
13800 kPa

S-- 14
1900 psi
13200 kPa

IN

RV1
2200 psi
15000 kPa

1150 psi
7900 kPa

DR
T3

SV1

SV2

SV3
T2

6.2 GPM @ 2400 RPM 23.5 LPM @ 2400 RPM

6.2 GPM @ 2400 RPM

23.5 LPM @ 2400 RPM

P

RV 8

SV4
C2

C1

500 psi
3400 kPa

SV5
C4

C3

M1

M2

M3

M5

M4

SV9
500 psi
3400 kPa

REAR LIFT

FRONT LIFT

REAR
BROOM

FRONT
BROOM
R SIDE
BROOM

25 psi
170 kPa

L SIDE
BROOM

RV 4

3 psi
20 kPa

800/810 MM337 (8--97)

5-- 63

HYDRAULICS
800 MAIN, S. BR. AND VAC FAN

1000 psi
6900 kPa
SV6

VAC FAN

PB

OUT

DOOR

PRESSURE
ROLL

RETURN
SUCTION

LIFT

RV2
2000 psi
13800 kPa
S-- 14
1900 psi
13200 kPa

IN

1150 psi
7900 kPa

RV1
2200 psi
15000 kPa

23.5 LPM @ 2400 RPM
6.2 GPM @ 2400 RPM

23.5 LPM @ 2400 RPM
6.2 GPM @ 2400 RPM

P

SV4
C2

DR
T3
SV1

SV3

M2

M4

T2

SV2

C1 800 psi
5500 kPa

REAR LIFT

M1
750 psi
5200 kPa

M5

SV9

250 psi
1700 kPa

MAIN BROOM
R SIDE
BROOM

L SIDE
BROOM

RV 4
25 psi
170 kPa

RV 8
3 psi
20 kPa

5-- 64

800/810 MM337 (8--97)

HYDRAULICS
810 ALL BROOMS AND VAC FAN

1000 psi
6900 kPa
SV6

VAC FAN

PB

OUT

DOOR

PRESSURE

ROLL

RETURN
SUCTION

LIFT

RV2
2000 psi
13800 kPa

S-- 14
1900 psi
13200 kPa

IN

RV1
2200 psi
15000 kPa
DR
T3
SV1

P

SV2

SV3

6.2 GPM @ 2400 RPM23.5 LPM @ 2400 RPM

6.2 GPM @ 2400 RPM23.5 LPM @ 2400 RPM

T2
SV4
C2

C1

1200 psi
8300 KPA

SV5
C4

C3

M1
1150 psi
7900 kPa

M2

M3

M4

M5

SV9

REAR LIFT

FRONT LIFT

REAR
BROOM

FRONT
BROOM

650 psi
4500 kPa

R SIDE
BROOM

L SIDE
BROOM

250 psi
1700 kPa

RV4
RV8

25 psi
170 kPa

3 psi
20 kPa

800/810 MM337 (8--97)

5-- 65

HYDRAULICS
800 / 810 HOPPER LOWER
OUT

DOOR

ROLL

B

LIFT

A

LOWER
RV2
2000 psi
13800 kPA

6.2 GPM @ 2400 RPM

23.5 LPM @ 2400 RPM

IN

PRESSURE
RETURN
SUCTION

RV 8

3 psi
20 kPa

RV4
25 psi
170 kPa

5-- 66

800/810 MM337 (8--97)

HYDRAULICS
800 / 810 HOPPER LIFT
OUT

DOOR

ROLL

B

LIFT

A
LIFT
RV2
2000 psi
13800 kPa

6.2 GPM @ 2400 RPM

23.5 LPM @ 2400 RPM

IN

PRESSURE
RETURN
SUCTION

RV8

3 psi
20 kPa

RV4
,k psi
25
170 kPa

800/810 MM337 (8--97)

5-- 67

HYDRAULICS
800 / 810 DOOR OPEN

OUT

DOOR

F

E

OPEN
500 psi
3400 kPa

ROLL

LIFT

PRESSURE
RETURN
SUCTION
RV2
2000 psi
13800 kPa

23.5 LPM @ 2400 RPM

6.2 GPM @ 2400 RPM

IN

RV8
3 psi
20 kPa

RV4
,k psi
25
170 kPa

RES1

5-- 68

800/810 MM337 (8--97)

HYDRAULICS
800 / 810 DOOR CLOSE

OUT

DOOR

CLOSE

F

E

ROLL

LIFT

PRESSURE
RETURN
SUCTION
RV2
2000 psi
13800 kPa

6.2 GPM @ 2400 RPM

23.5 LPM @ 2400 RPM

IN

RV8
3 psi
20 kPa

RV4
,k psi
25
170 kPa

RES1

800/810 MM337 (8--97)

5-- 69

HYDRAULICS
800 / 810 ROLL IN
OUT

DOOR

ROLL

D

500 psi
3400 kPa

ROLL IN

C

LIFT

RV2
2000 psi
13800 kPa

23.5 LPM @ 2400 RPM

6.2 GPM @ 2400 RPM

IN

PRESSURE
RETURN
SUCTION
RV8
3 psi
20 pKA

RV4
,k psi
25
170 kPa

5-- 70

800/810 MM337 (8--97)

HYDRAULICS
800 / 810 ROLL OUT

SV6

RV9

OUT

200 psi

DOOR
SV7

D

ROLL

C

ROLL OUT

500 psi
3400 kPa

LIFT

RV2
2000 psi
13800 kPa

23.5 LPM @ 2400 RPM

6.2 GPM @ 2400 RPM

IN

PRESSURE
RETURN
SUCTION
RV8
3 psi
20 kPa

RV4
,k psi
25
170 kPa

RES1

800/810 MM337 (8--97)

5-- 71

HYDRAULICS
800 / 810 RIGHT TURN

STEERING SYSTEM

T

R

400 psi
2700 kPa

L

RV3
1300 psi
8900 kPa

P

17.8 LPM @ 2400 RPM

4.7 GPM @ 2400 RPM

900 psi
6200 kPa

PRESSURE
RETURN
SUCTION

STRN1
RV8
3 psi
20 pKa

RV4
,k psi
25
170 kPa

RES1

5-- 72

800/810 MM337 (8--97)

HYDRAULICS
800 / 810 LEFT TURN

STEERING SYSTEM

T

R

400 psi
2700 kPa

L

RV3
1300 psi
8900 kPa

P

17.8 LPM @ 2400 RPM

4.7 GPM @ 2400 RPM

900 psi
6200 kPa

PRESSURE
RETURN
SUCTION

RV8

3 psi
20 kPa

RV4
,k psi
25
170 kPa

RES1

800/810 MM337 (8--97)

5-- 73

HYDRAULICS
800/810 COOLANT FAN
COOLANT FAN

500 psi
3400 kPa

T
E
RV3
1300 psi
8900 kPa
P

T1
T2

PRESSURE

17.8 LPM @ 2400 RPM

4.7 GPM @ 2400 RPM

RETURN

SUCTION

STRN1
RV4
25 psi
170 kPa

RV8
3 psi
20 kPa

HTX1

FLTR1
RES1

5-- 74

800/810 MM337 (8--97)

ENGINE--G/LPG
CONTENTS
Page
FORD 2.3 LITER ENGINE . . . . . . . . . . . . . . 6--3
TO REMOVE ENGINE . . . . . . . . . . . . . . 6--4
TO INSTALL ENGINE . . . . . . . . . . . . . . . 6--5
TO CHANGE ENGINE TIMING BELT . 6--7
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 6--9
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--9
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 6--9
ENGINE BELT . . . . . . . . . . . . . . . . . . . . . . . 6--10
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . 6--11
AIR FILTER INDICATOR . . . . . . . . . . . 6--11
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . 6--11
TO REPLACE AIR FILTER
ELEMENT . . . . . . . . . . . . . . . . . . . . . 6--12
FUEL SYSTEM -- GASOLINE . . . . . . . . . . 6--13
FUEL FILTERS . . . . . . . . . . . . . . . . . . . 6--13
CARBURETOR . . . . . . . . . . . . . . . . . . . 6--13
FUEL SYSTEM -- LPG . . . . . . . . . . . . . 6--14
LPG FUEL TANK . . . . . . . . . . . . . . . . . . 6--16
TO CHANGE LPG FUEL TANK . . . . . 6--18
FUEL FILTER LOCK . . . . . . . . . . . . . . . 6--19
VAPORIZER-REGULATOR . . . . . . . . . 6--19
CARBURETOR . . . . . . . . . . . . . . . . . . . 6--19
OIL PRESSURE SWITCH . . . . . . . . . . 6--20
LPG FUEL TROUBLESHOOTING . . . 6--20
GOVERNOR ACTUATOR
(LSG ENGINE) . . . . . . . . . . . . . . . . . . . . 6--21
TO REPLACE GOVERNOR
ACTUATOR (LSG ENGINE) . . . . . 6--21
TO ADJUST GOVERNOR
(LSG ENGINE) . . . . . . . . . . . . . . . . . 6--22
GOVERNOR TROUBLESHOOTING
(LSG ENGINE) . . . . . . . . . . . . . . . . . 6--23
GOVERNOR ACTUATOR
(LRG ENGINE) . . . . . . . . . . . . . . . . . 6--26
TO REPLACE GOVERNOR
ACTUATOR (LRG ENGINE) . . . . . 6--26
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . 6--28
SPARK PLUGS . . . . . . . . . . . . . . . . . . . 6--28
TO REPLACE SPARK PLUGS . . . . . . 6--28
ENGINE IGNITION TIMING . . . . . . . . 6--28
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . 6--28
VALVE TAPPET CLEARANCE . . . . . . 6--28
ENGINE ELECTRICAL SYSTEM . . . . . . . 6--29
TO REPLACE ENGINE STARTER . . . 6--29
TO REPLACE ENGINE STARTER
WITH AIR CONDITIONING . . . . . . 6--30
TO REPLACE ENGINE
ALTERNATOR . . . . . . . . . . . . . . . . . 6--31
TO REPLACE ENGINE ALTERNATOR
WITH AIR CONDITIONING . . . . . . 6--32

800/810 MM337 (6--01)

GAS ENGINE SERVICE MANUALS
FORD LSG--423 (2.3 Litre)
TENNANT Part Number 61875
FORD LRG--423 (2.3 Litre)
TENNANT Part Number 21791
FORD LRG--425 (2.5 Litre)
TENNANT Part Number 385439

6-- 1

ENGINE--G/LPG

6-- 2

800/810 MM337 (8--97)

ENGINE--G/LPG
FORD 2.3 LITER ENGINE
The Ford 2.3 liter engine in the early model
800/810 G/LP machines has a LSG--423
designation. Later model 800/810 G/LP machines
use a Ford 2.3 liter engine with a LRG--423
designation.
The easiest way to distinguish which engine your
machine is equipped with is the LSG--423 has a
distributor and distributor cap. The LRG--423 does
not have a distributor or distributor cap, instead,
the spark plug wires are attached to a ignition coil
module.

