ATLV 4300 Service Manual Tennant Rider Floor Sweeper

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330495

Rev. 03 (5--02)

Service Manual

ATLVt

t4300

*330495*

This service manual is intended to be used as an aid in the detailed service, repair, and troubleshooting of

your TENNANT Model ATLV--4300.

The set is organized into six major groups: General Information, Chassis, Vacuuming, Electrical,

Hydraulics, and Engine--D.

General Information: Safety precautions, machine specifications, machine maintenance chart, machine

tieing, machine jacking, machine storing, machine pushing or towing, and hardware information.

Chassis: Tire/wheel replacement, brake adjustment and replacement, steering adjustment and

replacement.

Vacuuming: Hopper repair/replacement, vacuum head repair/replacement, skirt/seal repair/replacement,

and vacuuming troubleshooting.

Electrical: Battery maintenance and replacement, electrical schematics, and electrical troubleshooting.

Hydraulics: Valve replacement, motor replacement/repair, cylinder replacement/repair, pump

replacement/repair, filter replacement, hydraulic schematic, and hydraulic troubleshooting.

Engine -- D: Air filter replacement, oil changing, cooling system maintenance/repair,

engine troubleshooting, engine removal, and engine repairs.

Manual Number -- 330495

Revision: 03

Published: 5--02

GENERAL INFORMATION

1-1

ATLV 4300 330495 (12--01)

CONTENTS

Page

SAFETY PRECAUTIONS 1-3..............

SPECIFICATIONS 1-6....................

GENERAL MACHINE

DIMENSIONS/CAPACITIES 1-6......

GENERAL MACHINE PERFORMANCE 1-6

POWER TYPE 1-7.....................

STEERING 1-7

HYDRAULIC SYSTEM 1-7..............

BRAKING SYSTEM 1-7................

TIRES 1-7............................

MACHINE DIMENSIONS 1-8............

MAINTENANCE 1-10.....................

MAINTENANCE CHART 1-10...........

PUSHING, TOWING, AND

TRANSPORTING THE MACHINE 1-12

PUSHING OR TOWING THE

MACHINE 1-12..................

TRANSPORTING THE MACHINE 1-13

MACHINE JACKING 1-15...............

STORING MACHINE 1-15..............

HARDWARE INFORMATION 1-16..........

STANDARD BOLT TORQUE CHART 1-16

METRIC BOLT TORQUE CHART 1-16...

BOLT IDENTIFICATION 1-16............

THREAD SEALANT AND LOCKING

COMPOUNDS 1-16.................

HYDRAULIC FITTING INFORMATION 1-17..

HYDRAULIC TAPERED PIPE FITTING

(NPT) TORQUE CHART 1-17........

HYDRAULIC TAPERED SEAT FITTING

(JIC) TORQUE CHART 1-17.........

HYDRAULIC O--RING FITTING TORQUE

CHART 1-17.......................

GENERAL INFORMATION

1-2 ATLV 4300 330495 (8--94)

GENERAL INFORMATION

1-3

ATLV 4300 330495 (5--02)

SAFETY PRECAUTIONS

The following symbols are used throughout this

manual as indicated in their description:

WARNING: To warn of hazards or

unsafe practices that could result in

severe personal injury or death.

FOR SAFETY: To identify actions that

must be followed for safe operation of

equipment.

The machine is suited to vacuum disposable

debris. Do not use the machine other than

described in this Operator Manual.

WARNING: Machine Can Emit Excessive

Noise. Consult With Your Regulatory

Agency For Exposure Limits. Hearing

Loss Can Result. Wear Hearing

Protection.

WARNING: Moving fan blades. Keep

away.

WARNING: Sharp objects in debris

canister. Wear gloves.

WARNING: Spinning fan. Stop engine

before opening debris canister.

WARNING: Engine Emits Toxic Gases.

Severe Respiratory Damage Or

Asphyxiation Can Result. Provide

Adequate Ventilation. Consult With Your

Regulatory Agency For Exposure

Limits. Keep Engine Properly Tuned.

The following information signals potentially

dangerous conditions to the operator or

equipment:

FOR SAFETY:

1. Do not operate machine:

-- Unless trained and authorized.

-- Unless operation manual is read and

understood.

-- 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:

-- 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 slowly on inclines and slippery

surfaces.

-- Use care when reversing machine.

-- Do not carry riders on machine.

-- Always follow safety and traffic rules.

-- Report machine damage or faulty

operation immediately.

5. Before leaving or servicing machine:

-- Stop on level surface.

-- Set parking brakes.

-- Turn off machine and remove key.

6. Before Opening Or Emptying Hopper:

-- Stop on level surface.

-- Set parking brakes.

-- Turn off vacuum.

-- Turn off machine and remove key.

7. 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.

GENERAL INFORMATION

1-4 ATLV 4300 330495 (5--02)

8. When loading/unloding machine onto/off

truck or trailer:

-- 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 to truck or trailer.

GENERAL INFORMATION

1-5

ATLV 4300 330495 (6--01)

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.

SHARP OBJECTS HAZARD LABEL -- Located

On The Air Deflector.

EMISSIONS LABEL -- Located

Below The Operator’s Seat.

FOR SAFETY LABEL --

Located Below The Operator Seat.

FAN WARNING LABEL --

Located In The Engine

Compartment.

NOISE WARNING LABEL -- Located

Below The Operator’s Seat.

MOVING FAN HAZARD LABEL-- Located

On The Debris Canister.

GENERAL INFORMATION

1-6 ATLV 4300 330495 (12--01)

SPECIFICATIONS

GENERAL MACHINE DIMENSIONS/CAPACITIES

Item Dimension/capacity

Length 2590 mm (102 in)

Width 168 mm (46 in)

Height 2113 mm (83 in)

Track 965 mm (38 in)

Wheelbase 1320 mm (52 in)

Hopper weight capacity 68 kg (150 lb)

Hopper volume capacity 416 L (110 gal )

Water dust control tank capacity (option) 30L(8gal)

GVWR 910 kg (2600 lb)

Axle rating (front and rear) 680 kg (1500 lb)

GENERAL MACHINE PERFORMANCE

Item Measure

Maximum forward speed 26 kmh (16 mph)

Maximum reverse speed 8 kmh (5 mph)

Minimum isle turn 4064 mm (160 in)

Minimum turning radius 457 mm (18 in)

Maximum rated climb and descent angle 12_/ 21% Empty or Full hopper

GENERAL INFORMATION

1-7

ATLV 4300 330495 (6--01)

POWER TYPE

Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke

Kubota Piston Diesel 4Natural 378 mm

(3.07 in)

78.5mm

(3.09 in)

Displacement Net power, governed Net power, maximum

1.1L(60.9cuin) 20.9 kw (28 hp) @ 3000 rpm

Turbo engine--28.0 kw

(38 hp)@ 3000

20.9 kw (28 hp) @

3000 rpm

Turbo engine--28.0 kw

(38 hp)@ 3000

Fuel Cooling system Electrical system

Diesel Fuel tank: 31.42 L

(8.3 gal)

Water/ethylene glycol

antifreeze

12 V nominal

Total:4L(1gal) 30 A alternator

12V Battery -- 730 cca

Idle speed, no load Governed speed, under load

1200 rpm 3000 rpm maximum

Engine lubricating oil with filter

5.2 L (5.5 qt) 10W30 SAE--CD/SE rated engine oil

STEERING

Type Power source Emergency steering

Front wheels, hydraulic cylinder,

steering rod

Hydraulic accessory pump Manual

HYDRAULIC SYSTEM

System Capacity Fluid Type

Hydraulic reservoir 19L(5gal) TENNANT part no. 65869 -- above 7_C(45_F)

Hydraulic total 21 L (5.5 gal) TENNANT part no. 65870 -- below 7_C(45_F)

BRAKING SYSTEM

Type Operation

Service brakes Cable actuated disc brakes, one per each rear

wheel

Parking brake Utilize service brakes on rear wheels, cable

actuated

TIRES

Location Type Size Ply Rating Pressure

Front (2) Pneumatic 216 mm (8.5 in) x

457 mm (18 in)

4Ply 152 kPa (22 psi)

Rear (2) Pneumatic 216 mm (8.5 in) x

584 mm (23 in)

4Ply 124 kPa (18 psi)

Rear (2) (Optional) Pneumatic Traction 216 mm (8.5 in) x

584 mm (23 in)

4Ply 48 kPa (7 psi)

GENERAL INFORMATION

1-8 ATLV 4300 330495 (6--01)

ATLV 4300

2113 mm

(83 in)

168 mm

(46 in)

2590 mm

(102 in)

1320 mm

(52 in)

965 mm

(38 in)

MACHINE DIMENSIONS

GENERAL INFORMATION

1-9

ATLV 4300 330495 (12--01)

GENERAL INFORMATION

1-10 ATLV 4300 330495 (12--01)

MAINTENANCE

MAINTENANCE CHART

Interval Key Description Procedure

Lubricant/

Fluid

No. of

Service

Points

Daily 1Engine air filter Check indicator -- 1

Engine dust cap Empty -- 1

Engine crankcase Check oil level EO 1

2Radiator Check and clean inlet screen -- 1

Check coolant level in overflow

reservoir

WG 1

10 Vacuum hose support arm Check for damage and wear -- 3

Check gas cylinders for wear -- 2

7Vacuum head skirts (option) Check for damage and wear -- 1

8Vacuum head (option) Check for damage, wear, and

adjustment

-- 1

Check for blockage -- 1

9Vacuum hose Check for damage and blockage -- 1

4Vacuum fan screen Check for debris and clean -- 1

Vacuum bag Check for debris and clean -- 1

Dust filter bag (option) Check for debris and clean -- 1

Dust panel filter (option) Check for debris and clean -- 1

Water dust control (option)

spray nozzle

Check for debris and

adjustment

-- 1

GENERAL INFORMATION

1-11

ATLV 4300 330495 (12--01)

Interval Key Description Procedure

Lubricant/

Fluid

No. of

Service

Points

50 Hours 5Fuel lines and clamps Check for tightness and wear 4

2Radiator core Check and clean -- 2

3Hydraulic cooler core Check and clean -- 1

6Tires Check pressure -- 4

100 Hours 1Engine crankcase HChange oil and filter element EO 1

Engine fan belt Check tension -- 1

Engine air filter Replace -- 1

Hydraulic reservoir Check fluid level -- 6

4Vacuum bag Check for wear and damage -- 1

Dust panel filter (option) Check for wear and damage -- 1

200 Hours 2Radiator hoses and clamps Check for tightness and wear -- 2

11 Steering cylinder Lubricate steering cylinder SPL 2

13 Brakes Check brake adjustment -- 2

12 Wheel pivot points Lubricate pivots SPL 2

5Fuel filter Replace -- 1

5Fuel screen Clean -- 1

6Tires Check wear and rotate -- 4

3Hydraulic hoses Check for wear and damage -- All

1Battery HClean and tighten battery cable

connections

-- 1

Check electrolyte level DW 1

14 Directional pedal Check for wear, lubricate -- 2

1Engine door seals Check for wear -- 4

4Water dust control (option)

waterlines and clamps

Check for tension and wear -- 6

-- Windshield wiper blades

(option)

Check for wear -- 2

800 Hours 3Hydraulic reservoir Replace filler cap and suction

strainer

-- 1

Change hydraulic fluid HYDO 1

Hydraulic fluid filter Change filter element -- 1

-- Hydraulic drive motors Check for wear and damage -- 1

2 Cooling system Flush WG 1

6Wheels HCheck wheel nut torque -- 4

LUBRICANT/FLUID

EO Engine oil, 10W--30--CD/SE rated....

HYDO TENNANT 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)...

DW Distilled water....

Note: Also check procedures indicted (H)afterthe

first 50-hours of operation.

Note: More frequent intervals may be required in

extremely dusty conditions.

GENERAL INFORMATION

1-12 ATLV 4300 330495 (6--01)

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 front.

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.

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.

GENERAL INFORMATION

1-13

ATLV 4300 330495 (6--01)

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 rear holes of the

frame.

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.

GENERAL INFORMATION

1-14 ATLV 4300 330495 (6--01)

6. Set the parking brake, lower the vacuum

head and block the machine tires. Tie down

the machine to the truck or trailer before

transporting.

If the machine does not have the optional tie

down bracket, tie the front end down with a

tie strap over the floor of the machine.

If the machine does have an optional tie

down bracket, tie down the machine to the

truck or trailer with it.

The rear tie-down locations are through the

rear holes of the frame.

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.

GENERAL INFORMATION

1-15

ATLV 4300 330495 (6--01)

MACHINE JACKING

Empty the hopper before jacking the machine.

You can jack up the machine for service at the

designated locations. Use a hoist or jack that will

support the weight of the machine.

Always stop the machine on a flat, level surface

and block the tires before jacking up the machine.

The front jacking locations are on the frame near

the front tires.

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.

The rear jacking locations are below 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.

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.

GENERAL INFORMATION

1-16 ATLV 4300 330495 (10--98)

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 7--10 (9--14) 10--13 (14--38)

0.31 in 15--20 (20--27) 20--26 (27--35)

0.38 in 27--35 (37--47) 36--47 (49--64)

0.44 in 43--56 (58--76) 53--76 (72--103)

0.50 in 65--85 (88--115) 89--116

(121--157)

0.62 in 130--170

(176--231)

117--265

(159--359)

0.75 in 215--280

(291--380)

313--407

(424--552)

1.00 in 500--650

(678--881)

757--984

(1026--1334)

NOTE: Decrease torque by 20% when using a

thread lubricant.

METRIC BOLT TORQUE CHART

Thread

Size

Class 8.8

Torque ft lb

_Nm)

Class 10.9

Torque ft lb

(Nm)

M4 2(3) 3(4)

M5 4(5) 6(8)

M6 7(9) 10 (14)

M8 18 (24) 25 (34)

M10 32 (43) 47 (64)

M12 58 (79) 83 (112)

M14 94 (127) 133 (180)

M16 144 (195) 196 (265)

M20 260 (352) 336 (455)

M24 470 (637) 664 (900)

NOTE: Decrease torque by 20% when using a

thread lubricant.

Exceptions to the above chart:

Check the machine for exceptions!

BOLT IDENTIFICATION

Identification

Grade Marking

Specification and

Grade

SAE--Grade 5

SAE--Grade 8

ISO--Grade 8.8

ISO--Grade 10.9

01395

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.

GENERAL INFORMATION

1-17

ATLV 4300 330495 (6--01)

HYDRAULIC FITTING INFORMATION

HYDRAULIC TAPERED PIPE FITTING (NPT)

TORQUE CHART

NOTE: Ratings listed are when using teflon

thread seal.

Size Minimum

Torque

Maximum

Torque

1/4 NPT 10 ft lb (14 Nm) 30 ft lb (41 Nm)

1/2 NPT 25 ft lb (34 Nm) 50 ft lb (68 Nm)

3/4 NPT 50 ft lb (68 Nm) 100 ft lb (136

Nm)

HYDRAULIC TAPERED SEAT FITTING (JIC)

TORQUE CHART

Tibe O.D.

(in)

Thread Size Maximum

Torque

0.25 0.44--20 9ftlb(12Nm)

0.38 0.56--18 20 ft lb (27 Nm)

0.50 0.75--16 30 ft lb (41 Nm)

0.62 0.88--14 40 ft lb (54 Nm)

0.75 1.12--12 70 ft lb (95 Nm)

1.0 1.31--12 90 ft lb (122 Nm)

HYDRAULIC O--RING FITTING TORQUE

CHART

Tube

O.D.