LSG
engine

LRG
engine

800/810 MM337 (8--97)

6-- 3

ENGINE--G/LPG
TO REMOVE ENGINE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Remove the engine cover and side door.
2. Remove the battery cables from the battery.
3. Drain the fluid from the radiator.
4. Drain the engine oil.

Early Design

5. Remove the air cleaner assembly.
6. Remove the radiator hoses from the engine.
7. Disconnect the exhaust pipe at the engine
manifold.
8. Disconnect the wire harness from all of the
engine components and position it out of the
way.
9. Disconnect the engine ground strap from the
machine frame.

Later Design
(LSG)

10. Disconnect the fuel line from the tank at the
fuel pump on a gas machine. On LPG
machine, disconnect the line from the LP
tank at the fuel lock off / vaporizer.
11. Remove the two M12 hex screws holding
the propel pump to the flywheel housing.
12. Pull the propel pump out of the flywheel
coupling.
13. Using overhead hoist, hook a chain through
the two pick-up points on top of the engine.
Apply a slight amount of tension on the
chain.

Current Design
(LRG)

14. Remove the two M12 hex screws from the
front motor mounts. These are the vertical
ones coming through the rubber isolators.
15. Remove the two M10 hex screws from the
rear motor mount. These are the horizontal
ones holding the motor mount bracket to the
back of the bellhousing plate.
16. The engine can now be carefully lifted out.
NOTE: Be sure to disconnect engine oil drain
hose from oil pan before lifting engine completely
out of machine.
6-- 4

800/810 MM337 (8--97)

ENGINE--G/LPG
TO INSTALL ENGINE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Using an overhead hoist, hook a chain
through the two pick-up points on the top of
the engine. Position the engine into engine
compartment.
2. Carefully lower the engine assembly down
on the motor mounts.

Early Design

NOTE: Make sure the hoses, wire harness,
exhaust pipe and propel pump are pulled back out
of the way when lowering engine assembly in
place.
3. Reinstall the two M12 hex screws in the
front motor mounts. Tighten to 64 -- 83 Nm
(47 -- 61 ft lb).
4. Reinstall the rear motor mount on the
bellhousing plate using two M10 hex screws.
Tighten to 37 -- 48 Nm (26 -- 34 ft lb).

Later Design
(LSG)

5. Reinstall the propel pump back in the
bellhousing. Reuse the M12 hex screws.
Tighten to 64 -- 83 Nm (47 -- 61 ft lb).
NOTE: Make sure the splines on pump line up
with splines in coupler when installing pump.
6. Reinstall the exhaust pipe back on the
manifold using the four M10 hex screws.
Tighten to 52 -- 67 Nm (39 -- 50 ft lb).
NOTE: Make sure the steel gasket is in place
when installing exhaust pipe.
7. Reconnect the fuel lines.

Current Design
(LRG)

8. Reconnect the ground cable from the
bellhousing to the machine frame.

Gas

800/810 MM337 (8--97)

6-- 5

ENGINE--G/LPG
9. Reconnect the oil drain hose to oil pan and
fill the engine with the proper grade of
engine oil.
10. Reconnect the main wire harness to engine
components: alternator, starter, governor
actuator, oil switch, temperature sender,
distributor, and ignition module.
11. Reinstall the radiator hoses to engine and fill
the radiator with anti--freeze coolant.
12. Reinstall the air cleaner assembly.

LPG

13. Reconnect the battery cables.
14. Jack up the rear of the machine.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands
15. Start the engine. Check for leaks on the fuel
lines and hydraulic lines.
16. Reinstall the engine cover and side door.
Lower the machine and operate, checking
for proper operation.

6-- 6

800/810 MM337 (8--97)

ENGINE--G/LPG
TO CHANGE ENGINE TIMING BELT
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake. Turn Off Machine And Remove Key.
1. Disconnect the battery cables from machine.
2. Open the engine cover and side door.
3. Remove the engine spark plugs.
NOTE: Make sure the timing pointer on the timing
belt cover is lined up with the ”O” mark on the
crank shaft damper before removing the timing
belt.

LSG engine

4. Loosen the engine alternator and remove
the V--belt.
NOTE: If the engine is equipped with a smaller
top timing belt cover; it needs to be removed
before the larger timing belt cover can be
removed
5. Remove the three M6 hex screws and nyloc
nuts holding the smaller top cover to the
engine. Remove and retain the smaller
cover.

LRG engine

6. Remove the crankshaft damper pulley.
7. Pull the belt guide off the end of the
crankshaft where the damper was removed.
8. Remove the five hex screws holding the
large timing belt cover to the engine.
Remove and retain the large cover.
NOTE: The tension on the timing belt needs to be
released before the belt can be removed.

LSG engine

9. Loosen the belt tensioner adjustment screw
and release the tension on the timing belt.
Once the tension is released, re--tighten the
tensioner adjustment screw.

LSG engine

NOTE: A special tension release tool is available
from FORD. The part number is T74P--6254--A. A
small pry bar may be used in place of this tool.

800/810 MM337 (8--97)

6-- 7

ENGINE--G/LPG
10. Remove the old timing belt from the engine.

LSG engine

11. Before installing a new timing belt, make
sure the camshaft sprocket timing mark lines
up with the timing pointer on the engine.
12. (LSG only) Remove the distributor cap and
set the distributor rotor to number 1 firing
position by turning the auxiliary shaft
sprocket. Reinstall the distributor cap.
13. Install the new timing belt over the
crankshaft sprocket and then
counterclockwise over the the auxiliary and
camshaft sprockets. Align the belt fore and
aft on each sprocket.
14. Loosen the tensioner adjustment bolt to
allow the tensioner to move against the belt.

LRG engine

15. Rotate the crankshaft two complete turns in
normal rotation to remove the slack from the
belt.
16. Re--check the alignment of the timing marks.
17. Reinstall the belt guide and damper to the
crankshaft.
18. Reinstall the timing belt cover and the five
hex screws.
19. Reinstall the small, top cover on the timing
belt cover. Hand tighten the three M6 hex
screws and nyloc nuts.

LRG engine

20. Reinstall the spark plugs.
21. Reinstall the alternator V--belt, pull the
alternator to tension the belt, tighten the
alternator mount bolts.
22. Reconnect the battery cables. Start the
engine and check the timing. The timing
should be set at 10 degrees BTDC with the
engine at idle speed.

6-- 8

800/810 MM337 (8--97)

ENGINE--G/LPG
LUBRICATION
ENGINE
Check the engine oil level daily. Change the
engine oil and oil filter every 100 hours of machine
operation. Use 10W30 SAE--SG/SH rated engine
oil.

The engine oil drain is located on the left side of
the machine inside the main brush compartment.
Fill the engine with oil to the level indicated on the
oil dipstick. The engine oil capacity is 4.7 L (5 qt)
including the oil filter.

08448

COOLING SYSTEM
Check the radiator coolant every 100 hours of
operation. Use clean water mixed with a
permanent-type, ethylene glycol antifreeze to a
--34_ C (--30_ F) rating.
FOR SAFETY: When Servicing Machine, Avoid
Contact With Hot Engine Coolant.
ATTENTION! Never pour cold water or cold
antifreeze into the radiator of an overheated
engine. Allow the engine to cool down to
avoid cracking the cylinder head or block.
Keep the engine running while adding water.

800/810 MM337 (8--97)

08432

6-- 9

ENGINE--G/LPG
Clean the radiator screen every 100 hours of
operation.

Check the radiator hoses and clamps every
200 hours of operation. Tighten the clamps if they
are loose. Replace the hoses and clamps if the
hoses are cracked, harden, or swollen.

08582

Check the radiator core exterior and hydraulic
cooler fins for debris every 100 hours of
operation. Blow or rinse all dust, which may have
collected on the radiator, in through the grille and
radiator fins, opposite the direction of normal air
flow. The grille and hydraulic cooler open for
easier cleaning. Be careful not to bend the cooling
fins when cleaning. Clean thoroughly to prevent
the fins becoming encrusted with dust. Clean the
radiator and cooler only after the radiator has
cooled to avoid cracking.
FOR SAFETY: When Servicing Machine, Wear
Eye And Ear Protection When Using
Pressurized Air Or Water.

08454

Flush the radiator and the cooling system every
400 hours of operation, using a dependable
cleaning compound.

ENGINE BELT
The engine fan belt is driven by the engine
crankshaft pulley and drives the alternator pulley.
Proper belt tension is 9 to 10 mm (0.35 to
0.39 in) for a new belt and 10 to 11 mm (0.39
to 0.43 in) for a used belt with a force of
10 kg (22 lb).
Check and adjust the belt tension every 100 hours
of operation.
08486

6-- 10

800/810 MM337 (8--97)

ENGINE--G/LPG
AIR INTAKE SYSTEM
AIR FILTER INDICATOR
The air filter indicator shows when to clean or
replace the air filter element. Check the indicator
daily. The indicator’s red line will move as the air
filter element fills with dirt. Do not clean or replace
the air filter element until the red line reaches
5 kPa (20 in H2O) and the ”SERVICE WHEN
RED” window is filled with red. The indicator’s red
line may return to a lower reading on the scale
when the engine shuts off. The red line will return
to a correct reading after the engine runs for a
while.

08447

Reset the air filter indicator by pushing the reset
button on the end of the indicator after cleaning or
replacing the air filter element.

AIR FILTER
The engine air filter housing has a dust cap and a
dry cartridge-type air filter element. Empty the
dust cap daily. The air filter must be replaced
whenever the filter element is damaged or has
been cleaned three times.
Service the air filter element only when the air
filter indicator shows restriction in the air intake
system. Do not remove the air filter element from
the housing unless it is restricting air flow.
08455

800/810 MM337 (8--97)

6-- 11

ENGINE--G/LPG
TO REPLACE AIR FILTER ELEMENT
1. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine: Stop On Level Surface, Set The
Parking Brake, Turn Off Machine And Remove
Key.
2. Open the left side and top engine access
doors.
3. Unscrew the clamp ring on the filter.
4. Remove the dust cap.
5. Empty the dust cap.
6. Remove the filter wing nut.
7. Gently pull the filter element out of the filter
housing.
8. Clean the interior of the air cleaner housing
with a camp cloth. Clean the element
housing sealing surfaces.
9. Using an air hose, direct dry, clean air
maximum 205 kPa (30 psi) up and down
pleats on the inside of the filter. Do not rap,
tap, or pound dust out of the element.
FOR SAFETY: When Servicing Machine, Wear
Eye And Ear Protection When Using
Pressurized Air Or Water.
10. After cleaning the air filter element, inspect it
for damage by placing a bright light inside.
The slightest rupture requires replacement
of the filter. Clean and inspect the seals on
the ends of the element. They should be
unbroken and flexible. Remember to replace
the element after cleaning it three times.
11. Install the new or cleaned filter element so
the fins on the element are at the intake end
of the air cleaner. Be careful not to damage
the fins. Make sure the element is seating
evenly. Tighten the element wing nut.
12. Install the dust cap with the arrows pointing
up. Tighten the clamp ring to hold it in place.
Check all intake hose connections for leaks
or abrasions.
13. Reset the air filter restriction indicator.
14. Close the access doors.
02492

6-- 12

800/810 MM337 (8--97)

ENGINE--G/LPG
FUEL SYSTEM -- GASOLINE
FUEL FILTERS
The fuel filter traps fuel contaminants. The filter is
located on the fuel line going into the carburetor.
Replace the filter elements every 400 hours of
operation.
LSG engine

LRG engine

CARBURETOR
The carburetor has two basic adjustments. Those
adjustments are idle fuel mixture and idle speed.
Check and adjust idle fuel mixture and idle speed
every 100 hours of operation.
FOR SAFETY: When Servicing Machine, Keep
Flames And Sparks Away From Fuel System
Service Area. Keep Area Well Ventilated.
The idle speed is controlled by a screw located on
the side of the carburetor next to the throttle
linkage. Increase the engine speed by turning the
screw clockwise. Decrease the engine speed by
turning the screw counter-clockwise. Proper idle
speed is 950 + 50 rpm with all accessories off.

LSG engine

LRG engine

800/810 MM337 (8--97)

6-- 13

ENGINE--G/LPG
FUEL SYSTEM -- LPG
The liquid withdrawal LPG fuel system has up of
five components: the LPG fuel tank, pressure
relief valve, fuel filter lock, vaporizer-regulator,
and the carburetor.
Liquid LPG fuel flows from the LPG tank under its
own pressure, to the pressure relief valve. Usually
this valve is closed, preventing LPG fuel from
escaping into the atmosphere. The valve opens to
relieve pressure if the fuel pressure exceeds
system limits. From the pressure relief valve, the
liquid LPG fuel flows to the fuel filter lock.

LSG
engine

The fuel filter lock filters unwanted tank scale and
deposits out of the LPG fuel. The fuel filter lock
also stops the flow of LPG fuel when the engine is
not operating. The filter fuel lock allows LP fuel to
flow to the carburetor when engine vacuum is
sensed.
The vaporizer section of the vaporizer-regulator
converts the liquid LPG fuel into a gaseous LPG
fuel. From the vaporizer section, the gaseous
LPG fuel is sent to the primary regulator section
of the vaporizer-regulator. The primary regulator
section reduces the pressure of the LPG fuel. The
secondary regulator section reduces the LPG fuel
pressure to the level required by the carburetor.
From the vaporizer-regulator, the LPG fuel is sent
to the carburetor where it is finally metered into
the air flow sent to the engine combustion
chamber.
Never operate an LPG powered machine if the
LPG fuel system is leaking, or if any component in
the fuel system is malfunctioning. Operating the
machine under either of these conditions may
cause a fire or explosion.

LSG
engine

LSG
engine

Check for frosting. If frosting occurs on or near
any LPG component, there is a possible LPG fuel
leak or malfunctioning component.

LRG
engine

6-- 14

800/810 MM337 (8--97)

ENGINE--G/LPG
To locate the leak, apply a soapy water solution to
the suspected area. Watch for bubbles forming in
this suspected area. This area may have an LPG
fuel leak. Repair or replace the part. Use Loctite
brand Stainless Steel PST thread sealant when
reassembling. Aging or high humidity does not
affect this epoxy-type sealant. Be sure to follow
application directions and apply proper torque
when reconnecting fittings. Never bypass safety
components except to test. If they are defective,
replace them before operating the machine.
Frosting does not occur before the engine
reaches operating temperature. Check after
engine reaches operating temperature.

LRG
engine

Check routings of all LPG hoses. Keep them
away from sharp edges, exhaust manifolds, or
other hot surfaces. Check for signs of abrasion or
deterioration. Replace worn or damaged hoses.

LRG
engine

800/810 MM337 (8--97)

6-- 15

ENGINE--G/LPG
LPG FUEL TANK
The LPG fuel tank should be inspected for sharp
dents, gouges, leaks, and broken protecting rings
whenever the tanks are refilled. All tank valves
must be inspected for leaks using a soap solution.
Valves must also be checked for dirt, paint, or
other debris in the valve openings. The following
specific checks must also be made:
Filler Valve -- Check the valve for proper
functioning and the presence of the
handwheel. Valve must be closed except
during filling.

03485

Liquid Service Valves -- Check the valve
for proper functioning and presence of the
handwheel. The valve must be closed
except when in service.

03485

Tank Service Valve Coupling -- Check for
proper functioning, thread condition, and
damaged or missing washers or o-rings.

03485

6-- 16

800/810 MM337 (8--97)

ENGINE--G/LPG
Safety Relief Valve -- Check for damage.
Check for the presence of the relief valve
elbow and the proper direction of the elbow.
If the rain cap is missing, check for foreign
matter and replace the rain cap. Do not
tamper with the relief valve setting.
Magnetic Liquid Level Gauge -- Check the
operation against the maximum filling point
as determined by weight.
An LPG fuel tank with any of the stated defects
must be removed from service and be repaired or
destroyed accordingly.

03485

If an LPG fuel tank is damaged or leaking, it
should be removed to a designated safe area. Do
not attempt to make repairs to the tank,
regardless of condition. Qualified personnel must
make repairs or disposal.
The care an LPG fuel tank receives has a direct
bearing on how long that tank can be used safely.
LPG fuel tanks must not be dropped or dragged
across any surface. To move LPG fuel tanks, use
a hand truck or roll the tank on its foot ring while it
is being held in a position slightly off the vertical.
Whether the storage is inside or outside, fuel
tanks should not be stored near combustible
materials or high temperature sources such as
ovens and furnaces, since the heat may raise the
pressure of the fuel to a point where the safety
relief valves would function. Store the tanks in a
way that if the safety relief valves do function,
they will relieve vapor and not liquid.

03485

Valves on empty tanks must be closed during
storage and transportation.
Similar precautions should be taken in storing
machines fitted with LPG fuel tanks. The
machines may be stored or serviced inside
buildings, provided there are no leaks in the fuel
system and the tanks are not overfilled. While
machines are being repaired inside a building, the
shut-off valve on the tank must be closed, except
when the engine has to be operated.
Changing the tank is a chance for the machine
operator to carefully check over the tank, fittings,
and the fuel lines and fittings. If abnormal wear is
detected, report the findings to the appropriate
personnel.

800/810 MM337 (8--97)

6-- 17

ENGINE--G/LPG
TO CHANGE LPG FUEL TANK
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Park the machine in a designated safe area.
2. Close the tank service valve.
3. Operate the engine until it stops from lack of
fuel, then set the machine parking brake.
4. Put on gloves and remove the
quick-disconnect tank coupling.
5. Inspect the LPG fuel lines for wear or
damage.
6. Remove the empty LPG fuel tank from the
machine.

03485

7. Check the tank for damage or wear.
8. Store the tank in a designated, safe area.
9. Select a filled LPG fuel tank and inspect it
for damage or leaks.
NOTE: Make sure the LPG fuel tank matches the
fuel system (liquid tank with liquid system).
10. Carefully put the LPG tank in the machine
so that the tank centering pin enters the
aligning hole in the tank collar.
NOTE: If you cannot line up the centering pin,
make sure you have the correct LPG fuel tank
and then adjust the pin locator in or out.
11. Fasten the tank hold-down clamp to lock the
tank in position.
12. Connect the LPG fuel line to the tank service
coupling. Make sure the service coupling is
clean and free of damage. Also make sure it
matches the machine service coupling.
03485

13. Open the tank service valve slowly and
check for leaks. Close the service valve
immediately if an LPG leak is found, and tell
the appropriate personnel.
14. If no leaks are found, the engine is ready to
start.

6-- 18

800/810 MM337 (8--97)

ENGINE--G/LPG
FUEL FILTER LOCK
The fuel filter lock filters the LPG fuel. It also
stops the flow of LPG fuel to the engine when the
engine is not operating or when the engine
vacuum drops to zero.

VAPORIZER-REGULATOR
If any malfunction is found, completely
disassemble the vaporizer-regulator. Clean all the
parts in alcohol.
Inspect all the parts and replace where needed.
Carefully reassemble the vaporizer-regulator with
the seal repair kit. Check for proper operation.

CARBURETOR
If any malfunction is found, completely
disassemble the carburetor. Clean all the parts in
alcohol.
Inspect all the parts and replace where needed.
Carefully reassemble the carburetor with the seal
repair kit.

LSG engine

LRG engine

800/810 MM337 (8--97)

6-- 19

ENGINE--G/LPG
OIL PRESSURE SWITCH
The engine oil pressure switch requires no regular
maintenance. Never bypass the oil pressure
switch. The switch is a safety feature that
prevents the engine from starting until there is oil
pressure. The switch will also shut the engine off
if there is a loss of oil pressure.

LPG FUEL TROUBLESHOOTING
Problem

Cause

Remedy

Engine will not start

Out of fuel

Fill fuel tank

Service valve opened too quickly
-- check valve stopped fuel flow

Close service valve and reopen
slowly

Plugged fuel filter

Replace filter

Kinked or restricted fuel line

Straighten or replace fuel line

Engine out of tune

Tune-up engine

Oil pressure switch failure

Replace oil pressure switch

Fuel lock valve failure

Repair or replace fuel filter lock

Vaporizer-regulator failure

Repair or replace
vaporizer-regulator

Wrong type of fuel tank -- vapor
withdrawal tank

Replace vapor withdrawal tank
with liquid withdrawal tank

Plugged fuel filter

Replace filter

Kinked or restricted fuel line

Straighten or replace fuel line

Engine out of tune

Tune-up engine

Restricted air filter

Clean or replace air filter element

Vaporizer-regulator out of
adjustment

Adjust vaporizer-regulator

Engine runs unevenly or lacks
power

6-- 20

800/810 MM337 (8--97)

ENGINE--G/LPG
GOVERNOR ACTUATOR (LSG ENGINE)
The electronic governor controls the engine
speed. The governor consists of an ignition
control assembly, a control box, and an actuator
mounted to the carburetor. The ignition control
assembly and control box regulate the actuator,
which in turn controls the throttle.
The electronic governor is factory set and is not
user serviceable.