(in)

Thread

Size

Minimum

Torque

Maximum

Torque

0.25 0.44--20 6ftlb(8Nm) 9ftlb

(12 Nm)

0.38 0.56--18 13 ft lb

(18 Nm)

20 ft lb

(27 Nm)

*10 ft lb

(14 Nm)

12 ft lb

(16 Nm)

0.50 0.75--16 20 ft lb

(27 Nm)

30 ft lb

(41 Nm)

*21 ft lb

(28 Nm)

24 ft lb

(33 Nm)

0.62 0.88--14 25 ft lb

(34 Nm)

40 ft lb

(54 Nm)

0.75 1.12--12 45 ft lb

(61 Nm)

70 ft lb

(95 Nm)

1.0 1.31--12 60 ft lb

(81 Nm)

90 ft lb

(122 Nm)

NOTE: Do not use sealant on o--ring threads.

*Aluminum bodied components

GENERAL INFORMATION

1-18 ATLV 4300 330495 (12--01)

CHASSIS

2-1

ATLV 4300 330495 (12--01)

CONTENTS

Page

INTRODUCTION 2-3......................

SEAT 2-4.............................

OPERATOR SEAT 2-4...............

TO REMOVE SEAT ASSEMBLY 2-4..

TO INSTALL SEAT ASSEMBLY 2-5...

BRAKES AND TIRES 2-6...............

SERVICE BRAKES 2-6..............

TO REPLACE SERVICE BRAKE

PADS 2-6

TO REPLACE SERVICE BRAKE

CABLE 2-8......................

TO ADJUST SERVICE/PARKING

BRAKE 2-9......................

PARKING BRAKE 2-10..............

TIRES AND WHEELS 2-10...........

TO REPLACE FRONT TIRE

AND WHEEL 2-10................

TO REPLACE REAR TIRE AND

WHEEL 2-11....................

TO ALIGN FRONT TIRES 2-12.......

STEERING 2-13.......................

TO SET TURNING RADIUS

STOPS 2-13.....................

FRONT AXLE 2-14.....................

TO REMOVE FRONT AXLE

ASSEMBLY 2-14.................

TO INSTALL FRONT AXLE

ASSEMBLY 2-16.................

TO REPLACE FRONT AXLE LEAF

SPRING 2-18....................

TO REPLACE FRONT AXLE

ROD END 2-19..................

PROPEL CABLE 2-20..................

TO REPLACE PROPEL CABLE 2-20..

TO REPLACE PROPEL

HYDROBACK 2-24...............

TO SET TRAVEL SPEEDS 2-26......

TO ADJUST PROPEL NEUTRAL 2-27.

CHASSIS

2-2 ATLV 4300 330495 (10--98)

CHASSIS

2-3

ATLV 4300 330495 (10--98)

INTRODUCTION

This section includes information on the main

chassis related components for example the seat,

steering, brakes and tires.

CHASSIS

2-4 ATLV 4300 330495 (10--98)

SEAT

OPERATOR SEAT

The standard operators seat on the ATLVt4300

is a fixed back style with no adjustment for

operator weight. The optional operators seat has

an adjustable back and several settings for

operator weight.

TO REMOVE SEAT ASSEMBLY

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Raise the seat assembly and engage the

prop rod.

2. Hold the seat up with an overhead hoist or a

piece of wood.

3. Remove the four screws holding the seat

support to the machine frame.

4. Disengage the prop rod and drop the seat

assembly down slightly.

5. Remove the end of the prop rod through the

access hole.

6. Remove the seat assembly from the

machine.

CHASSIS

2-5

ATLV 4300 330495 (10--98)

TO INSTALL SEAT ASSEMBLY

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Position the seat assembly onto the

machine.

2. Hold the seat up with an overhead hoist or a

piece of wood.

3. Install the four hex screws and nuts. Tighten

to 8 -- 10 Nm (6 -- 8 ft. lb).

4. Drop the seat down enough to place the end

of the prop rod into the access hole.

5. Drop the seat assembly down and remove

the hoist.

CHASSIS

2-6 ATLV 4300 330495 (10--98)

BRAKES AND TIRES

SERVICE BRAKES

The service brakes on the model ATLVt4300 are

located on the rear wheels only. The service

brakes are mechanically actuated with two pedals

and two cables. The service brakes are

independent left to right.

There is a left and right brake pedal in the

operators compartment. These pedals can be

actuated together or just the right or just the left

pedal can be pressed.

TO REPLACE SERVICE BRAKE PADS

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Place blocks in front and back of the front

tires.

2. Jack up the rear of the machine at the

indicated jack points. Install jack stands

under the machine frame.

3. Make sure the parking brake is engaged.

Remove the five wheel nuts. Remove the

tire and wheel assembly from the machine.

4. Lift the hopper cover and tilt the hopper

back.

5. Disengage the parking brake.

CHASSIS

2-7

ATLV 4300 330495 (10--98)

6. Remove the tension spring and clevis pin

from the brake cable clevis and arm on the

brake assembly.

7. Remove the two M12 hex screws and nyloc

nuts holding the brake assembly to the top

side of the wheel motor.

8. Pull the brake assembly straight up and off

the brake hub.

9. Remove the brake pads from the brake

assembly. Note the orientation of the pads.

10. Install the new brake pads in the same

orientation as the used ones.

11. Spread the new brake pads and slide the

brake assembly onto the brake hub.

12. Align the holes in the brake assembly with

the mount holes in the wheel motor.

13. Reinstall the hardware. Tighten to

64 -- 83 Nm (47 -- 61 ft. lb.)

14. Reinstall the clevis pin in the end of the

brake cable at the brake arm.

15. Reinstall the tension spring on the brake

arm.

16. Go to the operators compartment and press

the brake pedal on the side where the brake

pads were just replaced. Adjust the brake

cable if necessary. See TO ADJUST BRAKE

CABLE instructions in this section.

17. Engage the parking brake.

18. Reinstall the rear tire and wheel assembly.

19. Reinstall the five wheel nuts and tighten to

122 -- 162 Nm (90 -- 120 ft. lb).

20. Repeat this procedure on both sides of the

machine.

21. Tilt the hopper forward and lower the hopper

cover.

22. Remove the jack stands and lower the

machine.

23. Remove the blocks from the front tires and

disengage the parking brake.

24. Operate the machine and check the service

brakes for proper operation.

CHASSIS

2-8 ATLV 4300 330495 (10--98)

TO REPLACE SERVICE BRAKE CABLE

1. Lower the vacuum head.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, turn off machine, and remove

key.

2. Place blocks in front and back of the front

tires.

3. Lift the hopper cover and tilt the hopper

back.

NOTE:MakesuretheparkingbrakeISNOT

engaged.

4. Remove the tension spring and clevis pin

from the brake cable clevis and arm on the

rear wheel brake assembly.

5. Loosen the large jam nut on the brake cable

where it attaches to the frame bracket.

6. Go under the front of the machine and

locate the lower part of the brake pedal

assembly.

7. Remove the cotter pin and clevis pin from

the end of the brake cable.

8. Loosen the large jam nut on the brake cable.

9. Note the routing of the brake cable and

remove it from the machine.

10. Note the location of the clevis on the old

cable and remove. Install on the new cable

in the same location. Leave the small jam

nuts loose for now.

11. Install the new cable in the machine. Make

sure to route the new cable in the same

manner that the old was routed.

12. Position the new cable into the mount hole

at the front of the machine. Lightly finger

tighten the large jam nut.

13. Reinstall the clevis pin and cotter pin into the

clevis on the front of the new brake cable.

14. Go to the back of the machine and position

the brake cable into the mount hole. Tighten

the large jam nut.

CHASSIS

2-9

ATLV 4300 330495 (10--98)

15. Reinstall the clevis pin and cotter pin into the

clevis on the rear of the new brake cable.

16. Reinstall the the tension spring onto the rear

brake assembly lever.

17. Check the foot pedal in the operators

compartment for proper adjustment. The

pedal should have less than 1” of free play.

Adjust the right pedal so it does not

contact the frame. Set the left pedal so

its surface is flush with the right pedal.

If the pedal needs to be adjusted----do so at

the front clevis. Tighten the large and small

jam nuts.

18. Reinstall any plastic ties that were removed.

19. Operate the machine and check the brakes

for proper operation.

TO ADJUST SERVICE/PARKING BRAKE

1. Open the hopper cover and tilt the hopper

back.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

2. Check the foot pedal in the operators

compartment for proper adjustment.

3. The pedal should have less than 1” of free

play.

NOTE: Adjust the right pedal so it does not

contact the frame. Set the left pedal so its surface

is flush with the right pedal.

4. If the pedal needs to be adjusted----do so at

the rear cable mount.

5. Loosen the jam nuts on the cable and adjust

until there is a slight pull on the cable.

Tighten the jam nuts. Repeat on both sides.

6. Close the hopper and cover.

7. Operate the machine and check the brakes

for proper operation.

CHASSIS

2-10 ATLV 4300 330495 (10--98)

PARKING BRAKE

The parking brake is activated by a pedal located

above the service brake pedal. Pushing on the

parking brake will lock the service brake pedal in

position. To release the parking brake----press on

the service brake pedal.

TIRES AND WHEELS

The front and rear tires on the ATLVt4300 are

pneumatic. The rims are one piece steel tubeless

style.

NOTE: Inflate the front tires to 22 psi and the rear

tires to (7 psi. standard, 18 psi. optional all terrain

tires).

TO REPLACE FRONT TIRE AND WHEEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Loosen the four wheel nuts before raising

the front end of the machine. DO NOT

remove the wheel nuts at this point.

2. Jack up the front of the machine at the

indicated jack points. Install jack stands

under the machine frame.

3. Finish removing the four wheel nuts.

Remove the tire and wheel assembly from

the machine.

4. Position the new tire and wheel assembly

onto the front axle hub.

5. Reinstall the four wheel nuts and tighten

finger tight.

6. Remove the jack stands and lower the

machine to the floor.

CHASSIS

2-11

ATLV 4300 330495 (10--98)

7. Go back and finish tightening the four wheel

nuts to 122 -- 162 Nm (90 -- 120 ft. lb).

8. Check the new tires for wear and rotate

every 200 hours of operation.

9. Check the tire pressure every 50 hours of

operation.

TO REPLACE REAR TIRE AND WHEEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Place blocks in front and back of the front

tires.

2. Jack up the rear of the machine at the

indicated jack points. Install jack stands

under the machine frame.

3. Make sure the parking brake is engaged.

Remove the five wheel nuts. Remove the

tire and wheel assembly from the machine.

4. Position the new tire and wheel assembly

onto the front axle hub.

5. Reinstall the five wheel nuts and tighten to

122 -- 162 Nm (90 -- 120 ft. lb).

6. Remove the jack stands and lower the

machine to the floor.

7. Remove the blocks from the front tires.

8. Check the new tires for wear and rotate

every 200 hours of operation.

9. Check the tire pressure every 50 hours of

operation.

CHASSIS

2-12 ATLV 4300 330495 (10--98)

TO ALIGN FRONT TIRES

1. Drive the machine forward with the steering

wheel pointed straight ahead.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

2. Use a tape measure to check the alignment

of the front tires. The rear of the front tires

should be 1/16” to 3/16” farther apart than

the front of the front tires (” toe--in”

condition).

3. If an adjustment is needed----go under the

machine on either side and locate the clevis

at each end of the steering cylinder.

4. Loosen the jam nut where the ball end is

attached to the cylinder clevis.

5. Remove the .50” hex screw and nyloc nut

from the clevis and cylinder end. Pull the

clevis off the cylinder.

NOTE: Make sure to retain the steel spacers

(2 per end) in the end of the cylinder.

6. Three full turns of the clevis on the rod end

equals 1/2” travel. Make adjustments to both

sides equally (this will keep piston travel of

the steering cylinder centered on the axle).

NOTE: There should be approximately 3/8” of

thread sticking through the block on the clevis.

7. Reinstall the clevis onto the end of the

cylinder. Reinstall the hardware and tighten

to 90 -- 117 Nm (65 -- 85 ft. lb).

8. Tighten the jam nut where the ball joint is

attached to the clevis.

9. Drive the machine forward with the steering

wheel pointed straight ahead.

10. Re--check the tire alignment. Re--adjust if

necessary.

CHASSIS

2-13

ATLV 4300 330495 (10--98)

STEERING

The steering system on the ATLVt4300 consists

of a hydraulic steering wheel motor and a dual

action hydraulic cylinder on the front axle. Service

instructions for these components can be found in

the HYDRAULIC section of this manual.

TO SET TURNING RADIUS STOPS

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Jack up the front of the machine at the

indicated jack points. Install jack stands

under the machine frame.

2. Turn the steering wheel all the way in one

direction.

3. Go under the machine and locate the

steering stop bolts on each end of the axle

assembly on the back side.

4. The wheel axle casting should NOT BE

touching the stop bolt. There should be

.030” clearance between the head of the

stop bolt and the edge of the wheel axle

casting.

5. If an adjustment needs to be made, loosen

the jam nut on the stop bolt and turn in or

out. Hold the bolt from turning and

re--tighten the jam nut.

6. Turn the steering wheel all the way the other

direction and repeat steps 4 and 5.

7. Remove the jack stands and lower the

machine.

CHASSIS

2-14 ATLV 4300 330495 (10--98)

FRONT AXLE

The front axle on the ATLVt4300 is a pivoting,

spring mounted design. The pivoting design

allows the machine to be driven over uneven

terrain and still have all four tires contact the

ground. The leaf spring provides a comfortable

ride.

TO REMOVE FRONT AXLE ASSEMBLY

1. Lower the vacuum head. Disconnect the

vacuum head from the axle assembly

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

2. Removal of the front axle is easier with the

front tires removed.

3. Loosen the eight wheel nuts before lifting the

front end of the machine. DO NOT remove

the wheel nuts at this point.

4. Jack up the front of the machine at the

indicated jack points. Install jack stands

under the machine frame.

5. Finish removing the eight wheel nuts.

Remove the tire and wheel assemblies from

the machine.

6. Remove the three hex screws holding the

head lift actuator assembly to the left side of

the operator compartment. Let the actuator

assembly drop down and out of the way so

the pivot pin can be removed.

7. Mark, remove, and cap the two hydraulic

hoses leading to the steering cylinder on the

front of the axle assembly.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

8. The front axle assembly must be supported

before any hardware is removed. Use jack

stands or a floor jack.

CHASSIS

2-15

ATLV 4300 330495 (10--98)

9. Remove the M12 hex screw and washer

holding each stabilizer bar to the machine

frame.

10. Remove the M8 hex screw and nyloc nut

holding the leaf spring pivot pin into the

frame. Carefully push the pivot pin toward

the front of the machine.

NOTE: Make sure the front axle is supported in

some manner.

11. Remove the two nyloc nuts holding the rear

facing shackle plate to the left side of the

leaf spring. Pull the shackle plate off the two

hex screws. Pull the front shackle plate and

two screws out the front of the spring and

axle.

12. Lift the end of the leaf spring that is

disconnected from the axle. Move the axle

assembly down and over slowly so the two

brake cables and propel cable can be

slipped off the end of the axle.

13. Carefully drop the front axle assembly down

and out of the machine.