TO REPLACE GOVERNOR ACTUATOR
(LSG ENGINE)
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Stop the engine and set the machine parking
brake.
2. Open the engine cover and side door.
3. Disconnect the battery cables.
WARNING: Always disconnect battery
cables from machine before working
on electrical components.
4. Disconnect the two wires leading to the top
of the governor actuator.
5. Pop the rod end of the throttle rod off the
ball on the actuator arm.
6. Remove the four screws and nuts holding
the actuator to the mount bracket.
7. Remove the arm from the actuator shaft and
install it on the new actuator in the same
orientation.
8. Position the new actuator on the mount
bracket and install the four screws and nuts.
Tighten to 9 -- 13 Nm (7 -- 10 ft lb).
9. Snap the throttle rod onto the ball on the
actuator arm.
10. Reconnect the two wires on top of the
actuator. Reconnect the battery cables.
11. Start the machine and check the new
actuator for proper operation. See TO
ADJUST GOVERNOR instructions.
800/810 MM337 (8--97)

6-- 21

ENGINE--G/LPG
TO ADJUST GOVERNOR (LSG ENGINE)
FOR SAFETY: Before Leaving Or Servicing
Machine: Stop On Level Surface, Set The
Parking Brake.
1. Raise the rear of the machine until the drive
wheel is off the floor.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands.
2. Start the engine and warm to operating
temperature.
3. Move the speed switch to idle, all
accessories off.
4. Move speed switch to fast position.
5. If more than three engine speed surges
occur, turn the surge adjustment screw
(located on back of governor control box
under hole plug) counterclockwise
one-eighth of a turn.
6. Repeat this procedure until less than three
engine surges occur.
7. Replace the hole plug if removed for
adjustment.

6-- 22

800/810 MM337 (8--97)

ENGINE--G/LPG
GOVERNOR TROUBLESHOOTING
(LSG ENGINE)
1. The first step in this troubleshooting is to
disconnect the throttle linkage at the
carburetor and work the throttle at the
carburetor by hand.
If you can run the engine by hand and it
works with no problems, go to step two.
If the problem continues, it is not with the
governor, it is with the ignition signal, fuel
systems or the engine itself.
2. The idle speed is the governor position. This
is 1100 -- 1500 RPM and is controlled by the
governor, NOT THE IDLE STOP SCREW
ON THE CARBURETOR! In order to adjust
the idle mixture and (SHUTOFF SPEED) on
the carburetor,either of the wires on the
actuator box must be disconnected. After
warming up the engine, adjust the shutoff
speed to 850 ¦ 25 RPM and adjust the idle
mixture for optimum idle quality. After doing
this, shut off the engine and reattach the
wires to the actuator. It is important that the
shutoff speed not be set any higher than 900
RPM or the engine will (diesel) when it is
shut off. Again, the idle speed screw on the
carburetor does not control the start/idle
speed of a correctly setup engine.
3. Fuel System
A common problem that has been
encountered on LPG machines is a
restricted fuel hose (a clogged fuel filter can
have the same effect).
If the governor opens the carburetor wide
open and the engine loses speed, the
problem is not in the governor. The fuel
system is at fault. The purpose of the
governor is to open the carburetor and to
bring the engine to set RPM’s depending on
where you have the speed control switch set
at.

800/810 MM337 (8--97)

6-- 23

ENGINE--G/LPG
4. System Grounds
The wire harness grounds are routed to the
stud on the alternator, and from there, a
separate cable is routed to the bolt on the
bell housing where the battery cable is
attached.
If a bad ground is present, the engine will
tend to run over speed.
The machine must have good grounds
throughout from the battery cable to the
control box.
The battery cable must be clean and tight.
The actuator is internally isolated and does
not require that the cable be grounded.
5. Start-Up Check
With the throttle switch in the engine start
position, turn the ignition switch to the on
position. The actuator should cycle the
carburetor lever once.
NOTE: A cycle is to move from the off or idle
position to the open position and then return to
the off or idle position.
If this does not happen, the power wiring to
the control box is probably at fault or the
control box is faulty. IT IS RARE TO HAVE
A FAULTY CONTROL BOX, so proceed
with the following voltage checks BEFORE
REPLACING IT.
6. Throttle Control Switch Check
If the engine doesn’t respond to the throttle
switch control:
a. With the engine running, disconnect
Wire 86, purple wire, at the actuator.
b. Connect a jumper wire from the battery
terminal on the starter to the terminal
where you removed Wire 86, purple
wire, from the actuator.

6-- 24

800/810 MM337 (8--97)

ENGINE--G/LPG
The engine should come up to operating speed.
If the engine comes up to speed, replace the
throttle control switch.
a. Hunts at running speed with the
accessories off.
b. Responds very sluggishly to switch
changes, an adjustment change in the
control box may be necessary.
Cut and remove the RTV seal on the back of
the box.
A slight adjustment of the sensitivity screw
may be necessary to correct the conditions
mentioned above. Turn the screw
approximately 2_ at a time and wait for 30
seconds to verify the change. Be careful.
Only a slight change is necessary, and the
“pot” can be broken if too much force is
used.
After the control throttle response is
achieved, verify that the operating speeds
are correct and adjust, if necessary. After
the speeds are reset, the sensitivity screw
may have to be readjusted.
In general, if a new box is being installed, a
gasoline-equipped machine may require that
the sensitivity be reduced slightly.
When the sensitivity is adjusted, the run
speed should not be affected. If the
adjustment is too great, the start speed will
be affected. Verify that the start speed is
correct.
If too much sensitivity is adjusted in, the
engine will either hunt in a no load condition
or over speed severely when the speed
switch is actuated.
The engine speed should not drop off, but
you can have the three hunts of the engine.
If, for some reason, the sensitivity
adjustment became grossly maladjusted, a
good starting point can be obtained by
rotating the pot fully counterclockwise and
then back clockwise 45_.
After the adjustments are made and verified,
reassemble the back plate and reseat the plate
with a bead of RTV to keep dust and moisture out
of the box.

800/810 MM337 (8--97)

6-- 25

ENGINE--G/LPG
GOVERNOR ACTUATOR (LRG ENGINE)
The governor actuator on the LRG engine is
smaller than on the LSG engine. The throttle rod
has been eliminated on this new actuator. The
unit is bolted directly to the carb base.

TO REPLACE GOVERNOR ACTUATOR
(LRG ENGINE)
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Stop the engine and set the machine parking
brake.
2. Open the engine cover and side door.
3. Unplug the governor actuator from the
electrical harness.
4. Remove and retain the cap screw holding
the wire clamp to the actuator mount
bracket.
5. Remove and retain the two cap screws
holding the mounting strap to the mount
bracket.
6. Carefully remove the actuator from the
mount bracket.
NOTE: When removing the actuator, slip the
slotted arm out from the shoulder bolt on the arm
of the carburetor.
7. Remove the arm from the old actuator and
install on the new actuator in the same
orientation.
8. Install the new actuator by sliding the slotted
arm under the shoulder bolt on the
carburetor arm and fitting the actuator in the
matching radius of the mount bracket.
9. Loosely assemble the mount strap using the
two cap screws. Use a small amount of
loctite on the threads of cap screws. Do not
tighten at this time.

6-- 26

800/810 MM337 (8--97)

ENGINE--G/LPG
10. Rotate the actuator to just close the
carburetor butterfly against the idle stop
screw----hold this position.
11. Mark the side (away from the arm) of the
actuator at the mount bracket top edge with
a pencil. Further rotate the actuator in the
direction of closing the butterfly until the
pencil mark is above the bracket edge by
approximately .20 inches.
12. Visually check that the slotted arm is
centered on the length of the shoulder bolt
and that there is no interference between
the arms or shafts. Tighten the strap cap
screws.
13. Check the arm movement----there must be
no binding throughout the full stroke and
there must be a spring pre--load holding the
carburetor in its throttle closed position.
14. Install the wire clamp to the side of the
bracket making approximately a 1 inch loop
between the actuator and bracket. Tighten
the cap screw.
15. Start the machine and check for proper
operation.

800/810 MM337 (8--97)

6-- 27

ENGINE--G/LPG
IGNITION SYSTEM
SPARK PLUGS
Clean or replace, and set the gap of the spark
plugs every 400 hours of operation. A wire gauge
is best for checking the spark plug gap. A flat
gauge should not be used unless the electrode
surfaces have been dressed with a small file to
get parallel surfaces between the center and side
electrode. Set the spark plug gap by bending the
side electrode. All spark plugs, new or used,
should have the gaps checked and reset if
necessary.
The proper spark plug gap is 1 mm (0.040 in).

01471

TO REPLACE SPARK PLUGS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Clean the spark plug seat in the cylinder
head.
2. Use a new seat gasket and screw the plug
in by hand.
3. Tighten the spark plugs with a socket
wrench of the correct size.
ENGINE IGNITION TIMING
The engine timing should be set at 10 BTDC with
the throttle is in the idle position.

CYLINDER HEAD
A three-stage torque procedure should be used
when reassembling the cylinder head. Tighten the
cylinder head bolts seasonally. See Ford
LRG--423, 2.3 Engine Service Manual at the end
of this section.
VALVE TAPPET CLEARANCE
The valve tappet clearance must be checked and
adjusted if necessary every 400 hours of
operation. See Ford LRG--423, 2.3 Engine
Service Manual at the end of this section.
Clean the crankcase ventilation hoses, tubes, and
fittings and replace the PCV valve every
400 hours of operation.
6-- 28

800/810 MM337 (8--97)

ENGINE--G/LPG
ENGINE ELECTRICAL SYSTEM
TO REPLACE ENGINE STARTER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.
3. Remove the air cleaner assembly from the
engine.
WARNING: Always disconnect battery
cables from machine before working
on electrical components.

4. The engine starter can now be accessed

from the engine compartment. Reach over
the top of the engine and locate the starter.

NOTE: The panel in the operators compartment
can be removed for more access.
5. Remove the wires attached to the starter.
Label the wires to make sure they are
returned to the proper location in the
re--assembly procedure.
6. Remove the three M10 hex screws holding
the starter to the engine bellhousing.
Remove the starter from the machine.
7. Reverse the order of these steps to reinstall
a new or rebuilt starter. Tighten the M10 hex
screw to 37 -- 48 Nm (26--34 ft lb).
8. Reinstall the air cleaner to the engine.
9. Reconnect the battery and start the
machine, checking for proper starter
operation.

800/810 MM337 (8--97)

6-- 29

ENGINE--G/LPG
TO REPLACE ENGINE STARTER WITH AIR
CONDITIONING
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.
WARNING: Always disconnect battery
cables from machine before working
on electrical components.
3. Remove the two nuts holding the air box
cover to the air conditioning air box. Remove
the air box cover from the machine.
4. Remove the four acorn nuts holding the
plastic fan duct assembly to the side panel
of the machine. Remove the fan duct from
the machine. This fan duct is accessed from
the operators compartment.
5. Remove the nuts holding the air conditioning
evaporator assembly to the side panel of the
machine. This air conditioning condenser
assembly is accessed from the operator
compartment. Pull the air conditioning
condenser assembly as far as possible into
the operators compartment.

6. The engine starter can now be accessed

from the engine compartment. Reach over
the top of the engine and locate the starter.

7. Remove the wires attached to the starter.
Label the wires to make sure they are
returned to the proper location in the
re--assembly procedure.
8. Remove the three M10 hex screws holding
the starter to the engine bellhousing.
Remove the starter from the machine.
9. Reverse the order of these steps to reinstall
a new or rebuilt starter. Tighten the M10 hex
screw to 37 -- 48 Nm (26--34 ft lb).
10. Reinstall the air conditioning condenser
assembly and the plastic fan duct assembly
to the machine side panel.
11. Reconnect the battery and start the
machine, checking for proper starter
operation.

6-- 30

800/810 MM337 (8--97)

ENGINE--G/LPG
TO REPLACE ENGINE ALTERNATOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.

LSG engine

3. The engine alternator can be accessed from
the engine compartment. Loosen the M8
hex screw on the top bracket of the
alternator.
4. Loosen the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Pivot the alternator in and
remove the V--belt.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.

LRG engine

5. Remove the wires attached to the alternator.
Label the wires to make sure they are
returned to the proper location in the
re--assembly procedure.
6. Remove the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Remove the alternator
from the machine.
7. Reverse the order of these steps to reinstall
a new or rebuilt alternator. Tighten the M8
hex screw to 18 -- 24 Nm (15--20 ft lb).
Tighten the M10 hex screw to 37 -- 48 Nm
(26--34 ft lb).

LSG engine

8. Reconnect the battery and start the
machine, checking for proper alternator
operation.

LRG engine

800/810 MM337 (8--97)

6-- 31

ENGINE--G/LPG
TO REPLACE ENGINE ALTERNATOR WITH
AIR CONDITIONING
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.
3. The engine alternator can be accessed from
the engine compartment.
4. Loosen the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Pivot the alternator in and
remove the V--belt.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.
5. Remove the wires attached to the alternator.
Label the wires to make sure they are
returned to the proper location in the
re--assembly procedure.
6. Remove the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Remove the alternator
from the machine.
7. Reverse the order of these steps to reinstall
a new or rebuilt alternator. Tighten the M8
hex screw to 18 -- 24 Nm (15--20 ft lb).
Tighten the M10 hex screw to 37 -- 48 Nm
(26--34 ft lb).
8. Reconnect the battery and start the
machine, checking for proper alternator
operation.

6-- 32

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
CONTENTS
Page
PERKINS 200 SERIES ENGINE . . . . . . . . 7--3
TO REMOVE ENGINE . . . . . . . . . . . . . . 7--4
TO INSTALL ENGINE . . . . . . . . . . . . . . . 7--5
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 7--7
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 7--7
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . 7--9
AIR FILTER INDICATOR . . . . . . . . . . . . 7--9
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . 7--9
TO REPLACE AIR FILTER
ELEMENT . . . . . . . . . . . . . . . . . . . . . 7--10
FUEL SYSTEM (early machines) . . . . . . 7--11
FUEL FILTER/WATER SEPARATOR
(early machines) . . . . . . . . . . . . . . . . 7--11
TO REPLACE FILTER/WATER
SEPARATOR CARTRIDGE
(early machines) . . . . . . . . . . . . . 7--11
FUEL LINES (early machines) . . . . . . 7--12
IN--LINE FUEL PUMP
(early machines) . . . . . . . . . . . . . . . . 7--12
FUEL SYSTEM (later machines) . . . . . . . 7--13
FUEL FILTER/WATER SEPARATOR
(later machines) . . . . . . . . . . . . . . . . 7--13
TO REPLACE FILTER/WATER
SEPARATOR CARTRIDGE
(later machines) . . . . . . . . . . . . . 7--13
FUEL LINES (later machines) . . . . . . 7--14
IN--LINE FUEL PUMP
(later machines) . . . . . . . . . . . . . . . . 7--14
ENGINE MOUNTED FUEL FILTER . . . . . 7--15
TO REPLACE ENGINE MOUNTED
FUEL FILTER CARTRIDGE . . . . . . 7--15
PRIMING FUEL SYSTEM . . . . . . . . . . . . . 7--16
TO PRIME FUEL SYSTEM
(early machines) . . . . . . . . . . . . . . . . 7--16
TO PRIME FUEL SYSTEM
(later machines) . . . . . . . . . . . . . . . . 7--16
ENGINE ELECTRICAL SYSTEM . . . . . . . 7--17
TO REPLACE ENGINE STARTER . . . 7--17
TO REPLACE ENGINE STARTER
WITH AIR CONDITIONING . . . . . . 7--18
TO REPLACE ENGINE
ALTERNATOR . . . . . . . . . . . . . . . . . 7--19
TO REPLACE ENGINE ALTERNATOR
WITH AIR CONDITIONING . . . . . 7--20
ENGINE FAN BELT . . . . . . . . . . . . . . . . . . 7--21

800/810 MM337 (6--01)

DIESEL ENGINE SERVICE MANUALS
PERKINS 200 Series
TENNANT Part Number 61838
PERKINS 700 Series
TENNANT Part Number 380503

7-- 1

ENGINE--D--PERKINS 200 SERIES

7-- 2

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
PERKINS 200 SERIES ENGINE
To verify that your machine is equipped with a
Perkins 200 Series engine----check the tag on the
front right corner of the engine valve cover. The
200 Series engine will have the numbers 204--25.

800/810 MM337 (8--97)

7-- 3

ENGINE--D--PERKINS 200 SERIES
TO REMOVE ENGINE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Remove the engine cover and side door.
2. Remove the battery cables from battery.
3. Drain the radiator coolant.
4. Drain the engine oil.
5. Remove the air cleaner assembly.
6. Remove the radiator hoses from the engine.
7. Disconnect the exhaust pipe at the engine
manifold.
8. Disconnect the wire harness from all engine
components and place it out of the way.
9. Disconnect the engine ground strap from the
machine frame.
10. Disconnect both the fuel lines and the return
line coming from the fuel tank at the fuel
filter.
11. Disconnect the throttle cable from the
engine.
12. Remove the two M12 hex screws holding
the propel pump to the flywheel housing.
13. Pull the propel pump out of flywheel
coupling.
14. Using overhead hoist, hook a chain through
the two pick-up points on the engine. Put a
slight amount of tension on the chain.
15. Remove the two M12 hex screws from front
motor mounts. (these are the vertical ones
coming through the rubber isolators.)
16. Remove the two M10 hex screws from rear
motor mount. (these are the horizontal ones
holding the mount bracket to the bellhousing
plate.)
17. The engine can now be carefully lifted out.
NOTE: Be sure to disconnect engine oil drain
hose from oil pan before lifting engine completely
out of machine.
7-- 4

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
TO INSTALL ENGINE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Using an overhead hoist, hook a chain
through the two pick-up points on the top of
the engine. Position the engine into the
engine compartment.
2. Lower the engine assembly carefully down
on the motor mounts.
NOTE: Make sure the hoses, wire harness,
exhaust pipe and propel pump are pulled back out
of the way when lowering engine assembly into
place.
3. Reinstall the M12 hex screws into the front
motor mounts. Tighten to 64 -- 83 Nm
(47 -- 61 ft lb).
4. Reinstall the rear motor mount on the
bellhousing plate using the two M10 hex
screws. Tighten to 37 -- 48 Nm
(26 -- 34 ft lb).
5. Reinstall the propel pump back in the
bellhousing. Reuse the M12 hex screws.
Tighten to 64 -- 83 Nm (47 -- 61 ft lb).
NOTE: Make sure the splines on pump line up
with splines in coupler when installing pump.
6. Reinstall the exhaust pipe back on the
manifold using four M10 hex screws. Tighten
to 52 -- 67 Nm (39 -- 50 ft lb).
NOTE: Make sure steel gasket is in place when
installing exhaust pipe.
7. Reconnect the fuel lines.
8. Reconnect the throttle cable to the engine.
9. Reconnect the ground cable from the
bellhousing to the machine frame.

800/810 MM337 (8--97)

7-- 5

ENGINE--D--PERKINS 200 SERIES
10. Reconnect the oil drain hose to the oil pan
and fill the engine with the proper grade of
engine oil.
11. Reconnect the main wire harness to the
engine components, alternator, starter, oil
switch, and the temperature sender.
12. Reinstall the radiator hoses to engine and fill
the radiator with antifreeze coolant.
13. Reinstall the air cleaner assembly.
14. Reconnect the battery cables.
15. Jack up the rear of the machine.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands
16. Start the engine and check for fuel or
hydraulic oil leaks.
17. Reinstall the engine cover and side door.
Lower the machine and operate, checking
for proper operation.

7-- 6

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
LUBRICATION
Check the engine oil level daily. Change the
engine oil and oil filter every 100 hours of machine
operation. Use 10W30 SAE--CC/CD rated engine
oil.

08431

The engine oil drain is located on the left side of
the machine inside the main brush compartment.
Fill the engine with oil to the level indicated on the
oil dipstick. The engine oil capacity is 6 L (6.3 qt)
including the oil filter.

08448

COOLING SYSTEM
Check the radiator coolant level every 100 hours
of operation. Use clean water mixed with a
permanent-type, ethylene glycol antifreeze to a
--34_ C (--30_ F) rating.
FOR SAFETY: When Servicing Machine, Avoid
Contact With Hot Engine Coolant.
ATTENTION! Never pour cold water or cold
antifreeze into the radiator of an overheated
engine. Allow the engine to cool down to
avoid cracking the cylinder head or block.
Keep the engine running while adding water.

800/810 MM337 (8--97)

08432

7-- 7

ENGINE--D--PERKINS 200 SERIES
Clean the radiator screen every 100 hours of
operation.