CHASSIS

2-16 ATLV 4300 330495 (12--01)

TO INSTALL FRONT AXLE ASSEMBLY

1. Jack up the front of the machine at the

indicated jack points. Install jack stands

under the machine frame.

2. Installation of the front axle is easier with the

front tires removed.

3. Position the front axle assembly under the

machine with the steering cylinder facing the

front of the machine and the stabilizer bars

pointing to the back of the machine.

4. Use a floor jack to carefully lift the axle into

position.

NOTE: Make sure the left side of the leaf spring is

disconnected from the axle.

5. Slowly move the axle assembly into position.

While doing so, place the two brake cables

and propel cable over the top of the axle and

below the leaf spring.

6. Reinstall the two shackle plates, two

shoulder screws, and two nyloc nuts into the

left end of the leaf spring. Tighten the two

hex screws with an impact then hit with a

hammer to seat knurls.

7. Line up the mount holes in the leaf spring

pivot bracket with the mount hole in the

machine frame. Install the pivot pin. Install

the M8 hex screw and washer and tighten to

18 -- 24 Nm (15 -- 20 ft.. lb).

8. Position the head lift actuator assembly onto

the left side of the operator compartment.

Reinstall the hardware and tighten to

18 -- 24 Nm (15 -- 20 ft. lb).

9. Line up the mount holes in the ends of the

two stabilizer bars with the mount hole in the

rubber dampners. Install the M12 hex

screws and washers. Hand tighten tight.

CHASSIS

2-17

ATLV 4300 330495 (12--01)

10. Reconnect the two hydraulic hoses to the

steering cylinder.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

11. Position the front tire and wheel assemblies

onto the front axle.

12. Reinstall the eight wheel nuts and tighten

finger tight.

13. Remove the jack stands and lower the

machine to the floor.

14. Go back and finish tightening the wheel nuts

to 122 -- 162 Nm (90 -- 120 ft. lb).

15. Reconnect the vacuum head to the front

axle.

16. Operate the machine and check for proper

operation.

CHASSIS

2-18 ATLV 4300 330495 (10--98)

TO REPLACE FRONT AXLE LEAF SPRING

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Remove the front axle assembly. See TO

REMOVE FRONT AXLE ASSEMBLY

instructions in this section.

2. Remove four hex screws and nyloc nuts

holding the pivot assembly to the top of the

leaf spring. Remove the pivot assembly.

3. Remove the hex screws (1 bolt on right side,

2 on left side) and nyloc nuts holding the

ends of the leaf spring to the front axle

assembly. The hex screws may need to be

hammered out of the mount holes because

of a knurl on the bolt shoulder.

4. Remove the shackle plates from the left side

of the leaf spring.

5. Remove the leaf spring from the axle

assembly.

6. Position the new leaf spring onto the axle

assembly in the same orientation as the old

leaf spring.

7. Install the two shackle plates, two hex

screws, and two nylocs to the left side of the

new leaf spring. Place the nylocs on the

back side.

8. Install the hex screw and nyloc to the right

side of the new leaf spring. Place the nyloc

on the back side.

9. Tighten all the hardware with an impact then

hit the bolt with a hammer to seat the knurl.

10. Reinstall the axle assembly. See TO

INSTALL FRONT AXLE ASSEMBLY

instructions in this section.

CHASSIS

2-19

ATLV 4300 330495 (10--98)

TO REPLACE FRONT AXLE ROD END

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Loosen the four wheel nuts before raising

the front end of the machine. DO NOT

remove the wheel nuts at this point.

2. Jack up the front of the machine at the

indicated jack points. Install jack stands

under the machine frame.

3. Finish removing the four wheel nuts.

Remove the tire and wheel assembly from

the machine.

4. Go under the machine on either side and

locate the clevis at each end of the steering

cylinder.

5. Loosen the jam nut where the rod end is

attached to the cylinder clevis.

6. Remove the cotter pin from the castle nut on

top of the rod end. Remove the castle nut.

7. Use a pickle fork to pop the rod end out of

thesteeringarmontheaxleassembly.

8. Unscrew the rod end from the steering

cylinder clevis. Note orientation of rod end to

clevis.

9. Install the new rod in the same orientation

as the old one. Leave 3/8” of the rod end

threads sticking through the clevis

block. Leave the jam nut loose for now.

10. Position the rod end into the bottom of the

axle steering arm. Install the castle nut and

tighten tight, then tighten to the next cotter

pin cross hole. Install the cotter pin.

11. Tighten the jam nut on the new rod end.

12. Reinstall the four wheel nuts and tighten

finger tight.

13. Remove the jack stands and lower the

machine to the floor.

14. Go back and finish tightening the four wheel

nuts to 122 -- 162 Nm (90 -- 120 ft. lb).

15. Check the front wheel alignment. See TO

ALIGN FRONT TIRES instructions in this

section.

CHASSIS

2-20 ATLV 4300 330495 (10--98)

PROPEL CABLE

The model ATLVt4300 is hydrostatically driven.

The foot pedal in the operators compartment is

connected to a push/pull cable that in turn is

connected to the propel pump arm.

TO REPLACE PROPEL CABLE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Go under the machine at the front right

corner. Locate the propel cable ball joint on

the bottom of the propel pedal.

2. Remove the nyloc nut holding the ball joint

to the pedal. Pull the ball joint out of the

mount hole.

3. Loosen the large jam nuts on the propel

cable where it is attached to the machine

frame. Pull the cable out of the slot.

4. Follow the propel cable back and remove

any plastic ties that are holding the cable to

the frame or other cables.

5. Open the hopper cover and tilt the hopper

back.

6. Open the top engine cover.

7. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

CHASSIS

2-21

ATLV 4300 330495 (10--98)

8. Locate the propel cable and hydroback on

the back side of the propel pump and

engine.

9. Cut the plastic tie. Remove the M6 hex

screw and nyloc nut from the ball joint where

it attaches to the propel pump arm. Retain

the two spacers.

10. Loosen the one large jam nut holding the

propel cable/hydroback to the mount

bracket. Pull the assembly out of the mount

slot. Remove the propel cable/hydroback

assembly from the machine.

NOTE: Note the how the cable is routed in the

machine.

11. Remove and retain the clevis and safety clip

from the hydroback end of the propel cable.

12. Loosen the jam nut at the back of the

hydroback. Screw the hydroback off the

propel cable. Retain the hydroback.

13. Remove and retain the ball joint from the

other end of the propel cable. Discard the

old propel cable.

14. Locate the end of the new propel cable with

1.5 inches of .25--28 thread. Remove the

small cable nut and one large jam nut from

this end of the cable. Position the hydroback

onto this end of the cable (large end first).

15. Spin the large jam nut down until it bottoms

out on the cable housing. Spin the

hydroback down until there is .50 inch of

threads between the large jam nut and the

end of the hydroback.

16. Install the one small cable nut on the other

side of the hydroback and lock it down.

Install the safety clip, rubber washer, and

the second cable nut. Lock the second nut

against the safety clip and the first cable nut.

Spin the clevis down against the second

cable nut. Lock the clevis to the nut.

CHASSIS

2-22 ATLV 4300 330495 (10--98)

17. Go to the other end of the new propel cable

(1 inch of thread) and install the small cable

nut.

18. Turn the small nut down until there is .25

inch of threads left on the cable. Place a

small amount of blue loctite (242) onto the

threads of the cable.

19. Install the ball joint and spin down against

the small cable nut. Lock the nut against the

ball joint.

20. Position the new cable assembly into the

machine. Route the cable in the machine in

the same orientation as the old one.

NOTE: It is very important that the new cable

follows the same routing as the old one.

21. Position the hydroback into the mount

bracket. on the back side of the propel

pump. Tighten the jam nut. Make sure the

internal lock washer is on the hydroback

side of the mount bracket.

22. Install the hex screw and two spacers in the

clevis end of the cable and into the propel

pump arm. Tighten to 8 -- 10 Nm

(6 -- 8 ft. lb). Reinstall a plastic tie.

23. Go under the front of the machine and

position the propel cable into the mount slot

on the machine frame. Leave the jam nuts

loose for now.

24. Place the ball joint into the hole in the

bottom of the propel pedal. Tighten the nyloc

nut to 8 -- 10 Nm (6 -- 8 ft. lb).

CHASSIS

2-23

ATLV 4300 330495 (10--98)

25. Set the heel of the foot pedal to 1--1/8 inch.

from the floor plate. Tighten the jam nuts on

the propel cable.

26. The neutral centering will have to be set at

this point. See TO ADJUST PROPEL

NEUTRAL instructions in this section.

CHASSIS

2-24 ATLV 4300 330495 (10--98)

TO REPLACE PROPEL HYDROBACK

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the hopper cover and tilt the hopper

back.

2. Open the top engine cover.

3. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

4. Locate the propel cable and hydroback on

the back side of the propel pump and

engine.

5. Cut the plastic tie. Remove the M6 hex

screw and nyloc nut from the ball joint where

it attaches to the propel pump arm. Retain

the two spacers.

6. Loosen the one large jam nut holding the

propel cable/hydroback to the mount

bracket. Pull the assembly out of the mount

slot. Remove the propel cable/hydroback

assembly from the machine.

NOTE: Note how the cable is routed in the

machine.

7. Remove and retain the clevis and safety clip

from the hydroback end of the propel cable.

8. Loosen the jam nut at the back of the

hydroback. Screw the hydroback off the

propel cable. Discard the hydroback.

9. Position the new hydroback onto the end of

the cable (large end first).

CHASSIS

2-25

ATLV 4300 330495 (10--98)

10. Spin the large jam nut down until it bottoms

out on the cable housing. Spin the new

hydroback down until there is .50 inch of

threads between the large jam nut and the

end of the hydroback.

11. Install the one small cable nut on the other

side of the hydroback and lock it down.

Install the safety clip, rubber washer, and

the second cable nut. Lock the second nut

against the safety clip and the first cable nut.

Spin the clevis down against the second

cable nut. Lock the clevis to the nut.

12. Position the new hydroback into the mount

bracket. on the back side of the propel

pump. Tighten the jam nut. Make sure the

internal lock washer is on the hydroback

side of the mount bracket.

13. Install the hex screw and two spacers in the

clevis end of the cable and into the propel

pump arm. Tighten to 8 -- 10 Nm

(6 -- 8 ft. lb). Reinstall a plastic tie.

14. The neutral centering will have to be set at

this point. See TO ADJUST PROPEL

NEUTRAL instructions in this section.

CHASSIS

2-26 ATLV 4300 330495 (10--98)

TO SET TRAVEL SPEEDS

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Go to the operators compartment and locate

the two hex screws and jam nuts at the front

and rear of the propel pedal.

2. Start with the bolt under the rear (heel)

portion of the propel pedal set at I--1/8 inch

from the top of the bolt head to the floor of

the operators compartment. This should give

about 4 mph.

3. Use the bolt under the front (toe) portion of

the propel pedal to set the maximum forward

speed to 16 mph.

4. Loosen the jam nut and screw the bolt up or

down to make any adjustments. Retighten

the jam nut after the speed adjustment has

been made.

CHASSIS

2-27

ATLV 4300 330495 (10--98)

TO ADJUST PROPEL NEUTRAL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the hopper cover and tilt the hopper

back.

2. Open the top engine cover.

3. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

NOTE: The rear wheels must be off the ground

when adjusting the neutral centering.

4. Place blocks in front and back of the front

tires.

5. Jack up the rear of the machine at the

indicated jack points. Install jack stands

under the machine frame.

6. Locate the propel pump directional arm hub

on the back side of the pump.

7. Loosen the two outside hex screws on the

hub. DO NOT loosen the cap screw in the

center of the hub. Place an allen wrench in

the cap screw (this will be used to rotate the

hub).

8. Start the machine and observe the rear tires.

If they are not turning----no adjustment is

needed and the hardware can be tightened.

If the tires are rotating----an adjustment is

needed. Go to the next step.

9. Rotate the allen wrench until the tires are

stationary. Hold the allen wrench so the hub

does not move. Tighten the two outside hex

screws. Re--observe the rear tires for

rotation. Repeat step if necessary.

10. Lower the machine and reinstall the rear

engine cover.

11. Operate the machine and check the propel

for proper operation.

CHASSIS

2-28 ATLV 4300 330495 (12--01)

VACUUMING

3-1

ATLV 4300 330495 (10--98)

CONTENTS

Page

INTRODUCTION 3--3......................

DEBRIS HOPPER 3--4.....................

TO ADJUST HOPPER STOP

BRACKET 3--4......................

TO ADJUST HOPPER LEVEL

BRACKETS 3--5.....................

TO ADJUST HOPPER COVER

PIVOT BRACKETS 3--6..............

SKIRTS 3--7..............................

TO REPLACE VACUUM HEAD

REAR SKIRT 3--7...................

TO REPLACE VACUUM HEAD

FRONT SKIRT 3--8..................

VACUUM HEAD 3--9......................

TO REPLACE VACUUM HEAD

ACTUATOR LIFT CABLE 3--9.........

TO REPLACE VACUUM HEAD

SECONDARY LIFT CABLES 3--12.....

TO ADJUST VACUUM HEAD

ACTUATOR LIFT CABLE 3--14........

VACUUM FAN 3--15.......................

TO REPLACE VACUUM FAN

IMPELLER 3--15....................

TO REPLACE VACUUM FAN

IMPELLER SCREEN 3--18............

MACHINE TROUBLESHOOTING 3--19......

VACUUMING

3-2 ATLV 4300 330495 (10--98)

VACUUMING

3-3

ATLV 4300 330495 (10--98)

INTRODUCTION

This section includes information on the

vacuuming operation. The vacuum head collects

debris which in turn is deposited in the hopper

using the suction created by the vacuum fan. The

vacuum fan pulls air from the vacuum head,

through the hopper, and out the back of the

hopper.

VACUUMING

3-4 ATLV 4300 330495 (10--98)

DEBRIS HOPPER

The hopper is plastic and is located behind the

operators compartment. Debris is deposited into

the hopper from the vacuum chamber above. With

the hopper cover raised, the hopper body can be

tilted back to assist in dumping and for access to

the components under the hopper.

TO ADJUST HOPPER STOP BRACKET

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Raise the hopper cover and tilt the hopper

back.

2. Locate the hopper stop bracket on the

bottom right side of the hopper.

3. The hopper stop bracket should contact and

then trip the spring pivot.

4. If the hopper stop bracket does not contact

then trip the spring pivot, the stop bracket

needs to be adjusted.

5. Loosen the hardware holding the stop

bracket to the bottom of the hopper.

6. Movethestopbracketupordownsoit

contacts and trips the spring pivot. Tighten

the hardware to 18 -- 24 Nm (15 -- 20 ft. lb).

7. Pivot the hopper forward and backward,

make sure the bracket is contacting the pivot

spring before the hopper is tilted all the way

back.

VACUUMING

3-5

ATLV 4300 330495 (10--98)

TO ADJUST HOPPER LEVEL BRACKETS

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Raise the hopper cover and tilt the hopper

back.

2. Locate the hopper level brackets on each

side of the frame, just in front of the drive

motors.

3. The hopper level brackets should contact

the bottom of the hopper when the hopper is

in a level position. The lip seal of the hopper

must contact the lip of the hopper cover for

proper operation of the vacuum system.

4. If the hopper is not level with the hopper

cover, the level brackets must be adjusted.