Check the radiator hoses and clamps every
200 hours of operation. Tighten the clamps if they
are loose. Replace the hoses and clamps if the
hoses are cracked, harden, or swollen.

08582

Check the radiator core exterior and hydraulic
cooler fins for debris every 100 hours of
operation. Blow or rinse all dust, which may have
collected on the radiator, in through the grille and
radiator fins, opposite the direction of normal air
flow. The grille and hydraulic cooler open for
easier cleaning. Be careful not to bend the cooling
fins when cleaning. Clean thoroughly to prevent
the fins becoming encrusted with dust. Clean the
radiator and cooler only after the radiator has
cooled to avoid cracking.
FOR SAFETY: When Servicing Machine, Wear
Eye And Ear Protection When Using
Pressurized Air Or Water.
08454

Flush the radiator and the cooling system every
400 hours of operation, using a dependable
cleaning compound.

7-- 8

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
AIR INTAKE SYSTEM
AIR FILTER INDICATOR
The air filter indicator shows when to clean or
replace the air filter element. Check the indicator
daily. The indicator’s red line will move as the air
filter element fills with dirt. Do not clean or replace
the air filter element until the red line reaches
5 kPa (20 in H2O) and the ”SERVICE WHEN
RED” window is filled with red. The indicator’s red
line may return to a lower reading on the scale
when the engine shuts off. The red line will return
to a correct reading after the engine runs for a
while.
Reset the air filter indicator by pushing the reset
button on the end of the indicator after cleaning or
replacing the air filter element.

08447

AIR FILTER
The engine air filter housing has a dust cap and a
dry cartridge-type air filter element. Empty the
dust cap daily. The air filter must be replaced
whenever the filter element is damaged or has
been cleaned three times.
Machines with the heavy duty air filter option have
a safety element. It is inside the standard
element. Replace, do not clean this element after
the regular element has been damaged or
cleaned three times.
Service the air filter element only when the air
filter indicator shows restriction in the air intake
system. Do not remove the air filter element
unless it is restricting air flow.

800/810 MM337 (8--97)

08455

7-- 9

ENGINE--D--PERKINS 200 SERIES
TO REPLACE AIR FILTER ELEMENT
1. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
2. Open the left side and top engine access
doors.
3. Unscrew the clamp ring on the filter.
4. Remove the dust cap.
5. Empty the dust cap.
6. Remove the filter wing nut.
7. Gently pull the filter element out of the filter
housing.

00051

8. Clean the interior of the air cleaner housing
with a damp cloth. Clean the element
housing sealing surfaces.
9. Using an air hose, direct dry, clean air
maximum 205 kPa (30 psi) up and down
pleats on the inside of the filter. Do not rap,
tap, or pound dust out of the element.
FOR SAFETY: When Servicing Machine, Wear
Eye And Ear Protection When Using
Pressurized Air Or Water.
10. After cleaning the air filter element, inspect it
for damage by placing a bright light inside.
The slightest rupture requires replacement
of the filter. Clean and inspect the seals on
the ends of the element. They should be
unbroken and flexible. Remember to replace
the element after cleaning it three times.

00000

11. Install the new or cleaned filter element so
the fins on the element are at the intake end
of the air cleaner. Be careful not to damage
the fins. Make sure the element is seating
evenly. Tighten the element wing nut.
12. Install the dust cap with the arrows pointing
up. Tighten the clamp ring to hold it in place.
Check all intake hose connections for leaks
or abrasion.
13. Reset the air filter restriction indicator.

02492

14. Close the access doors.

7-- 10

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
FUEL SYSTEM (early machines)
The diesel fuel system is made up of five basic
components which are: fuel tank, fuel filter, fuel
water trap filter, fuel pump, injection pump, and
injectors.
Fuel flows from the fuel tank through the fuel
water trap-filter. The water trap-filter separates
water and impurities from the fuel. From the fuel
water trap-filter, fuel is drawn through the electric
fuel pump and pumped to the engine mounted
fuel filter and then to the injection pump. The
injection pump pressurizes and sends fuel to the
injectors. The injectors atomize and inject proper
amounts of fuel into the combustion chamber at
the proper times. Excess fuel is returned to the
fuel tank through an overflow pipe.
FUEL FILTER/WATER SEPARATOR
(early machines)
The fuel filter/water separator separates water
and impurities from the fuel. It is located at the
back of the machine underneath and behind the
bumper. The bottom portion of the unit is the
water trap. The middle portion is the filter element.
Drain the water trap of water daily. To drain the
water trap, loosen the drain knob on the bottom of
the unit. First water, then diesel fuel will drain.
Tighten the drain knob when diesel fuel appears.
Replace the fuel filter element and clean the water
trap every 400 hours of operation.

TO REPLACE FILTER/WATER SEPARATOR
CARTRIDGE (early machines)
1. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
2. Loosen the unit vent plug and open the
water trap drain to drain diesel fuel.
3. Remove the filter cartridge from the filter
head.
4. Lubricate the o-ring of the new filter
cartridge and spin it onto the filter head.
5. Bleed the fuel lines of air as described in TO
PRIME FUEL SYSTEM.
800/810 MM337 (8--97)

7-- 11

ENGINE--D--PERKINS 200 SERIES
FUEL LINES (early machines)
Check the fuel lines every 50 hours of operation.
If the clamp band is loose, apply oil to the screw
of the band, and securely tighten the band.
Made of rubber, the fuel lines become worn out
whether the engine has been used much or not.
Replace the fuel lines and clamp bands every two
years.
If the fuel lines and clamp bands are found worn
or damaged before two years’ time, replace or
repair them at once. Bleed the fuel system after
replacement of any of the fuel lines, see TO
PRIME THE FUEL SYSTEM. When the fuel lines
are not installed, plug both ends with clean cloth
or paper to prevent dirt from entering the lines.
Dirt in the lines can cause fuel injection pump
malfunction.

IN--LINE FUEL PUMP
(early machines)
The in--line fuel pump is used to pull fuel from the
tank, through the fuel/water separator and into the
engine mounted fuel filter. The in--line fuel pump is
electric and runs off the 12VDC battery of the
machine.

7-- 12

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
FUEL SYSTEM (later machines)
The diesel fuel system is made up of five basic
components which are: fuel tank, fuel filter, fuel
water trap filter, fuel pump, injection pump, and
injectors.
Fuel flows from the fuel tank through the in--line
fuel pump, into the fuel water trap-filter, and then
to the engine mounted fuel filter. The water
trap-filter separates water and impurities from the
fuel. From the fuel water trap-filter, fuel is drawn
through the electric fuel pump and pumped to the
injection pump. The injection pump pressurizes
and sends fuel to the injectors. The injectors
atomize and inject proper amounts of fuel into the
combustion chamber at the proper times. Excess
fuel is returned to the fuel tank through an
overflow pipe.
FUEL FILTER/WATER SEPARATOR
(later machines)
The fuel filter/water separator separates water
and impurities from the fuel. It is located at the
back of the machine underneath and behind the
bumper. The bottom portion of the unit is the
water trap. The middle portion is the filter element.
Drain the water trap of water daily. To drain the
water trap, loosen the drain knob on the bottom of
the unit. First water, then diesel fuel will drain.
Tighten the drain knob when diesel fuel appears.
Replace the fuel filter element and clean the water
trap every 400 hours of operation.
TO REPLACE FILTER/WATER SEPARATOR
CARTRIDGE (later machines)
1. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
2. Loosen the unit vent plug and open the
water trap drain to drain diesel fuel.
3. Remove the filter cartridge from the filter
head.
4. Lubricate the o-ring of the new filter
cartridge and spin it onto the filter head.
5. Bleed the fuel lines of air as described in TO
PRIME FUEL SYSTEM.
800/810 MM337 (8--97)

7-- 13

ENGINE--D--PERKINS 200 SERIES
FUEL LINES (later machines)
Check the fuel lines every 50 hours of operation.
If the clamp band is loose, apply oil to the screw
of the band, and securely tighten the band.
Portions of the fuel line system are made of
rubber The fuel lines may become worn out
whether the engine has been used much or not.
Replace the fuel lines and clamp bands every two
years.
If the fuel lines and clamp bands are found worn
or damaged before two years’ time, replace or
repair them at once. Bleed the fuel system after
replacement of any of the fuel lines, see TO
PRIME THE FUEL SYSTEM. When the fuel lines
are not installed, plug both ends with clean cloth
or paper to prevent dirt from entering the lines.
Dirt in the lines can cause fuel injection pump
malfunction.

IN--LINE FUEL PUMP
(later machines)
The in--line fuel pump is used to pull fuel from the
tank, through the in--line filter, and into the
fuel/water separator. The in--line fuel pump is
electric and runs off the 12VDC battery of the
machine.

7-- 14

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
ENGINE MOUNTED FUEL FILTER
The Perkins 200 Series engine comes equipped
with a factory installed fuel filter. The engine
mounted filter has a replaceable cartridge.

TO REPLACE ENGINE MOUNTED FUEL
FILTER CARTRIDGE
1. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
2. Loosen the unit vent plug and open the
water trap drain to drain diesel fuel.
3. Remove the filter cartridge from the filter
head.
4. Remove the water trap bowl from the filter
element.
5. Discard the old filter cartridge.
6. Lubricate the o-ring and spin the new filter
cartridge onto the filter base.
7. Bleed the fuel lines of air as described in TO
PRIME FUEL SYSTEM.

800/810 MM337 (8--97)

7-- 15

ENGINE--D--PERKINS 200 SERIES
PRIMING FUEL SYSTEM
Priming the fuel system removes pockets of air in
the fuel lines and fuel components. Air in the fuel
system will prevent smooth engine operation.
Prime the fuel system after running out of fuel,
changing fuel filter elements or repairing a fuel
system component.
TO PRIME FUEL SYSTEM (early machines)
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
1. Stop the engine and set the machine parking
brake.
2. Fill the fuel tank.
3. Open the side and top engine access doors.
4. Open the air vent on top of the fuel filter
mounted on engine.
5. Start the engine, operate it for one minute,
then stop it; or operate the starter motor in
ten-second intervals until a steady stream of
fuel flows from the vent.
6. Close the air vent.
7. Close the access doors.
TO PRIME FUEL SYSTEM (later machines)
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
1. Stop the engine and set the machine parking
brake.
2. Fill the fuel tank.
3. Open the side and top engine access doors.
4. Open the air vent on top of the fuel filter
mounted on engine fan shroud.
5. Start the engine, operate it for one minute,
then stop it; or operate the starter motor in
ten-second intervals until a steady stream of
fuel flows from the vent.
6. Close the air vent.
7. Close the access doors.
7-- 16

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
ENGINE ELECTRICAL SYSTEM
TO REPLACE ENGINE STARTER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.
3. Remove the air cleaner assembly from the
engine.