5. Loosen the two hex screws holding the level

bracket to each side of the frame.

6. Move the level brackets up or down until the

hopper and hopper cover seal evenly with

each other. Re--tighten the hardware to

18 -- 24 Nm (15 -- 20 ft. lb).

7. Open and close the hopper cover. Check for

proper sealing of the cover to hopper seal.

VACUUMING

3-6 ATLV 4300 330495 (10--98)

TO ADJUST HOPPER COVER PIVOT

BRACKETS

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. The lip seal of the hopper must contact the

lip of the hopper cover for proper operation

of the vacuum system.

2. If the hopper cover is not level with the

hopper, the pivot brackets must be

adjusted.

3. Raise the hopper cover and tilt the hopper

back.

4. Loosen the hex screws holding the pivot

brackets to each front side of the hopper

cover.

5. Move the front of the hopper cover up or

down until the hopper and hopper cover seal

evenly with each other. Re--tighten the

hardware to 18 -- 24 Nm (15 -- 20 ft. lb).

6. Open and close the hopper cover. Check for

proper sealing of the cover to hopper seal.

VACUUMING

3-7

ATLV 4300 330495 (10--98)

SKIRTS

The vacuum head on the model ATLVt4300 is

equipped with front and rear rubber skirts. These

skirts allow debris to enter the vacuum head

chamber, move through the vacuum hose, and be

deposited into the hopper. The vacuum head

skirts need to be in place and in good condition for

optimal vacuuming performance.

TO REPLACE VACUUM HEAD REAR SKIRT

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake.

1. The vacuum head should be in the raised

position to replace skirts.

2. Remove the three hex screws holding the

left hand skirt retainer to the left side of the

vacuum head.

3. Remove the cotter pin and washer holding

the edge roller wheel to the mount pin. Pull

the wheel off the pin.

4. Remove the two hex screws holding the

right hand skirt retainer to the vacuum head

frame.

5. Pull the rear skirt off the vacuum head.

Discard the rubber skirt.

6. Position the new rear vacuum head skirt on

the back of the vacuum head. NOTE: The

notched end of the blade is positioned

opposite the tube end of the head (left side).

7. Reinstall the right hand side retainer first.

Reinstall the two hex screws. Leave loose

for now.

8. Reinstall the left hand side retainer second.

Reinstall the three hex screws. Make sure

the skirt is positioned over all of the tabs.

9. Tighten the corner bolts first, then the front

bolts, then the center bolt.

10. Reinstall the edge roller wheel onto the

mount pin. Reinstall the cotter pin and

washer.

11. Operate the machine and check the vacuum

head for proper operation.

VACUUMING

3-8 ATLV 4300 330495 (10--98)

TO REPLACE VACUUM HEAD FRONT SKIRT

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake.

1. The vacuum head rear skirt retainers must

be removed before the front skirt can be

changed. See TO REPLACE VACUUM

HEAD REAR SKIRT instructions in this

section.

2. Remove the five hex screws holding the skirt

retainer to the front of the vacuum head.

3. Remove the cotter pin and washer holding

the edge roller wheel to the mount pin. Pull

the wheel off the pin.

4. Remove the retainer from the vacuum head.

Pull the skirt off the retainer tabs. Discard

the rubber skirt.

5. Position the new front skirt onto the front

retainer tabs.

6. Position the skirt and retainer assembly onto

the front of the vacuum head. Reinstall the

five hex screws and washers. Tighten to

18 -- 24 Nm (15 -- 20 ft. lb).

7. Reinstall the rear skirt and retainers. See TO

REPLACE VACUUM HEAD REAR SKIRT

instructions in this section.

8. Reinstall the edge roller wheel onto the

mount pin. Reinstall the cotter pin and

washer.

9. Operate the machine and check the vacuum

head for proper operation.

VACUUMING

3-9

ATLV 4300 330495 (10--98)

VACUUM HEAD

The vacuum head is positioned at the front of the

machine. Airflow from the vacuum fan is routed to

the vacuum head through the large, clear debris

tube. The vacuum head is raised and lowered with

a lift actuator and cable. The knob on the front,

right side of the machine is used to control how

far down the head is allowed to travel.

TO REPLACE VACUUM HEAD ACTUATOR

LIFT CABLE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake.

1. Position a block of wood under the front of

the vacuum head.

2. Lower the vacuum head down onto the block

of wood, lower the head enough so there is

some slack in the lift cable.

3. Go under the machine at the front right side

of the machine.

4. Locate the vacuum head lift actuator and the

long, black cable nut at the end of the lift

cable.

5. Hold the cable from turning with a pliers or a

vice grip.

6. Loosen the jam nut against the long, black

cable nut.

7. Un--screw the long, black cable nut from the

end of the lift cable.

8. Remove the small jam nut and washer from

the lift cable.

9. Loosen the two larger jam nuts holding the

head lift cable to the actuator mount bracket.

10. Remove the outer most jam nut. Pull the lift

cable out of the mount bracket.

11. Remove the hex screw and nut holding the

lift cable clamp to the machine frame.

Removethecableclamp.

VACUUMING

3-10 ATLV 4300 330495 (10--98)

12. Go to the operators compartment and locate

the vacuum head adjustment knob. Remove

the adjustment knob.

13. Remove the clevis pin holding the propel

pedal to the pivot bracket. Position the

propel pedal back out of the way of the

vacuum head cable assembly mount plate.

14. Remove the three hex screws holding the

slide assembly to the cable assembly mount

plate. Remove the slide assembly from the

machine.

15. Remove the three hex screws holding the

vacuum head cable assembly mount plate to

the machine (one on top, two from under

front of frame).

16. Pull the vacuum head cable assembly mount

plate back away from the machine frame.

17. Remove the cotter pin and clevis pin from

the end of the vacuum head lift cable.

18. Loosen the two larger lift cable jam nuts on

the cable.

19. Pull the cable out of the mount slot. Remove

the lift cable from the machine.

NOTE: Note how the cable was routed in the

machine.

20. Position the new cable into the machine.

The end of the cable with the clevis goes to

the front of the machine. Make sure the new

cable is routed the same manner as the old

one.

21. Install the upper end of the lift cable into the

mount slot on the cable assembly mount

plate. Center the jam nuts on the threads

and tighten tight. Install the clevis and cotter

pin.

22. Position the cable assembly mount plate

back against the front of the machine frame.

Reinstall the three hex screws and tighten to

18 -- 24 Nm (15 -- 20 ft. lb).

23. Reinstall the slide assembly and tighten the

three hex screws to 18 -- 24 Nm

(15 -- 20 ft. lb).

24. Reinstall the propel pedal, clevis pin, and

cotter pin.

VACUUMING

3-11

ATLV 4300 330495 (10--98)

25. Reinstall the vacuum head adjustment knob.

26. Go under the machine and remove one

large jam nut from the lower end of the new

lift cable.

27. Position the new lift cable through the mount

hole in the actuator mount bracket. Reinstall

the large jam nut. Leave loose for now.

28. Install one small cable nut and washer on

the lower end of the cable.

29. Position the long, black cable lift nut through

the hole in the actuator lift block.

30. Thread the long, black lift nut onto the new

cable. Leave loose for now.

31. Install the cable clamp on the new cable and

into the machine frame. Reinstall the hex

screw and nut. Tighten to 18 -- 24 Nm

(15 -- 20 ft. lb).

32. See TO ADJUST VACUUM HEAD

ACTUATOR LIFT CABLE instructions in this

section.

33. Go back and tighten all jam nuts.

34. Raise the vacuum head and remove the

wood block.

35. Operate the machine and check the vacuum

head lift actuator for proper operation.

VACUUMING

3-12 ATLV 4300 330495 (10--98)

TO REPLACE VACUUM HEAD SECONDARY

LIFT CABLES

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake.

1. Position a block of wood under the front of

the vacuum head

2. Lower the vacuum head down onto the block

of wood, lower the head enough so there is

some slack in the main actuator lift cable

3. Locate the two secondary vacuum head lift

cables where they attach to the vacuum

head.

4. Pull down on the cable that needs to be

changed. Remove the cotter pin and clevis

pin from the end of the secondary lift cable

where it attaches to the vacuum head.

5. Locate the adjustment end of the secondary

vacuum head lift cables at the front, bottom

of the machine frame. Hold the cable from

turning and remove the adjustment nut.

6. Remove the nut and jam nut from the end of

the cable attached to the front of the

machine frame.

7. Go to the operators compartment and locate

the vacuum head adjustment knob. Remove

the adjustment knob.

8. Remove the clevis pin holding the propel

pedal to the pivot bracket. Position the

propel pedal back out of the way of the

vacuum head cable assembly mount plate.

9. Remove the three hex screws holding the

slide assembly to the cable assembly mount

plate. Remove the slide assembly from the

machine.

10. Remove the three hex screws holding the

vacuum head cable assembly mount plate to

the machine (one on top, two from under

front of frame).

11. Pull the vacuum head cable assembly mount

plate back away from the machine frame.

12. Remove the tension spring holding the two

cable pulley pivot brackets together.

VACUUMING

3-13

ATLV 4300 330495 (10--98)

13. Remove the hex screw and nut holding the

pulley and pulley cover to the pivot bracket.

Pull the pulley cover up far enough to

remove the lift cable from the pulley groove.

Remove and discard the cable.

14. Position the new cable over the pulley. Push

the pulley cover down and tighten the

hardware to 18 -- 24 Nm (15 -- 20 ft. lb). The

threaded end of the cable should be looped

toward the center of the pivot brackets.

15. Position the cable assembly mount plate

back against the front of the machine frame.

Reinstall the three hex screws and tighten to

18 -- 24 Nm (15 -- 20 ft. lb).

NOTE: Make sure the new cable is routed through

the holes in the front of the frame.

16. Reinstall the slide assembly and tighten the

three hex screws to 18 -- 24 Nm

(15 -- 20 ft. lb).

17. Reinstall the propel pedal, clevis pin, and

cotter pin.

18. Reinstall the vacuum head adjustment knob.

19. Route the threaded end of the new cable

down and around the curved frame bracket

and into the adjustment hole. Reinstall the

adjustment nut. Leave loose for now.

20. Connect the clevis end of the new cable to

the lift bracket on the vacuum head.

Reinstall the clevis and cotter pin.

21. Go the the other end of the new cable and

hold it from turning. Turn the adjustment nut

all the way down to the end of the threads.

22. Raise the vacuum head and remove the

wood block.

23. Operate the vacuum head lift. Check for

proper operation.

VACUUMING

3-14 ATLV 4300 330495 (10--98)

TO ADJUST VACUUM HEAD ACTUATOR LIFT

CABLE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake.

1. Make sure the two shorter vacuum head lift

cables have the jam nuts screwed on as far

as possible.

2. Extend (raise) the vacuum head lift actuator

as far as possible. Go under the front of the

machine and check the two black rubber

bumpers. The vacuum head should

compress the bumpers no more than 1/8

inch. If needed, adjust the vacuum head lift

height (see next step).

3. Loosen the jam nut at the end of the long,

black lift cable sleeve. Turn the black cable

sleeve until the head compresses the rubber

bumpers 1/8 inch. Tighten the washer and

jam nut against the black cable sleeve. Use

blue loctite (242) on the threads of the cable.

4. Go to the head stop adjustment knob and

turn all the way clockwise (lowest head

position). Lower the actuator until it stops.

5. Go back under the machine and check the

black cable sleeve. There should be

approximately 1/2 inch of clearance between

the head of the black sleeve and the top of

the thrust bushing.

6. This procedure will leave the rubber skirts

approximately flush with the floor when the

head stop is adjusted to the highest position

(counter--clockwise).

VACUUMING

3-15

ATLV 4300 330495 (10--98)

VACUUM FAN

The vacuum fan is mounted to the top of the

hopper assembly. A hydraulic motor is used to

spin the impeller which creates airflow. This

airflow creates vacuum through the vacuum tube

and down to the vacuum head. Debris is brought

up through the vacuum tube and deposited in the

hopper. A screen on the vacuum fan impeller

keeps debris from contacting the impeller.

TO REPLACE VACUUM FAN IMPELLER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake.

NOTE: Anytime hopper or vacuum system parts

are serviced the seals should be inspected and

replaced if necessary.

1. Remove the six screws holding the vacuum

fan motor cover plate to the top of the

plenum assembly on top of the hopper

cover. Remove the plate.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

2. Mark, disconnect, and plug the hydraulic

lines leading to the vacuum fan motor.

3. Open the hopper cover and tilt the hopper

back.

4. Go under the hopper cover and remove the

six hex screws holding the cover assembly

to the hopper plenum. Remove the cover

assembly.

5. Go back under the hopper plenum and

locate the vacuum fan impeller screen.

Remove the three flat head screws and the

one hex screw holding the screen to the

impeller.

6. Pull the impeller screen, spacer, and sleeve

off the vacuum fan motor shaft.

7. Remove the four hex screws holding the

vacuum fan assembly retainer plate to the

bottom of the hopper plenum.

VACUUMING

3-16 ATLV 4300 330495 (10--98)

8. Go to the top of the hopper plenum and

remove the vacuum fan assembly from the

machine. Set the assembly up side down on

a flat surface.

9. Pull the vacuum fan impeller off the fan

motor shaft. Retain the key from the motor

shaft.

10. Install the new vacuum fan impeller onto the

motor shaft.

NOTE: Make sure to use the key that was

removed with the old impeller.

11. Turn the assembly over and place it back on

top of the hopper plenum. Hold the impeller

in place while turning over. Line up the holes

in the motor bracket with the holes in the

cover.

12. Go under the hopper cover and install the

four hex screws into vacuum fan assembly

retainer plate. Leave the hardware loose for

now.

13. Reinstall the impeller screen, spacer, and

sleeve onto the vacuum fan motor shaft.

14. Use blue loctite (242) on the threads of the

impeller screen hardware. Reinstall the one

M8 hex screw and three M6 flat screws.

15. Tighten the M8 hex screw to 18 -- 24 Nm

(15 -- 20 ft.. lb) and the M6 flat screws to

8 -- 10 Nm (6 -- 8 ft.. lb).

16. After the screen has been tighten down,

center the string guard (on the retainer

plate) around the outside of the screen.

Tighten the four screws to 18 -- 24 Nm

(15 -- 20 ft. lb).Use blue loctite (242) on the

threads of this hardware.

17. Reinstall cover assembly onto the hopper

plenum.

VACUUMING

3-17

ATLV 4300 330495 (10--98)

18. Reinstall six hex screws holding the cover

assembly to the hopper plenum. Tighten the

screws to 18 -- 24 Nm (15 -- 20 ft. lb).

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

19. Reconnect the hydraulic lines leading to the

vacuum fan motor. See hydraulic schematic

in the HYDRAULIC section.

20. Reinstall the six screws holding the vacuum

fan motor cover plate to the top of the

plenum assembly on top of the hopper

cover. Tighten the screws to 18 -- 24 Nm

(15 -- 20 ft. lb).

21. Tilt the hopper forward and close the cover.

22. Operate the machine and check the vacuum

fan for proper operation.

VACUUMING

3-18 ATLV 4300 330495 (10--98)

TO REPLACE VACUUM FAN IMPELLER

SCREEN

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake.

NOTE: Anytime hopper or vacuum system parts

are serviced the seals should be inspected and

replaced if necessary.

1. Open the hopper cover.

2. Go under the hopper cover and locate the

vacuum fan impeller screen. Remove the

three flat head screws and the one hex

screw holding the screen to the impeller.

3. Pull the impeller screen off the vacuum fan

motor shaft. Make note of the orientation of

the spacers.

4. Install the new impeller screen, spacers, and

sleeve onto the vacuum fan motor shaft.

5. Use blue loctite (242) on the threads of the

impeller screen hardware. Reinstall the one

M8 hex screw and three M6 flat screws.

6. Close the hopper cover.

7. Operate the machine and check the vacuum

fan for proper operation.

VACUUMING

3-19

ATLV 4300 330495 (5--02)

MACHINE TROUBLESHOOTING

Problem Cause Remedy

Machine does not start Glow plug not warmed up properly Turnkeytowarmupglowplug

Fuel filter plugged Replace fuel filter

Fuel pump damaged Replace fuel pump

Machine propels slowly Cables not adjusted Readjust stops or cables

Machine does not propel Machine not on Start machine

Parking brake on Release parking brake

Towing valve on Turn towing valve 90°

Poor vacuum performance Vacuum head or hose clogged Remove vacuum head or hose

blockage

Hopper vacuum fan clogged Clean off fan vacuum screen

Vacuum head not lowered

completely

Lower vacuum head completely

Vacuum head seals damaged Replace or repair worn vacuum

head seals

Machine propelling too fast Slow machine speed

Vacuum not close enough to

debris

Move vacuum closer to debris

Debris hopper full Empty debris hopper

Engine throttle too low Increase engine throttle

Vacuum bag (option) clogged Empty Vacuum bag (option)

Dust filter bag (option) clogged Empty dust filter bag (option)

Panel filter (option) clogged Clean panel filter (option)

No vacuum power Hopper Thermo Sentryton Check for fire in hopper

Solenoid valve not operating Contact TENNANT service

personnel

Vacuum fan not on Turn vacuum fan on

Vacuum fan failure Contact TENNANT service

personnel

Main vacuum hose gate valve

closed

Open main vacuum hose gate

valve

Vacuum hose unsupported or

too low

Gas cylinders damaged Contact TENNANT service

personnel

Excessive Dusting Vacuum bag (option) open Close Vacuum bag

Panel filter (option) door open Close panel filter door

Water dust control (option) not on Turn on water dust control

Water dust control (option) water

tank empty

Fill water dust control tank

Water dust control (option) spray

nozzle clogged

Clean water dust control spray

nozzle

VACUUMING

3-20 ATLV 4300 330495 (10--98)

ELECTRICAL

4-1

ATLV 4300 330495 (10--98)

CONTENTS

Page

INTRODUCTION 4--3......................

ELECTRICAL SYSTEM 4--4................

BATTERY 4--4............................

TO CHARGE BATTERY 4--4.............

TO REPLACE BATTERY 4--5............

INSTRUMENT PANEL 4--6.................

TO REMOVE INSTRUMENT PANEL 4--6..

TO INSTALL INSTRUMENT PANEL 4--7..

FUSES 4--8..............................

CIRCUIT BREAKERS 4--8.................

TO REPLACE CIRCUIT BREAKER 4--9...

TO REPLACE RELAY 4--11..............

ACTUATOR 4--12.........................

TO REPLACE VACUUM HEAD

LIFT ACTUATOR 4--12...............

TO REPLACE ENGINE ALTERNATOR 4--14.

TO REPLACE ENGINE STARTER 4--16.....

ELECTRICAL SCHEMATIC 4--17............

WIRE HARNESS 4--19....................

TROUBLESHOOTING 4--25................

ELECTRICAL

4-2 ATLV 4300 330495 (10--98)

ELECTRICAL

4-3

ATLV 4300 330495 (10--98)

INTRODUCTION

The machines electrical system consists of the

batteries, instrument panel, actuators, switches,

relays, and circuit breakers.

ELECTRICAL

4-4 ATLV 4300 330495 (10--98)

ELECTRICAL SYSTEM

The electrical system on the model ATLV 4300 is

a 12 volt system consisting of a battery, alternator,

circuit breakers, relays, and switches.

BATTERY

The battery is located under the operator’s seat

and can be accessed by lifting the seat up.

After the first 50 hours of operation, and every

200 hours after that, clean and tighten the battery

connections.

Check the electrolyte level every 200 hours of

operation. Only add distilled water.

FOR SAFETY: When Servicing Machine,

Avoid Contact With Battery Acid.

TO CHARGE BATTERY

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the seat support and engage the prop

rod.

2. Locate the battery at the center of the

machine, on top and ahead of the front axle.

3. Remove the battery negative cable.

4. Connect the battery charger to the battery.

Make sure to hook the red clamp on the

positive post and the black clamp to the

negative post.

5. Start the charger. Check the voltage meter

on the charger for proper charge voltage.

6. Remove the charger after the voltage meter

reads a full charge.

7. Reinstall the negative battery cable and start

the machine. Check the battery for proper

operation.

8. Disengage the prop rod and lower the seat

support.

ELECTRICAL

4-5

ATLV 4300 330495 (10--98)

TO REPLACE BATTERY

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the seat support and engage the prop

rod.

2. Locate the battery at the center of the

machine, on top and ahead of the front axle.

3. Unhook and remove the rubber battery hold

down strap or remove the threaded hold

down bracket.

4. Remove the battery negative and positive

cables.

5. Lift the battery out of the machine.

6. Install the new battery in the machine in the

same orientation as the old one.

7. Reconnect the battery cables to the battery

(red cable to positive post, black cable to

negative post)

8. Reinstall the rubber battery hold down strap

or reinstall the threaded hold down bracket.

9. Disengage the prop rod and lower the seat

support.

10. Check the new battery for proper operation.

If battery needs charging, see TO CHARGE

BATTERY instructions in this section.

ELECTRICAL

4-6 ATLV 4300 330495 (10--98)

INSTRUMENT PANEL

The instrument panel on the model ATLVt4300

is used to hold most of the electrical switches,

indicator lights, circuit breakers, and meters.

TO REMOVE INSTRUMENT PANEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the seat support and engage the prop

rod.

2. Locate the battery at the center of the

machine, on top and ahead of the front axle.

3. Remove the battery negative cable.

4. Disengage the prop rod and lower the seat

support.

5. Remove the cap from the center of the

steering wheel (snap out).

6. Remove the M20 hex nut from the center of

the steering wheel.

7. Use a puller to remove the steering wheel

from the steering column.

8. Remove the knob from the tilt steering wheel

pull lever.

9. If the machine is equipped with turn signals,

remove the turn signal unit from the steering

column.

10. Remove the two smaller pan screws from

the top side of the instrument panel.

11. Remove the two larger pan screws from the

back side of the instrument panel.

12. Carefully pull the instrument panel up until

the rubber boot clears the steering column.

13. Place the instrument panel back, against the

kick panel of the operators compartment.

14. The components located on the instrument

panel can now be serviced.

ELECTRICAL

4-7

ATLV 4300 330495 (10--98)

TO INSTALL 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 instrument panel and rubber

boot over the top of the steering column. Be

careful not to tear the boot.

2. Push the panel down until the four mount

holes line up with the weldnuts.

3. Reinstall the two small pan screws on top of

the panel and the two larger pan screws on

the back side of the panel. Hand tighten

tight.

4. Reinstall the tilt steering rod knob. Spin

down tight.

5. Reinstall the steering wheel and M20 nut.

Tighten tight.

6. Reinstall the cap in the center of the steering

wheel (snap in).

7. Reinstall the turn signal assembly if the

machine is equipped with road light option.

8. Open the seat support and engage the prop

rod.

9. Reconnect the battery cable to the battery

(red cable to positive post, black cable to

negative post).

10. Disengage the prop rod and lower the seat

support.

11. Start the machine and check for proper

operation.

ELECTRICAL

4-8 ATLV 4300 330495 (10--98)

FUSE

The fuse is a one-time protection device designed

to stop the flow of current in the event of a circuit

overload.

NOTE: Never substitute higher value fuses than

specified.

Thefuseisanin--linetypeandislocatedinthe

main harness, behind the circuit breaker panel.

Fuse Rating Circuit Protected

FU-1 30 A Glow plug

CIRCUIT BREAKERS

The circuit breakers are resettable electrical

circuit protection devices. Their design stops the

flow of current in the event of a circuit overload.

Once a circuit breaker is tripped, it must be reset

manually. Press the reset button after the breaker

has cooled down.

If the overload that caused the circuit breaker to

trip is still there, the circuit breaker will continue to

stop current flow until the problem is corrected.

The circuit breaker panel is located above the foot

pedals

The chart lists the circuit breakers and the

electrical components they protect.

Breaker Rating Circuit Protected

CB-1 15 A Accessory/ Vac/ Hyd

CB-2 15 A Horn

CB--3 15 A Work Lights (Opt)

CB-4 15 A Operating Lights

CB-5 15 A Brake/ Turn signals (Opt)

CB-6 15 A Options

CB-7 15 A Options

CB-8 15 A Options

ELECTRICAL

4-9

ATLV 4300 330495 (10--98)

TO REPLACE CIRCUIT BREAKER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the seat support and engage the prop

rod.

2. Locate the battery at the center of the

machine, on top and ahead of the front axle.

3. Remove the battery negative cable.

4. Disengage the prop rod and lower the seat

support.

5. Remove the instrument panel. See TO

REMOVE INSTRUMENT PANEL

instructions in this section.

6. Locate the circuit breaker that needs to be

changed.

7. Mark and disconnect the wires leading to the

back of the circuit breaker.

8. Remove the metal retainer ring from the

back of the circuit breaker.

9. Push the circuit breaker out of the hole.

Retain the clear, rubber boot and discard the

circuit breaker.

10. Position the new circuit breaker into the

mount hole.

NOTE: The mount hole has a “D” shape to match

the shape of the circuit breaker.

11. Install the metal retainer ring onto the back

of the new circuit breaker. Push the retainer

all the way down the circuit breaker.

ELECTRICAL

4-10 ATLV 4300 330495 (10--98)

12. Install the rubber boot onto the out side of

the new circuit breaker.

13. Reconnect the electrical wires to the new

circuit breaker. See schematic in the

ELECTRICAL section.

14. Reinstall the instrument panel. See TO

INSTALL INSTRUMENT PANEL instructions

in this section.

15. Open the seat support and engage the prop

rod.

16. Reconnect the battery cable to the battery

(red cable to positive post, black cable to

negative post)

17. Disengage the prop rod and lower the seat

support.

18. Start the machine and check for proper

operation.

ELECTRICAL

4-11

ATLV 4300 330495 (10--98)

TO REPLACE RELAY

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the seat support and engage the prop

rod.

2. Locate the battery at the center of the

machine, on top and ahead of the front axle.

3. Remove the battery negative cable.

4. Disengage the prop rod and lower the seat

support.

5. Remove the instrument panel. See TO

REMOVE INSTRUMENT PANEL

instructions in this section.

6. Locate the relay that needs to be changed.

7. Disconnect the wire connector leading to the

back of the relay.

8. Remove the hex screw and nut holding the

relay to the machine frame. Remove and

discard the relay.

9. Position the new relay in the machine and

reinstall the hex screw and nut. Hand

tighten.

10. Reconnect the electrical connector to the

new relay. See schematic in the

ELECTRICAL section.

11. Reinstall the instrument panel. See TO

INSTALL INSTRUMENT PANEL instructions

in this section.

12. Open the seat support and engage the prop

rod.

13. Reconnect the battery cable to the battery

(red cable to positive post, black cable to

negative post)

14. Disengage the prop rod and lower the seat

support.

15. Start the machine and check for proper

operation.

ELECTRICAL

4-12 ATLV 4300 330495 (10--98)

ACTUATOR

The actuator on the model ATLVt4300 is used

to raise and lower the vacuum head on the front

of the machine. The actuator is connected to a lift

cable that pulls on a pulley assembly to raise the

vacuum head.

TO REPLACE VACUUM HEAD LIFT

ACTUATOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Position a block of wood under the front of

the vacuum head.

2. Lower the vacuum head down onto the block

of wood, lower the head enough so there is

some slack in the lift cable.

3. Go under the machine at the front right side

of the machine.

4. Locate the vacuum head lift actuator and the

long, black cable nut at the end of the lift

cable.

5. Hold the cable from turning with a pliers or a

vice grip.

6. Loosen the jam nut against the long, black

cable nut.

7. Un--screw the long, black cable nut from the

end of the lift cable.

8. Disconnect the actuator from the main

electrical harness.

ELECTRICAL

4-13

ATLV 4300 330495 (10--98)

9. Go to the operators compartment and

remove the three actuator mount screws

from the back kick panel.

10. Drop the vacuum head lift actuator assembly

out of the machine.

11. Remove the three hex screws and two

mount brackets holding the actuator to the

main mount bracket. Remove the actuator.

NOTE: Make sure to retain the gasket.

12. Remove the long M8 hex screw holding the

cable block to the shaft of the actuator.

Remove the cable block and position it onto

the new actuator in the same orientation.

13. Reinstall the long M8 hex screw. Tighten to

18 -- 24 Nm (15 -- 20 ft. lb).

14. Position the new actuator onto the main

mount bracket. Reinstall the two brackets

and three hex screws. Tighten to

18 -- 24 Nm (15 -- 20 ft. lb).

NOTE: Make sure to reinstall the gasket to protect

the aluminum housing on the actuator.

15. Position the actuator assembly back into the

machine. Reinstall the three hex screws.

Tighten to 18 -- 24 Nm (15 -- 20 ft. lb).

16. Reconnect the actuator to the main electrical

harness.

17. Position the long, black cable lift sleeve

through the hole in the actuator lift block.

18. Thread the long, black lift sleeve onto the

end of the vacuum head lift cable. Leave

loose for now.

19. See TO ADJUST vacuum HEAD

ACTUATOR LIFT CABLE instructions in the

vacuum section.

20. Operate the machine and check the vacuum

head lift actuator for proper operation.

ELECTRICAL

4-14 ATLV 4300 330495 (10--98)

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. Tilt the seat assembly forward and engage

the prop rod. Disconnect the battery cables

from the battery.

2. Open the top engine cover.

3. Locate the alternator at the front right area

of the engine.

4. Disconnect the wires from the back of the

alternator.

5. Loosen the hex screw holding the top of the

alternator to the pivot bracket.

6. Loosen the hex screw on the bottom of the

alternator.

7. Pivot the alternator in toward the engine and

remove the fan belt from the sheave.

8. Remove both hex screws. Remove the old

alternator out past the exhaust pipe.

9. Position the new alternator in place. Go in

front the exhaust pipe.

10. Reinstall the longer lower hex bolt and nut.

Leave loose for now.

11. Reinstall the shorter hex bolt in the top of

the alternator. Leave loose for now.

12. Reinstall the fan/alternator belt.

ELECTRICAL

4-15

ATLV 4300 330495 (10--98)

13. Using a pry bar, pull the alternator away

from the engine until the belts are tight.

Proper belt tension is 10 mm (0.40 in) from

aforceof4to5kg(8to10lb)appliedatthe

mid-point of the longest span. Check and

adjust the belt tension every 100 hours of

operation. Hand tighten the top hex bolt

tight.

WARNING: Moving Belt And Fan Blades.

Keep Away.

14. Firmly tighten the lower hex bolt.

15. Reconnect the electrical wires to the back of

the alternator. See schematic in this section.