4. The engine starter can now be accessed

from the engine compartment. Reach over
the top of the engine and locate the starter.

NOTE: The panel in the operators compartment
can be removed for more access.
5. Remove the wires attached to the starter.
Label the wires to make sure they are
returned to the proper location in the
re--assembly procedure.
6. Remove the three M10 hex screws holding
the starter to the engine bellhousing.
Remove the starter from the machine.
7. Reverse the order of these steps to reinstall
a new or rebuilt starter. Tighten the M10 hex
screw to 37 -- 48 Nm (26--34 ft lb).
8. Reconnect the battery and start the
machine, checking for proper starter
operation.

800/810 MM337 (8--97)

7-- 17

ENGINE--D--PERKINS 200 SERIES
TO REPLACE ENGINE STARTER WITH AIR
CONDITIONING
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.
3. Remove the two nuts holding the air box
cover to the air conditioning air box. Remove
the air box cover from the machine.
4. Remove the four acorn nuts holding the
plastic fan duct assembly to the side panel
of the machine. Remove the fan duct from
the machine. This fan duct is accessed from
the operators compartment.
5. Remove the nuts holding the air conditioning
evaporator assembly to the side panel of the
machine. This air conditioning condenser
assembly is accessed from the operator
compartment. Pull the air conditioning
condenser assembly as far as possible into
the operators compartment.
6. Remove the wires attached to the starter.
Label the wires to make sure they are
returned to the proper location in the
re--assembly procedure.
7. Remove the three M10 hex screws holding
the starter to the engine bellhousing.
Remove the starter from the machine.
8. Reverse the order of these steps to reinstall
a new or rebuilt starter. Tighten the M10 hex
screw to 37 -- 48 Nm (26--34 ft lb).
9. Reinstall the air conditioning condenser
assembly and the plastic fan duct assembly
to the machine side panel.
10. Reconnect the battery and start the
machine, checking for proper starter
operation.

7-- 18

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
TO REPLACE ENGINE ALTERNATOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.
3. The engine alternator can be accessed from
the engine compartment. Reach over the top
of the engine and remove the M8 hex screw
holding the alternator to the top mounting
bracket.
NOTE: The panel in the operators compartment
can be removed for more access.
4. Loosen the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Pivot the alternator in and
remove the V--belt.
WARNING: Always disconnect battery
cables from machine before working on
electrical components.
5. Remove the wires attached to the alternator.
Label the wires to make sure they are
returned to the proper location in the
re--assembly procedure.
6. Remove the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Remove the alternator
from the machine.
7. Reverse the order of these steps to reinstall
a new or rebuilt alternator. Tighten the M8
hex screw to 18 -- 24 Nm (15--20 ft lb).
Tighten the M10 hex screw to 37 -- 48 Nm
(26--34 ft lb).
8. Reconnect the battery and start the
machine, checking for proper alternator
operation.

800/810 MM337 (8--97)

7-- 19

ENGINE--D--PERKINS 200 SERIES
TO REPLACE ENGINE ALTERNATOR WITH
AIR CONDITIONING
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.
WARNING: Always disconnect battery
cables from machine before working on
electrical components.
3. Remove the two nuts holding the air box
cover to the air conditioning air box. Remove
the air box cover from the machine.
4. Remove the four acorn nuts holding the
plastic fan duct assembly to the side panel
of the machine. Remove the fan duct from
the machine. This fan duct is accessed from
the operators compartment.
5. Remove the nuts holding the air conditioning
evaporator assembly to the side panel of the
machine. This air conditioning condenser
assembly is accessed from the operator
compartment. Pull the air conditioning
condenser assembly as far as possible into
the operators compartment.
6. The engine alternator can now be accessed
from the engine compartment. Reach over
the top of the engine and remove the M8
hex screw holding the alternator to the top
mounting bracket.
7. Loosen the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Pivot the alternator in and
remove the V--belt.
WARNING: Always disconnect battery
cables from machine before working on
electrical components.

7-- 20

800/810 MM337 (8--97)

ENGINE--D--PERKINS 200 SERIES
8. Remove the wires attached to the alternator.
9. Remove the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Remove the alternator
from the machine.
10. Install the new alternator in the machine.
Reinstall the M10 screw in the lower mount
hole and the M8 in the upper mount hole.
11. Position the V--belt over the alternator pulley.
Pull the alternator tight and tighten the
hardware. Tighten the M8 hex screw to
18 -- 24 Nm (15--20 ft lb). Tighten the M10
hex screw to 37 -- 48 Nm (26--34 ft lb).
12. Check the V--belt for proper tension. See
ENGINE ALTERNATOR BELT instructions.
13. Reconnect the wires to the new alternator.
See schematic in the ELECTRICAL section.
14. Reconnect the battery and start the
machine. Check for proper alternator
operation.

ENGINE FAN BELT
The engine fan belt is driven by the engine
crankshaft pulley and drives the alternator pulley.
Proper belt tension is 13 mm (0.50 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.
08935

800/810 MM337 (8--97)

7-- 21

ENGINE--D--PERKINS 200 SERIES

7-- 22

800/810 MM337 (8--97)

ENGINE--D--PERKINS 700 SERIES
CONTENTS
Page
PERKINS 700 SERIES ENGINE . . . . . . . . 8--3
TO REMOVE ENGINE . . . . . . . . . . . . . . 8--4
TO INSTALL ENGINE . . . . . . . . . . . . . . . 8--5
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 8--7
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 8--7
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . 8--9
AIR FILTER INDICATOR . . . . . . . . . . . . 8--9
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . 8--9
TO REPLACE AIR FILTER
ELEMENT . . . . . . . . . . . . . . . . . . . . . 8--10
FUEL SYSTEM -- DIESEL . . . . . . . . . . . . . 8--11
DIESEL FUEL SYSTEM . . . . . . . . . . . . 8--11
FUEL FILTER/WATER SEPARATOR . 8--11
TO REPLACE THE FUEL FILTER
CARTRIDGE . . . . . . . . . . . . . . . . . . . 8--11
IN--LINE FILTER . . . . . . . . . . . . . . . . . . 8--12
IN--LINE FUEL PUMP . . . . . . . . . . . . . . 8--12
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . 8--12
PRIMING FUEL SYSTEM . . . . . . . . . . 8--13
TO PRIME FUEL SYSTEM . . . . . . . . . 8--13
ENGINE ELECTRICAL SYSTEM . . . . . . . 8--14
TO REPLACE ENGINE STARTER . . . 8--14
TO REPLACE ENGINE
ALTERNATOR . . . . . . . . . . . . . . . . . 8--15
ENGINE ALTERNATOR BELT . . . . . . 8--16

800/810 MM337 (6--01)

DIESEL ENGINE SERVICE MANUALS
PERKINS 200 Series
TENNANT Part Number 61838
PERKINS 700 Series
TENNANT Part Number 380503

8-- 1

ENGINE--D--PERKINS 700 SERIES

8-- 2

800/810 MM337 (8--97)

ENGINE--D--PERKINS 700 SERIES
PERKINS 700 SERIES ENGINE
To verify that your machine is equipped with a
Perkins 700 Series engine----check the tag on the
top of the engine valve cover.

800/810 MM337 (8--97)

8-- 3

ENGINE--D--PERKINS 700 SERIES
TO REMOVE ENGINE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Remove the air cleaner assembly.
2. Remove the engine covers and side door.
3. Remove the battery cables from battery.
4. Drain the radiator coolant.
5. Drain the engine oil.
6. Remove the radiator hoses from the engine.
7. Disconnect the exhaust pipe at the engine
manifold.
8. Disconnect the wire harness from all engine
components and place it out of the way.
9. Disconnect the engine ground strap from the
machine frame.
10. Disconnect both the fuel lines at the fuel
filter.
11. Remove the two M12 hex screws holding
the propel pump to the flywheel housing.
12. Pull the propel pump out of flywheel
coupling.
13. Using overhead hoist, hook a chain through
the two pick-up points on the engine. Put a
slight amount of tension on the chain.
14. Remove the two M12 hex screws from front
motor mounts. (these are the vertical ones
coming through the rubber isolators.)
15. Remove the two M10 hex screws from rear
motor mount. (these are the horizontal ones
holding the mount bracket to the bellhousing
plate.)
16. The engine can now be carefully lifted out.
NOTE: Be sure to disconnect engine oil drain
hose from oil pan before lifting engine completely
out of machine.

8-- 4

800/810 MM337 (8--97)

ENGINE--D--PERKINS 700 SERIES
TO INSTALL ENGINE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Using an overhead hoist, hook a chain
through the two pick-up points on the top of
the engine. Position the engine into the
engine compartment.
2. Lower the engine assembly carefully down
onto the motor mounts.
NOTE: Make sure the hoses, wire harness,
exhaust pipe and propel pump are pulled back out
of the way when lowering engine assembly into
place.
3. Reinstall the M12 hex screws into the front
motor mounts. Tighten to 64 -- 83 Nm
(47 -- 61 ft lb).
4. Reinstall the rear motor mount on the
bellhousing plate using the two M10 hex
screws. Tighten to 37 -- 48 Nm
(26 -- 34 ft lb).
5. Reinstall the propel pump in the back of the
bellhousing. Reuse the M12 hex screws.
Tighten to 64 -- 83 Nm (47 -- 61 ft lb).
NOTE: Make sure the splines on pump line up
with splines in coupler when installing pump.
6. Reinstall the exhaust pipe back on the
manifold using four M10 hex screws. Tighten
to 52 -- 67 Nm (39 -- 50 ft lb).
NOTE: Make sure steel gasket is in place when
installing exhaust pipe.
7. Reconnect the fuel lines.
8. Reconnect the ground cable from the
bellhousing to the machine frame.

800/810 MM337 (8--97)

8-- 5

ENGINE--D--PERKINS 700 SERIES
9. Reconnect the oil drain hose to the oil pan
and fill the engine with the proper grade of
engine oil.
10. Reconnect the main wire harness to the
engine components, alternator, starter, oil
switch, and the temperature sender.
11. Reinstall the radiator hoses to engine and fill
the radiator with antifreeze coolant.
12. Reconnect the battery cables.
13. Jack up the rear of the machine.
FOR SAFETY: Block machine tires before
jacking machine up. Jack machine up at
designated locations only. Block machine up
with jack stands
14. Start the engine and check for fuel or
hydraulic oil leaks.
15. Reinstall the engine covers and side door.
16. Reinstall the air cleaner assembly.
17. Lower the machine and operate. Check for
proper operation.