16. Reconnect the battery cables to the battery.

17. Close the engine cover and lower the seat

assembly.

18. Start the engine and check the alternator for

proper operation.

ELECTRICAL

4-16 ATLV 4300 330495 (10--98)

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. Tilt the seat assembly forward and engage

the prop rod. Disconnect the battery cables

from the battery.

2. Open the top engine cover.

3. Disconnect the wires from the starter motor.

4. Remove the two hex screws holding the

exhaust pipe to the exhaust manifold. Pull

the pipe out of the way for clearance to

remove the starter.

5. Remove the two hex nuts holding the starter

to the engine. Remove the starter from the

flywheel housing and out of the machine.

6. Position the new starter back in the flywheel

housing. Re--use the two hex nuts and

tighten to 18 -- 24 Nm (15 -- 20 ft lb).

7. Reconnect the electrical wires to the starter.

See schematic in this section.

8. Reinstall the exhaust pipe to the exhaust

manifold. Reinstall the two hex screws and

tighten to 18 -- 24 Nm (15 -- 20 ft lb).

9. Reconnect the battery cables to the battery

and check the starter for proper operation.

10. Close the engine cover and pivot the seat

assembly down.

ELECTRICAL

4-17

ATLV 4300 330495 (6--01)

ELECTRICAL SCHEMATIC

352281

ELECTRICAL

ATLV 4300 330495 (6--01)

4-18

ELECTRICAL SCHEMATIC

352281

ELECTRICAL

4-19

ATLV 4300 330495 (6--01)

WIRE HARNESS

ELECTRICAL

ATLV 4300 330495 (6--01)

4-20

WIRE HARNESS

ELECTRICAL

4-21

ATLV 4300 330495 (6--01)

WIRE HARNESS

ELECTRICAL

ATLV 4300 330495 (6--01)

4-22

WIRE HARNESS

ELECTRICAL

4-23

ATLV 4300 330495 (6--01)

WIRE HARNESS

ELECTRICAL

ATLV 4300 330495 (6--01)

4-24

WIRE HARNESS

ELECTRICAL

4-25

ATLV 4300 330495 (10--98)

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.

ELECTRICAL

4-26 ATLV 4300 330495 (10--98)

First check to make sure that:

1. Battery is charged.

2. Fuel in the fuel tank.

3. Unrestricted air filter.

Is there battery

voltage at the battery cable terminal

of the starter motor

Check battery,

battery cables, and

connections.

Check for battery

voltage at terminal

30 of the key

switch.

Repair

connections or

replace battery

cables

While turning the key

switch to the start

position, check for

battery voltage at

Terminal 50 of the key

switch with respect to

battery negative (--).

yes

Check wire 1/RED from the

starter motor, to the alternator, to

the key switch and repair or

replace as necessary.

Again, while turning the

key to the start position,

check for battery

voltage at wire 4C/YEL

at the starter motor

solenoid M1.

Replace the ignition

switch

yes

Repair or

replace wire

4C/YEL

yes

yesno

Starter motor turns

Starter motor won’t turn

Replace the starter motor

solenoid or starter motor

assembly

ENGINE WILL NOT CRANK

ELECTRICAL

4-27

ATLV 4300 330495 (10--98)

ENGINE WILL NOT RUN First check to make sure :

1. Battery is charged.

2. Fuel in the fuel tank.

3. Unrestricted air filter.

4. Engine oil at full level.

5. CB--1 is not tripped

Starter motor

will not crank

Check the oil pressure

switch:

Disconnect wire 10A/

GRN and check the oil

pressure switch with an

ohmmeter connected to

the pressure switch

terminal and engine

ground. Crank the

engine for a few

seconds to see if the

contacts change from a

closed to an open

condition Caution,

keep clear of rotating

fan and belt drive!

Engine runs

See previous pagenoEngine turns over, but won’t start. Engine will not run

Checking M2 Relay:

With M2 installed, disconnect the electric fuel pump. Using a voltmeter, look for battery voltage

at the main harness connector to the fuel pump wires 9A/BRN and 13Q/BLK while trying to

start the engine.Caution, keep clear of rotating fan and belt drive! Battery voltage should

be present while the engine is cranking and after the oil pressure lamp goes out.

Replace

relay M2

Does the oil pressure light turn on with the key switch in the run position, and then go out after

cranking the engine for a while? Caution, keep clear of rotating fan and belt drive!

Check the key switch: With a voltmeter, check for battery voltage at the key switch terminal AC (wire 2/BRN) with any

13/BLK wire while the key switch is in the on position.

Check wiring and repair or, reset

or replace circuit breaker CB--1.

Check for fuel delivery from the fuel pump to the engine while

cranking the engine.

Caution, keep clear of rotating fan and belt drive!

yes

Replace the oil

pressure switch or

check for low oil

pressure problem.

yes

Disconnect the diesel fuel solenoid mounted to the side of the engine.

Check for battery voltage at each of the 4/YEL and 3/BLU wires with

respect to ground, while cranking the engine and after the oil

pressure light has gone out.

Caution, keep clear of rotating fan and belt drive!

Replace the key switch

Checking the fuel solenoid:

Remove the diesel solenoid from the engine and reconnect to the

main harness. Disconnect the 4/YEL wire from the starter solenoid to

prevent the starter motor from turning. Turn the key switch to the start

positionand notice if the plunger on the solenoid moves.

Check engine circuit breaker:With a voltmeter, check for battery voltage at CB--1, wire 3/BLU with

any 13/BLK wire while the key switch is in the on position.

Replace

fuel

pump

Replace fuel

solenoid

ELECTRICAL

4-28 ATLV 4300 330495 (10--98)

VACUUM FAN WILL NOT RUN

With the engine off ,First check to make sure that:

1.The vacuum fan rotates free.

2. The hydraulic oil level is correct.

3. The hopper is not full.

Vacuum fan runs

Checking for battery voltage to the vacuum fan switch:

With the key switch in the on position and the engine NOT running , check for

battery voltage between the 3//BLU wire at the vacuum fan switch and any 13/

BLK wire.

Checking the vacuum switch:

With the key switch in the on position and the engine NOT running , turn on the vacuum

switch and check for battery voltage between wire 18/GRN at the vacuum switch and any

13/BLK wire..

battery

voltage

present

Reset or replace if

defective, CB--1

circuit breaker.

battery

voltage

present

no battery

voltage

no battery

voltage

battery

voltage

present

no battery

voltage

Replace if the defective

Vacuum fan switch.

Is the optional thermal

sentry light on?

Make sure the key switch is off with

the engine NOT running, check for

possible fire or high temperatures in

the hopper cover area !!!

yes

Checking the thermal sentry switch:

With the key switch in the on position and the engine NOT

running , turn on the vacuum switch and check for battery

voltage between wire 18/GRN at the vacuum switch and 20/BRN

at the thermal sentry switch.

Replace if the defective thermal sentry

switch.

Replace if the defective vacuum fan

solenoid valve coil.

ELECTRICAL

4-29

ATLV 4300 330495 (10--98)

HEAD LIFT WILL NOT OPERATE

With the key switch in the on position, check for battery

voltage between the 3/BLU wire at the CB--1 circuit breaker

and any 13/BLK wire.

This troubleshooting guide deals primarily

with the optional head lift motorized linear

actuator

With the engine NOT running and the key switch in the

on position, check for battery voltage between both 3/BLU

wires, and any 13/BLK wire.

Replace CB--1

circuit breaker

Head lift operates correctly

Check to see that the head lift mechanism has not been damaged or prevented from traveling its normal range of movement.

Vacuum head lift does not operate

no yes

Does the engine

run ?

yes

First check to make sure :

1. Battery is charged.

2. Engine runs good.

Check wiring of 3/BLU wires

between CB--1 and the head

lift switch and repair

battery

voltage battery

voltage

With the key switch in the on position and the engine NOT

running , hold the head lift switch in the raise position while

measuring for battery voltage between both 21/Brn and 22/

YEL wires to any 13/BLK wire.

battery

voltage

battery

voltage

battery

voltage

battery

voltage

With the key switch in the on position

and the engine NOT running , hold

the head lift switch in the lower position

while measuring for battery voltage

between both 21/Brn and 22/YEL wires

to any 13/BLK wire.

battery

voltage

Replace the head

lift switch

battery

voltage

Replace the head lift actuator.ok

ELECTRICAL

4-30 ATLV 4300 330495 (10--98)

HYDRAULICS

5-1

ATLV 4300 330495 (10--98)

CONTENTS

Page

INTRODUCTION 5--3.......................

HYDRAULIC FLUID RESERVOIR 5--4........

HYDRAULIC FLUID 5--5....................

HYDRAULIC HOSES 5--5...................

HYDRAULIC FLUID COOLER 5--6...........

HYDRAULIC FLUID FILTER 5--6.............

TO REPLACE HYDRAULIC FLUID

FILTER 5--6...........................

HYDRAULIC PUMPS 5--7...................

TO REPLACE PROPEL PUMP 5--7........

TO REPLACE ACCESSORY PUMP 5--10...

HYDRAULIC MOTORS 5--12.................

TO REPLACE VACUUM FAN

MOTOR 5--12.........................

TO REPLACE STEERING WHEEL

MOTOR 5--15.........................

TO REPLACE DRIVE WHEEL

MOTOR 5--17........................

STEERING CYLINDER 5--19.................

TO REPLACE STEERING CYLINDER 5--19.

STEERING CYLINDER BREAKDOWN 5--21.

CONTROL VALVE 5--22......................

TO REPLACE SOLENOID CONTROL

VALVE 5-- 22..........................

HYDRAULIC SCHEMATIC 5--25..............

HYDRAULIC HOSE GROUP 5--26............

TROUBLESHOOTING 5--27..................

EATON HYDRAULIC REPAIR MANUAL 5--33...

HYDRAULICS

5-2 ATLV 4300 330495 (10--98)

HYDRAULICS

5-3

ATLV 4300 330495 (10--98)

INTRODUCTION

The hydraulic system consists of the propel pump,

accessory pump, control valve, drive motors,

steering cylinder, and vacuum fan motor.

HYDRAULICS

5-4 ATLV 4300 330495 (10--98)

HYDRAULIC FLUID RESERVOIR

The reservoir is located on the left side of the

machine next to the engine.

A filler cap is mounted on top of the reservoir. It

has a built in breather and fluid level dipstick.

Replace the cap after every 800 hours of

operation.

Check the hydraulic fluid level at operating

temperature daily. The dipstick is marked with full

and add markings to indicate the level of hydraulic

fluid in the reservoir. Cold fluid level is mid-point of

add and full lines.

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.

Drain and refill the hydraulic fluid reservoir with

new hydraulic fluid every 800 hours of operation.

NOTE: When the hydraulic filter bypass light

(optional) comes on, replace the filter, and change

the hydraulic fluid as soon as possible.

The hydraulic fluid filter is located in front of the

hydraulic reservoir near the rear of the engine

compartment. Replace the filter element every

800 hours of operation.

HYDRAULICS

5-5

ATLV 4300 330495 (10--98)

HYDRAULIC FLUID

The quality and condition of the hydraulic fluid

plays a very important role in how well the

machine operates. TENNANT’s hydraulic fluid is

specially selected to meet the needs of TENNANT

machines.

TENNANT’s hydraulic fluids provide a longer life

for the hydraulic components. There are two

TENNANT fluids available for different

temperature ranges:

TENNANT part no. Ambient

Temperature

65869 above 7_C(45_F)

65870 below 7_C(45_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.

If you discover a fluid leak, contact your

mechanic/supervisor.

00002

HYDRAULICS

5-6 ATLV 4300 330495 (10--98)

HYDRAULIC FLUID COOLER

The hydraulic fluid cooler is located on the outside

of the engine radiator. Hydraulic fluid flows

through the cooler when the machine is running.

Airflow from the engine fan cools the fluid.

HYDRAULIC FLUID FILTER

The hydraulic fluid filter is located on the left side

of the machine frame, behind the engine. The

filter is used to keep the fluid free from

contaminates. The filter should be changed every

800 hours.

TO REPLACE HYDRAULIC FLUID FILTER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the hopper cover and tilt the hopper

back.

2. Open the top engine cover.

3. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

4. Locate the hydraulic fluid filter on the left

side of the upper machine frame. Place a

drain pan under the filter, on top of the

muffler guard.

5. Un--screw the filter from the filter head.

Properly discard the old filter.

6. Place a small amount of hydraulic oil on the

rubber O--ring on the new filter.

7. Screw the new filter onto the filter head.

Tighten until snug then 1/4 turn.

8. Reinstall the rear engine cover.

9. Remove the drain pan. Tilt the hopper

forward and close the hopper cover.

10. Start the machine and check the new

hydraulic fluid filter for any leaks.

HYDRAULICS

5-7

ATLV 4300 330495 (10--98)

HYDRAULIC PUMPS

The propel pump is used to provide hydraulic flow

to the drive motors. The accessory pump is used

to provide flow to the vacuum fan and steering

circuit.

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. Open the hopper cover and tilt the hopper

back.

2. Open the top engine cover.

3. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

4. Remove the grill from the left side fender

panel.

5. Disconnect the air intake tube from the collar

on the left side machine fender.

6. Remove the seven pan screws holding the

left fender to the machine. Pull the fender

out slightly and disconnect the turn signal.

Remove the fender from the machine.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

7. Disconnect and plug the small hydraulic

hose leading to the back side of the

accessory pump. Leave the larger suction

line connected.

8. Remove the two cap screws holding the

accessory pump to the propel pump. Pull the

accessory pump straight back out of the

propel pump. Let the accessory pump drop

down out of the way for access to the propel

pump.

NOTE: Make sure to retain the O--ring.

9. Locate the propel pump directional arm on

the back side of the propel pump. Remove

the two hex screws holding the pump arm to

the pump hub.

HYDRAULICS

5-8 ATLV 4300 330495 (10--98)

10. Mark, disconnect, and plug the four

hydraulic hoses leading to the propel pump.

11. Remove the two hex screws holding the

propel pump to the bellhousing.

NOTE: The bottom hex screw can be accessed

easier with the motor mount removed.

12. Pull the propel pump out of the bellhousing

and remove it from the machine.

13. Remove the directional hub from the side of

the propel pump and install on the new

pump in the same orientation. Use blue

loctite (242) on the threads of the cap screw.

Tighten to 18 -- 24 Nm (15 -- 20 ft. lb).

14. Remove the hydraulic fittings from the old

propel pump and install into the new pump in

the same orientation.

15. Position the new pump assembly into the

engine bellhousing. Line up splines on the

pump input shaft with the teeth in the

flywheel coupling. Push the pump in until it is

against the bellhousing plate.

16. Reinstall the two hex screws into the pump

mount holes. Tighten to 31 -- 40 Nm

(27 -- 35 ft. lb).

NOTE: The pump directional hub faces the rear of

the machine.

17. Reconnect the four hydraulic hoses to the

propel pump. See hose diagram in this

section.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

18. Reinstall the accessory pump into the propel

pump. Make sure the O--ring is installed on

the face of the pump. Reinstall the hardware

and tighten to 31 -- 40 Nm (27 -- 35 ft. lb).

19. Reconnect the one small hydraulic hose to

the accessory pump. See hose diagram in

this section.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

HYDRAULICS

5-9

ATLV 4300 330495 (10--98)

20. Reinstall the directional pump arm onto the

pump hub. Reinstall the two hex screws.

Leave the screws loose for now.

21. The neutral centering will have to be set at

this point. See TO ADJUST PROPEL

NEUTRAL instructions in the CHASSIS

section.

22. Reinstall the left hand side panel and left

hand grill.

23. Reinstall the rear engine cover.

24. Tilt the hopper forward, close the hopper

cover, and close the top engine cover.

25. Start the machine and operate the propel

circuit. Check for proper operation.

HYDRAULICS

5-10 ATLV 4300 330495 (10--98)

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. Open the hopper cover and tilt the hopper

back.

2. Open the top engine cover.

3. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

4. Remove the grill from the left side fender

panel.

5. Disconnect the air intake tube from the collar

on the left side machine fender.

6. Remove the seven pan screws holding the

left fender to the machine. Pull the fender

out slightly and disconnect the turn signal.

Remove the fender from the machine.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

7. Disconnect and plug the two hydraulic hoses

leading to the accessory pump.

NOTE: The hydraulic fluid reservoir must be

drained or a suction device used to minimize fluid

lose.

8. Remove the two cap screws holding the

accessory pump to the propel pump. Pull the

accessory pump straight back out of the

propel pump.

NOTE: Make sure to retain the O--ring.

9. Remove the hydraulic fittings from the old

accessory pump and install into the new

pump in the same orientation.

HYDRAULICS

5-11

ATLV 4300 330495 (10--98)

10. Reinstall the accessory pump into the propel

pump. Make sure the O--ring is installed on

the face of the pump. Reinstall the hardware

and tighten to 31 -- 40 Nm (27 -- 35 ft. lb).

11. Reconnect the two hydraulic hose to the

accessory pump. See hose diagram in this

section.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

12. Reinstall the left hand side panel and left

hand grill.

13. Tilt the hopper forward, close the hopper

cover, and close the top engine cover.

14. Start the machine and operate the hydraulic

circuit. Check for proper operation.

HYDRAULICS

5-12 ATLV 4300 330495 (10--98)

HYDRAULIC MOTORS

The vacuum fan impeller is driven by a hydraulic

motor located on top of the hopper cover. The

vacuum fan motor is controlled by a solenoid

valve located on the machine frame.

The steering wheel motor is used to provide

hydraulic flow to the steering cylinder.

The drive wheel motors propel the machine

forward and reverse. The propel pump provides

hydraulic flow to the drive motors.

TO REPLACE VACUUM FAN MOTOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

NOTE: Anytime hopper or vacuum system parts

are serviced the seals should be inspected and

replaced if necessary.

1. Remove the six screws holding the vacuum

fan motor cover plate to the top of the

plenum assembly on top of the hopper

cover. Remove the plate.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

2. Mark, disconnect, and plug the hydraulic

lines leading to the vacuum fan motor.

3. Open the hopper cover and tilt the hopper

back.

4. Go under the hopper cover and remove the

six hex screws holding the cover assembly

to the hopper cover. Remove the cover

assembly.

5. Locate the vacuum fan impeller screen.

Remove the three flat head screws and one

hex screw holding the screen to the impeller.

6. Pull the impeller screen, spacer, and sleeve

off the vacuum fan motor shaft.

7. Remove the four hex screws holding the

vacuum fan assembly retainer plate to the

bottom of the hopper cover.

8. Go to the top of the hopper cover and

remove the vacuum fan assembly from the

machine. Set the assembly up side down on

a flat surface.

HYDRAULICS

5-13

ATLV 4300 330495 (10--98)

9. Pull the vacuum fan impeller off the fan

motor shaft. Retain the key form the motor

shaft.

10. Remove the two hex screws and nyloc nuts

holding the vacuum fan motor to the mount

plate. Remove the motor.

NOTE: The orientation of the motor ports and the

reference hole in the mount plate.

11. Remove the hydraulic fittings from the old

motor and install in the new motor in the

same orientation.

12. Position the new motor assembly on the

mount plate in the same orientation as the

old one. Reinstall the hardware and tighten

to 37 -- 48 Nm (26 -- 34 ft. lb).

NOTE: The orientation of the motor ports and the

reference hole in the mount plate.

13. Install the vacuum fan impeller onto the

motor shaft.

NOTE: Make sure to use the key that was

removed with the old impeller.

14. Turn the assembly over and place it back on

top of the hopper cover. Hold the impeller in

place while turning over. Line up the holes in

the motor bracket with the holes in the

cover.

15. Go under the hopper cover and install the

four hex screws into vacuum fan assembly

retainer plate. Leave the hardware loose for

now. Use blue loctite (242) on the threads of

this hardware.

16. Reinstall the impeller screen, spacer, and

sleeve onto the vacuum fan motor shaft.

17. Use blue loctite (242) on the threads of the

impeller screen hardware. Reinstall the one

M8 hex screw and three M6 flat screws.

18. Tighten the M8 hex screw to 18 -- 24 Nm

(15 -- 20 ft.. lb) and the M6 flat screws to

8--10Nm(6--8ft.lb).

HYDRAULICS

5-14 ATLV 4300 330495 (10--98)

19. After the screen has been tighten down,

center the string guard (on the retainer

plate) around the outside of the screen.

Tighten the four screws to 18 -- 24 Nm

(15 -- 20 ft. lb).

20. Reinstall cover assembly onto the hopper

plenum.

21. Reinstall six hex screws holding the cover

assembly to the hopper plenum. Tighten the

screws to 18 -- 24 Nm (15 -- 20 ft. lb). Use

blue loctite (242) on the threads of this

hardware.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

22. Reconnect the hydraulic lines leading to the

vacuum fan motor. See hydraulic schematic

in this section.

23. Reinstall the six screws holding the vacuum

fan motor cover plate to the top of the

plenum assembly on top of the hopper

cover. Tighten the screws to 18 -- 24 Nm

(15 -- 20 ft. lb).

24. Tilt the hopper forward and close the cover.

25. Operate the machine and check the vacuum

fan for proper operation.

HYDRAULICS

5-15

ATLV 4300 330495 (10--98)

TO REPLACE STEERING WHEEL MOTOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the seat support and engage the prop

rod.

2. Locate the battery at the center of the

machine, on top and ahead of the front axle.

3. Remove the battery negative cable.

4. Disengage the prop rod and lower the seat

support.

5. Remove the cap from the center of the

steering wheel (snap out).

6. Remove the M20 hex nut from the center of

the steering wheel.

7. Use a puller to remove the steering wheel

from the steering column.

8. Remove the knob from the tilt steering wheel

pull lever.

9. If the machine is equipped with turn signals,

remove the turn signal unit from the steering

column.

10. Remove the two smaller pan screws from

the top side of the instrument panel.

11. Remove the two larger pan screws from the

back side of the instrument panel.

12. Carefully pull the instrument panel up until

the rubber boot clears the steering column.

13. Place the instrument panel back, against the

kick panel of the operators compartment.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

14. Mark, disconnect, and plug the five hydraulic

hoses leading to the steering wheel motor.

15. Loosen the hardware holding the lock collars

to the tilt bracket. Pull the steering wheel

motor and column down until the four hex

screws are accessible.

16. Remove the four M6 hex screws holding the

steering column to the motor. Remove the

motor from the machine. Note the

orientation of the motor and fittings.

HYDRAULICS

5-16 ATLV 4300 330495 (10--98)

17. Remove the five hydraulic fittings from the

motor and install in the new steering wheel

motor.

18. Install the new steering wheel motor

assembly in the machine in the same

orientation as the old one.

19. Reinstall the four M6 hex screws and tighten

to 8 -- 10 Nm (6 -- 8 ft. lb).

20. Push the motor and column back up in

position. Tighten the locking collars to

8--10Nm(6--8ft.lb).

21. Connect the five hydraulic hoses to the new

steering wheel motor. See hose diagram in

this section.

22. Position the instrument panel and rubber

boot over the top of the steering column.

NOTE: Be careful not to tear the boot.

23. Push the panel down until the four mount

holes line up with the weldnuts.

24. Reinstall the two small pan screws on top of

the panel and the two larger pan screws on

the back side of the panel. Hand tighten

tight.

25. Reinstall the tilt steering rod knob. Turn the

knob down tight.

26. Reinstall the steering wheel and M20 nut.

Tighten tight.

27. Reinstall the cap in the center of the steering

wheel (snap in).

28. Reinstall the turn signal assembly if the

machine is equipped with road light option.

29. Open the seat support and engage the prop

rod.

30. Reconnect the battery cable to the battery

(red cable to positive post, black cable to

negative post).

31. Disengage the prop rod and lower the seat

support.

32. Start the machine and check for proper

operation.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

HYDRAULICS

5-17

ATLV 4300 330495 (10--98)

TO REPLACE DRIVE WHEEL MOTOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Place blocks in front and back of the front

tires.

2. Jack up the rear of the machine at the

indicated jack points. Install jack stands

under the machine frame.

NOTE: Make sure the parking brake is engaged.

3. Remove the five wheel nuts. Remove the

tire and wheel assembly from the machine.

4. Remove the castle nut from the center of the

wheel hub.

5. Disengage the parking brake.

6. Remove the tension spring and clevis pin

from the brake cable clevis and arm on the

brake assembly.

7. Remove the two M12 hex screws and nyloc

nuts holding the brake assembly to the top

side of the wheel motor.

8. Pull the brake assembly straight up and off

the brake hub.

9. A large wheel puller must be used to remove

the wheel hub from the hydraulic drive

motor. Remove the hub.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

10. Mark, disconnect, and plug the hydraulic

hoses leading to the drive motor.

11. Remove the remaining two M12 hex screws

and nyloc nuts holding the drive motor to the

machine frame. Remove the drive motor

from the machine.

NOTE: Note that the two longer bolts go in the

upper mount holes.

12. Remove the hydraulic fittings from the old

drive motor and install in the new motor in

the same orientation.

HYDRAULICS

5-18 ATLV 4300 330495 (10--98)

13. Install the new motor in the machine (fittings

face up). Line up the mount holes and

reinstall the lower hex screws (short ones)

and nuts. Leave loose for now.

14. Apply a small amount of white grease on the

shaft of the new drive motor before installing

the wheel hub.

15. Use a small amount of blue loctite (242)

on the threads of the motor shaft

Install the wheel hub and castle nut. Tighten

to at least 170 Nm (125 ft. lb).

16. Spread the brake pads and slide the brake

assembly onto the wheel hub.

17. Align the holes in the brake assembly with

the mount holes in the wheel motor.

18. Reinstall the two longer hex screws. Tighten

all four hex screws to 64 -- 83 Nm

(47 -- 61 ft. lb.).

NOTE: Make sure to install the two longer bolts

into the upper holes.

19. Reconnect the hydraulic hoses to the new

drive motor. See hose diagram in this

section.

20. Reinstall the clevis pin in the end of the

brake cable at the brake arm.

21. Reinstall the tension spring on the brake

arm.

22. Engage the parking brake.

23. Reinstall the rear tire and wheel assembly.

24. Reinstall the five wheel nuts and tighten to

122 -- 162 Nm (90 -- 120 ft. lb).

25. Tilt the hopper forward and lower the hopper

cover.

26. Remove the jack stands and lower the

machine.

27. Remove the blocks from the front tires and

disengage the parking brake. Operate the

machine and check for proper operation.

HYDRAULICS

5-19

ATLV 4300 330495 (10--98)

STEERING CYLINDER

The steering cylinder on the model ATLVt4300

is located at the front of the front axle assembly,

between the front wheels. The steering cylinder is

controlled by the steering wheel motor and

hydraulic flow from the accessory pump.

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. Jack up the front of the machine at the

indicated jack points. Install jack stands

under the machine frame.

2. Remove the .50” hex screws and nyloc nuts

from the clevises and cylinder ends. Pull the

clevis off the cylinder.

NOTE: Make sure to retain the steel spacers

(2 per end) in the end of the cylinder.

3. Mark, disconnect, and plug the two hydraulic

hoses leading to the steering cylinder.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

4. Remove the two M12 hex screws holding

the steering cylinder to the front axle. Make

sure to retain the two tube spacers and

vacuum head mount plate (if equipped).

5. Remove the fittings from the old steering

cylinder and install in the new cylinder in the

same orientation.

6. Position the new steering cylinder onto the

front of the front axle. Reinstall the two tube

spacers, vacuum head mount plate

(if equipped), and two hex screws. Tighten

to 64 -- 83 Nm (47 -- 61 ft. lb.)

7. Grab the front tires and move inward until

the ball end clevis mount hole lines up with

the end of the new steering cylinder. Make

sure the steel spacers are in place at the

end of the cylinder.

HYDRAULICS

5-20 ATLV 4300 330495 (10--98)

8. Reinstall the hex screws and nuts into the

clevises. Tighten to 64 -- 83 Nm

(47 -- 61 ft. lb.)

9. Reconnect the hydraulic hoses to the new

steering cylinder. See hose diagram in this

section.

10. Check the front wheel alignment. See TO

ALIGN FRONT TIRES instructions in this

section.

11. Remove the jack stands and lower the

machine to the floor.

12. Operate the machine and check the new

steering cylinder for proper operation.

HYDRAULICS

5-21

ATLV 4300 330495 (10--98)

STEERING CYLINDER BREAKDOWN

HYDRAULICS

5-22 ATLV 4300 330495 (10--98)

CONTROL VALVE

The solenoid control valve is located on the lower

frame behind the engine, just below the bottom of

the hopper. The solenoid control valve receive

hydraulic flow from the accessory pump and

distributes this flow to the steering and vacuum

fan circuit. The vacuum fan function is controlled

by a dash mounted switch.

TO REPLACE SOLENOID CONTROL VALVE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, turn off

machine, and remove key.

1. Open the hopper cover and tilt the hopper

back.

2. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

3. Locate the solenoid control valve behind the

engine, just below the rear frame member.

4. Disconnect the main harness from the

electrical solenoid on the back side of the

valve.

5. Mark, disconnect, and plug the hydraulic

hoses leading to the control valve.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

6. Remove the two M6 hex screws and nyloc

nuts holding the control valve to the mount

bracket. Remove the control valve from the

machine.

7. Remove the hydraulic fittings from the old

control valve and install into the new valve in

the same orientation.

8. Position the new valve assembly on the

mount bracket. Reinstall the hardware and

tighten to 8 -- 10 Nm (6 -- 8 ft. lb).

HYDRAULICS

5-23

ATLV 4300 330495 (10--98)

9. Reconnect the hydraulic hoses to the new

valve. See hose diagram in this section.

10. Reconnect the solenoid valve to the main

electrical harness.

11. Reinstall the rear engine cover.

12. Tilt the hopper forward and lower the hopper

cover.

13. Operate the machine and check the new

steering cylinder for proper operation.

HYDRAULICS

5-24 ATLV 4300 330495 (10--98)

HYDRAULICS

5-25

ATLV 4300 330495 (6--01)

HYDRAULIC SCHEMATIC

HYDRAULICS

ATLV 4300 330495 (6--01)

5-26

HYDRAULIC HOSE GROUP

HYDRAULICS

5-27

ATLV 4300 330495 (10--98)

TROUBLESHOOTING

The troubleshooting charts that follow are

organized to lead you through the circuits.

HYDRAULICS

5-28 ATLV 4300 330495 (10--98)

POWER STEERING IS NOT NORMAL

STEER CYLINDER

ROD ENDS & SEALS

OK?