8-- 6

800/810 MM337 (8--97)

ENGINE--D--PERKINS 700 SERIES
LUBRICATION
Check the engine oil level daily. Change the
engine oil and oil filter every 100 hours of machine
operation. Use 10W30 SAE--CC/CD rated engine
oil.

The engine oil drain is located on the left side of
the machine inside the main brush compartment.
Fill the engine with oil to the level indicated on the
oil dipstick. The engine oil capacity is 6 L (6.3 qt)
including the oil filter.

COOLING SYSTEM
Check the radiator coolant level every 100 hours
of operation. Use clean water mixed with a
permanent-type, ethylene glycol antifreeze to a
--34_ C (--30_ F) rating.
FOR SAFETY: When Servicing Machine, Avoid
Contact With Hot Engine Coolant.
ATTENTION! Never pour cold water or cold
antifreeze into the radiator of an overheated
engine. Allow the engine to cool down to
avoid cracking the cylinder head or block.
Keep the engine running while adding water.

800/810 MM337 (8--97)

8-- 7

ENGINE--D--PERKINS 700 SERIES
Clean the radiator fins every 100 hours of
operation.

Check the radiator hoses and clamps every
200 hours of operation. Tighten the clamps if they
are loose. Replace the hoses and clamps if the
hoses are cracked, harden, or swollen.
Check the radiator core exterior and hydraulic
cooler fins for debris every 100 hours of
operation. Blow or rinse all dust, which may have
collected on the radiator, in through the grille and
radiator fins, opposite the direction of normal air
flow. The grille and hydraulic cooler open for
easier cleaning. Be careful not to bend the cooling
fins when cleaning. Clean thoroughly to prevent
the fins becoming encrusted with dust. Clean the
radiator and cooler only after the radiator has
cooled to avoid cracking.
FOR SAFETY: When Servicing Machine, Wear
Eye And Ear Protection When Using
Pressurized Air Or Water.
Flush the radiator and the cooling system every
400 hours of operation, using a dependable
cleaning compound.

8-- 8

800/810 MM337 (8--97)

ENGINE--D--PERKINS 700 SERIES
AIR INTAKE SYSTEM
AIR FILTER INDICATOR
The air filter indicator shows when to clean or
replace the air filter element. Check the indicator
daily. The indicator’s red line will move as the air
filter element fills with dirt. Do not clean or replace
the air filter element until the red line reaches
5 kPa (20 in H2O) and the ”SERVICE WHEN
RED” window is filled with red. The indicator’s red
line may return to a lower reading on the scale
when the engine shuts off. The red line will return
to a correct reading after the engine runs for a
while.
Reset the air filter indicator by pushing the reset
button on the end of the indicator after cleaning or
replacing the air filter element.

AIR FILTER
The engine air filter housing has a dust cap and a
dry cartridge-type air filter element. Empty the
dust cap daily. The air filter must be replaced
whenever the filter element is damaged or has
been cleaned three times.
Machines with the heavy duty air filter option have
a safety element. It is inside the standard
element. Replace, do not clean this element after
the regular element has been damaged or
cleaned three times.
Service the air filter element only when the air
filter indicator shows restriction in the air intake
system. Do not remove the air filter element
unless it is restricting air flow.

800/810 MM337 (8--97)

8-- 9

ENGINE--D--PERKINS 700 SERIES
TO REPLACE AIR FILTER ELEMENT
1. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
2. Locate the air cleaner assembly on top of
the engine cover.
3. Unscrew the clamp ring on the filter.
4. Remove the dust cap.
5. Empty the dust cap.
6. Remove the filter wing nut.
7. Gently pull the filter element out of the filter
housing.
8. Clean the interior of the air cleaner housing
with a damp cloth. Clean the element
housing sealing surfaces.
9. Using an air hose, direct dry, clean air
maximum 205 kPa (30 psi) up and down
pleats on the inside of the filter. Do not rap,
tap, or pound dust out of the element.
FOR SAFETY: When Servicing Machine, Wear
Eye And Ear Protection When Using
Pressurized Air Or Water.
10. After cleaning the air filter element, inspect it
for damage by placing a bright light inside.
The slightest rupture requires replacement
of the filter. Clean and inspect the seals on
the ends of the element. They should be
unbroken and flexible. Remember to replace
the element after cleaning it three times.
11. Install the new or cleaned filter element so
the fins on the element are at the intake end
of the air cleaner. Be careful not to damage
the fins. Make sure the element is seating
evenly. Tighten the element wing nut.
12. Install the dust cap with the arrows pointing
up. Tighten the clamp ring to hold it in place.
Check all intake hose connections for leaks
or abrasion.
13. Reset the air filter restriction indicator.

8-- 10

800/810 MM337 (8--97)

ENGINE--D--PERKINS 700 SERIES
FUEL SYSTEM -- DIESEL
DIESEL FUEL SYSTEM
The diesel fuel system is made up of six basic
components which are: fuel tank, in--line fuel filter,
in--line fuel pump, fuel filter/water trap, injection
pump, and injectors.
Fuel flows from the fuel tank through the in--line
fuel filter, into the in--line pump, into the fuel/water
trap-filter, and into the injector pump. The water
trap-filter separates water and impurities from the
fuel. From the fuel water trap-filter, fuel is drawn
through the electric fuel pump and pumped to the
injection pump. The injection pump pressurizes
and sends fuel to the injectors. The injectors
atomize and inject proper amounts of fuel into the
combustion chamber at the proper times. Excess
fuel is returned to the fuel tank through an
overflow pipe.
FUEL FILTER/WATER SEPARATOR
The fuel filter/water separator cartridge filters
impurities from the fuel. It is located at the rear of
the engine, near the starter.

TO REPLACE THE FUEL FILTER CARTRIDGE
1. Stop the engine and set the machine parking
brake.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
2. Open the left side and top engine access
doors.
3. Loosen the unit vent plug and open the
water trap drain to drain diesel fuel.
4. Remove the filter cartridge from the filter
head.
5. Lubricate the o-ring of the new filter
cartridge and spin it onto the filter head.
6. Bleed the fuel lines of air as described in TO
PRIME FUEL SYSTEM.
800/810 MM337 (8--97)

8-- 11

ENGINE--D--PERKINS 700 SERIES
IN--LINE FILTER
The fuel system on the 800/810 diesel includes an
in--line fuel filter. This filter is ahead of the fuel
pump and is used to filter any impurities before
they reach the pump.

IN--LINE FUEL PUMP
The in--line fuel pump is used to pull fuel from the
tank, through the in--line filter, and into the
fuel/water separator. The in--line fuel pump is
electric and runs off the 12VDC battery of the
machine.

FUEL LINES
Check the fuel lines every 50 hours of operation.
If the clamp band is loose, apply oil to the screw
of the band, and securely tighten the band.
Portions of the fuel line system are made of
rubber The fuel lines may become worn out
whether the engine has been used much or not.
Replace the fuel lines and clamp bands every two
years.
If the fuel lines and clamp bands are found worn
or damaged before two years time, replace or
repair them at once. Bleed the fuel system after
replacement of any of the fuel lines, see TO
PRIME THE FUEL SYSTEM. When the fuel lines
are not installed, plug both ends with clean cloth
or paper to prevent dirt from entering the lines.
Dirt in the lines can cause fuel injection pump
malfunction.

8-- 12

800/810 MM337 (8--97)

ENGINE--D--PERKINS 700 SERIES
PRIMING FUEL SYSTEM
Priming the fuel system removes pockets of air in
the fuel lines and fuel components. Air in the fuel
system will prevent smooth engine operation.
Prime the fuel system after running out of fuel,
changing fuel filter elements or repairing a fuel
system component.

TO PRIME FUEL SYSTEM
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
1. Stop the engine and set the machine parking
brake.
2. Fill the fuel tank.
3. Open the side and top engine access doors.
4. Open the air vent on top of the fuel filter
mounted on the bellhousing.
5. Start the engine, operate it for one minute,
then stop it; or operate the starter motor in
ten-second intervals until a steady stream of
fuel flows from the vent.
6. Close the air vent.
7. Close the access doors.

800/810 MM337 (8--97)

8-- 13

ENGINE--D--PERKINS 700 SERIES
ENGINE ELECTRICAL SYSTEM
TO REPLACE ENGINE STARTER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, And Turn Off Machine.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.

3. The engine starter can be accessed from
the engine compartment

4. Remove the wires attached to the starter.
Label the wires to make sure they are
returned to the proper location in the
re--assembly procedure.
5. Remove the three M10 hex screws holding
the starter to the engine bellhousing.
Remove the starter from the machine.
6. Reinstall the starter in the bellhousing.
Tighten the M10 hex screws to 37 -- 48 Nm
(26--34 ft lb).
7. Reconnect the wires to the new starter. See
schematic in the ELECTRICAL section.
8. Reconnect the battery and start the
machine. Check for proper starter operation.

8-- 14

800/810 MM337 (8--97)

ENGINE--D--PERKINS 700 SERIES
TO REPLACE ENGINE ALTERNATOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake., Turn Off Machine And Remove Key.
1. Open the engine cover and side door.
2. Disconnect battery cables from machine.

WARNING: Always disconnect battery
cables from machine before working on
electrical components.
3. The engine alternator is accessed from the
left side of the engine compartment.
Remove the M8 hex screw holding the
alternator to the top mounting bracket.
4. Loosen the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Pivot the alternator in and
remove the V--belt.
5. Remove the wires attached to the back of
the alternator.
6. Remove the M10 hex screw and nyloc nut
holding the alternator to the bottom
mounting bracket. Remove the alternator
from the machine.
7. Install the new alternator in the machine.
Reinstall the M10 screw in the lower mount
hole and the M8 in the upper mount hole.
8. Position the V--belt over the alternator pulley.
Pull the alternator tight and tighten the
hardware. Tighten the M8 hex screw to
18 -- 24 Nm (15--20 ft lb). Tighten the M10
hex screw to 37 -- 48 Nm (26--34 ft lb).
9. Check the V--belt for proper tension. See
ENGINE ALTERNATOR BELT instructions.
10. Reconnect the wires to the new alternator.
See schematic in the ELECTRICAL section.
11. Reconnect the battery and start the
machine. Check for proper alternator
operation.

800/810 MM337 (8--97)

8-- 15

ENGINE--D--PERKINS 700 SERIES
ENGINE ALTERNATOR BELT
The engine alternator belt is driven by the engine
crankshaft pulley and drives the alternator pulley.
Proper belt tension is 13 mm (0.50 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.

8-- 16

800/810 MM337 (8--97)

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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.
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