Yes

REPAIR / REPLACE

STEER CYLINDER

OR ROD ENDS

PLUMBING OK? REPAIR / REPLACE

PLUMBING

Yes

STEERING INLET

PRESSURE OK? No

REPAIR / REPLACE

STEERING

CONTROL

REPAIR / REPLACE

RV1 RELIEF

CARTRIDGE

RV1 RELIEF

CARTRIDGE

PRESSURE OK?

STEERING

COLUMN OK?

Yes

REPAIR / REPLACE

COMPENSATOR

CARTRIDGE

COMPENSATOR

CARTRIDGE FLOW

OK?

Yes

REPAIR / REPLACE

STEERING

COLUMN

VACUUM FAN

WORKS OK?

REPAIR / REPLACE

PUMP

Yes

HYDRAULICS

5-29

ATLV 4300 330495 (10--98)

VACUUM FAN WILL NOT TURN ON

SV1 STEM

MAGNETIZED? No

Yes

REPAIR

ELECTRICAL

SYSTEM

SV1 VALVE

CARTRIDGE

SHIFTING OK?

REPAIR / REPLACE

SV1 VALVE

CARTRIDGE

Yes

REPAIR / REPLACE

MOTOR

MOTOR INLET

FLOW

OK?

Yes

REPAIR / REPLACE

PLUMBING

PLUMBING OK? No

Yes

RV2 RELIEF

CARTRIDGE OK? No

REPAIR / REPLACE

RV2 CARTRIDGE

REPAIR / REPLACE

PUMP

CIRCUIT

FLOW OK? No

Yes

REPAIR / REPLACE

PC1 CHECK VALVE

CARTRIDGE

PC1 CHECK VALVE

SHIFTING

OK?

Yes

HYDRAULICS

5-30 ATLV 4300 330495 (10--98)

VACUUM FAN WILL NOT TURN OFF

SV1 STEM

MAGNETIZED? Yes

REPAIR

ELECTRICAL

SYSTEM

SV1 STEM

CARTRIDGE

SHIFTING OK?

REPAIR / REPLACE

SV1 STEM

CARTRIDGE

FAN TURNS

SLOWLY Yes

REPAIR / REPLACE

PC1 PILOT CHECK

CARTRIDGE

HYDRAULICS

5-31

ATLV 4300 330495 (10--98)

PROPEL MOTOR WILL NOT PROPEL

REPAIR / REPLACE

PROPEL MOTOR

MOTOR INLET

FLOW OK? Yes

REPAIR / REPLACE

PLUMBING

PLUMBING OK? No

Yes

RELIEF PRESSURE

OK?

REPAIR / REPLACE

RELIEF

CARTRIDGE

REPAIR / REPLACE

PROPEL PUMP

CIRCUIT FLOW

OK?

Yes

ADJUST TOW

DUMP VALVE

CIRCUIT FLOW

OK? No

Yes

HYDRAULICS

5-32 ATLV 4300 330495 (10--98)

No. 7-124

July, 1999

Char-Lynn®

Hydraulic Motor

2000 Series

Disc Valve Geroler Motor 006

Repair Information

2000 Series Disc Valve Motors

Exclusion

Seal

Bearing

Housing

Seal

Back-up

Washer

Shaft

Seal

Bearing and

Shaft

Assembly

Key

Shaft

Face Seal Wear

Plate

Seal

Valve

Plate

Splined

Drive

Geroler

Valve

Drive

Spring

Valve

Housing Tie

Bolt

Inner

Face Seal

O-ring/

Plug S/A

O-ring/

Plug S/A

O-ring/

Plug S/A

Shuttle Vave Option

Piston

Spring

Poppet

Spring

Dash Pot

Balance

Ring

Outer

Face Seal

Valve

Seal

8,0 [.312]

Grind flat spots on each side

Approx. 13,0 [.50]

200,0 [8.00]

Alignment studs (2)

25,0 [1.00]

3/8-24 UNF thread

9,5 [.375] Dia. Steel Rod

Tools required for disassembly and reassembly.

Torque wrench 57Nm [500 lb-in] capacity

300-450 [12-16]* breaker bar

9/16 socket

Small screwdriver 150-200 x 6,5 [6-8 x 1/4] blade

3/16 Allen wrench

Press

* Unless indicated otherwise, measurements

are given in mm [inches]

** Shaft seal installation tool (600496)

** Bullet (600465) for 1 diameter shafts

The following tools are not necessary for disassembly and reassem-

bly, but are extremely helpful.

Alignment studs (2)

2000 Series Disc Valve Motors

Tie Bolts

Seal Seal Case Drain Plug

Cleanliness is extremely important when repairing a hydraulic motor.

Work in a clean area. Before disconnecting the lines, clean the port

area of the motor thoroughly. Use a wire brush to remove foreign

material and debris from around the exterior joints of the motor.

Check the shaft and key slot, remove all nicks, burrs or sharp edges

that might damage the bearing housing seals when installing the shaft

and bearing assembly. Before starting the disassembly procedures,

drain the oil from inside the motor.

1 Place the motor in a vise with the output shaft down. Clamp

across the mounting flange of the motor not the housing. Excessive

clamping pressure will cause distortion. When clamping, use some

protective device on the vise, such as special soft jaws, pieces of hard

rubber or board.

Although not all drawings show the motor in a vise, we recommend

that you keep the motor in the vise during disassembly and reas-

sembly. Follow the clamping procedures explained throughout the

manual.

2 Remove 4 bolts from motor.

3 Lift valve housing straight up. If done carefully the pins, springs,

balance ring assembly, and valve will remain on the valve plate.

4 Carefully remove 76,0 [3.00] diameter seal from valve housing.

5 Remove case drain plug—with seal, from valve housing.

6 Remove 2 pins and 2 springs from balance ring assembly, see

Figure 5.

Figure 1

Figure 2

Figure 4

Figure 3

Disassembly

2000 Series Disc Valve Motors

Outer Face Seal

Inner

Face Seal

Pin (2) and

Spring (2)

Valve Balance Ring

Seal

Valve Drive

Valve Plate

Seal

Seal Geroler

Bearing

Housing Seal

Shaft Face Seal

Wear

Plate

Bearing Housing Shaft Seal

Back-up Washer

Exclusion

Seal

7 Remove balance ring assembly.

8 Remove inner and outer face seals from balance ring.

9 Remove the valve.

10 Remove the valve plate.

11 Remove the 76,0 [3.00] diameter seal from valve plate.

12 Remove the valve drive.

13 Remove the Geroler. Be sure to retain the rollers in the outer ring

if they are loose.

14 Remove the drive.

15 Remove the 76,0 [3.00] diameter seal from wear plate,

see Figure 7.

16 Remove the wear plate.

17 Remove the shaft face seal from the wear plate.

18 Remove the 76,0 [3.00] diameter seal from bearing housing.

19 You may need a press to remove shaft and bearing assembly from

bearing housing. (Key must be removed before removing shaft.)

20 Use a small screwdriver to remove shaft seal, back-up washer and

exclusion seal from bearing housing, see Figure 10. Do not damage

bore of housing.

Note: Individual parts of shaft and bearing assembly are not sold

separately. Replace as a unit.

Figure 5

Figure 6

Figure 7

Figure 10

Figure 9

Figure 8

Disassembly

Bearing

Housing

Shaft and

Bearing

Assembly

2000 Series Disc Valve Motors

Shaft Seal

Back-up

Washer

Exclusion

Seal

Shaft Face

Seal

Wear Plate

Seal

Shaft and

Bearing

Assembly

Geroler Valve Plate Valve

Drive Valve

Drive

Largest

Open Pocket Alignment

Ref. Only

Anyone of

6 Ports Open

to Ouside of Vave

Rotate

Valve

Clockwise

1/2 tooth max.

to Engage Spline

Check all mating surfaces. Replace any parts that have scratches or

burrs that could cause leakage. Clean all metal parts in clean solvent.

Blow dry with air. Do not wipe dry with cloth or paper towel because

lint or other matter can get in the hydraulic system and cause damage.

Do not use a coarse grit or try to file or grind these parts. Check

around the keyway and chamfered area of the shaft for burrs, nicks or

sharp edges that can damage the seals when reassembling the bearing

housing.

Note: Lubricate all seals (prior to installation) with petroleum jelly such

as Vaseline. Use new seals when reassembling this motor. Refer to

parts list (6-129) for proper seal kit number.

21 Use a press to install exclusion seal in outer bore of bearing

housing. Lip of seal must face outward. See Figure 11. If a press is

not available use a plastic or rubber hammer, being careful not to

damage or cock seal in the bore.

22 Place back-up washer into seal bore. Place shaft seal onto

installation tool (600496) and press seal into seal bore of the

housing.

23 Clamp housing in vise, see Figure 1.

24 Place protective bullet (see note below) over shaft. Apply

petroleum jelly to inside diameter of dust and shaft seal. You may

need a press to install shaft and bearing assembly. Do not distort

shaft seal. Damage to this seal will cause leakage.

Note: Bullet (600465), for 1inch dia. shafts, available— by special

order. Use tape over other shafts to prevent cutting the seals.

25 Apply petroleum jelly to the 76,0 [3.00] diameter seal. Install

seal into the bearing housing.

26 Alignment studs can be very helpful in reassembly of the motor.

See special tool listing page 2. If you use studs, install 2 studs

diagonally opposed in the bearing housing.

27 Install the shaft face seal in the wear plate as shown in Figure 11.

Do not distort seal.

28 Install the wear plate, see Figure 11.

29 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter seal

and install seal in the wear plate.

30 Install the drive into the output shaft.

31 Align the notch on the outside of the Geroler with the notch on the

wear plate. Install the Geroler against the wear plate. Be sure to retain

the rollers in the outer ring if they are loose.

32 Install the valve drive in the Geroler.

Note: Installation at this time involves 3 steps in the timing of the

motor. Timing determines the direction of rotation of the output shaft.

Timing parts include:

1. Geroler

2. Valve Drive

3. Valve Plate

4. Valve

Timing Step # 1 — Locate the largest open pocket in the Geroler and

mark it on the outside edge of the Geroler.

33 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter

seal. Install seal in groove of valve plate.

Figure 11

Figure 12 Timing Alignment

Reassembly

2000 Series Disc Valve Motors

Spring and Pin

Seal Valve

Housing

Balance Ring

Inner Seal Pin NotchOuter Seal

Alignment

Studs

Balance

Ring

Valve

Housing

Valve

Plate

34 Align the notch on the outside of the valve plate with the notch on

the Geroler as shown in Figure 12.

Timing Step # 2 — Locate the slot opening in the valve plate which is

in line with the largest open pocket of the Geroler.

Timing Step # 3 — Locate any one of the side openings of the valve

and align this opening with the open slot of the valve plate that is in

line with the largest open pocket of the Geroler. Install the valve by

rotating it clockwise until the spine teeth engage (1/2 spine tooth

max.). This will provide the proper rotation when pressurized as

shown in Figure 13.

35 Install 2 springs and 2 pins in the holes located in the bore of the

valve housing, as shown in Figure 14.

36 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter

seal. Install seal in the valve housing.

37 Apply petroleum jelly to inner and outer face seals. Install seals

on balance ring as shown in Figure 15.

Important: Install face seals in the positions shown in Figure 15, or the

motor will not operate properly. Do not force or bend the face seals.

Any damage to these seals will affect the operation of the motor.

38 Align pin notches in balance ring with pins in bore of valve housing.

Install balance ring assembly in valve housing.

39 Insert your finger through port of valve housing. Apply pressure

to side of balance ring as shown in Figure 16. Hold ring in position

until valve housing is in place against valve plate (see Figure 17).

Note: After installing the valve housing on the valve plate check for

proper placement. Push down on the valve housing. You should

get a slight spring action.

Figure 13

Figure 14

Figure 17

Figure 16

Figure 15

Reassembly

Clockwise

Rotation

Counter

Clockwise

Rotation

2000 Series Disc Valve Motors

Case Drain Plug with Seal

Tie Bolts

Exclusion Seal

Housing with Seal Guard Groove

Seal Guard

4,40[.177]

40 Install tie bolts. If you use alignment Studs, install 2 bolts opposite

the studs. Finger tighten the bolts. Remove the alignment studs and

replace with the two remaining bolts. Torque all four bolts alternately

to 50 Nm [450 lb-in].

41 Install seal on case drain plug then install in valve housing. Torque

to 6 Nm [50 lb-in.]

On wheel motors, a different bearing housing is used, see Figure 19.

Other than this the parts are the same as the standard motor and the

same disassembly and reassembly procedures apply.

Figure 18

Figure 19

Reassembly

Wheel Motor

with Seal Guard

Installation of Seal Guard:

After completing assembly of the shaft and bearing assembly into the

bearing housing, press the seal guard onto the shaft with a tool that

will provide an even push over the seal. This tool must bottom out

against the bearing housing and provide a 4,5 mm [.177 inch] stop for

the seal guard.

Exclusion Seal

Castle Nut

Bearing Housing

Seal

Shaft Seal

Shaft and Bearing

Assembly

Shaft Face Seal

Back-up Washer

2000 Series Disc Valve Motors

This motor is the same as the standard motor without the shaft/

bearing assembly, and bearing housing. The mounting flange replaces

the bearing housing, see Figure 20. Follow same disassembly and

reassembly procedures as rear section of standard motor.

Seal

Flange

Figure 20

Figure 21

Bearingless Motor

Disassembly Reassembly

Shuttle Valve Option

Disassembly of shuttle valve option, this valve is

located in the valve housing. Clean and inspect

shuttle valve parts and reassemble with new

seals, torque plugs to 8-11 Nm [75-100 lb-in].

Shuttle Location

when Applicable

O-ring/Plug S/A

Torque to 8-11 Nm [75-100 lb-in]

O-ring/Plug S/A

Torque to 8-11 Nm [75-100 lb-in]

Shuttle Vave Option

Piston

Spring

Poppet

Spring

Dash Pot

2000 Series Disc Valve Motors

90°

Alignment Notch

Speed Sensor Body

Speed Sensor Installation

Figure 22 Figure 23

Figure 24 Figure 25

Alignment Notchs

Perpendicular to

Centerline of Motor

Alignment Nut

9/16 inch

Hex Head

Lock Nut

11/16 inch

Hex Head

Parallel with

Centerline of Motor Shaft

Alignment Nut

Speed Sensor Port

Lock Nut

Housing

Back out

Gear/Target

Tooth

Washer

O-ring

1 Rotate the motor shaft until a (gear/target)

tooth is centered in the speed sensor port. If

this is not done, the sensor may be damaged

during the operation of the motor.

2 Make sure the lock nut and its threads are

clean and dry for the proper torque. Position

the lock nut against the alignment nut as

shown in Figure 22.

3 Move the washer and the o-ring up against

the speed sensor body threads as shown in

Figure 22.

4 By hand, lightly thread the speed sensor

body into the housing until the sensor

touches against the motor (gear/target) tooth.

Do not force the sensor against the (gear/

target) tooth, damage may occur. Make sure

the o-ring or the washer do not touch the

housing — see Figure 23.

5 Turn the speed sensor body out one quarter

turn (CCW) plus the additional amount (CCW)

needed to make the alignment notches

perpendicular to the motor shaft centerline

(90° +/-5 degrees from the motor shaft

centerline — Figure 24 and 25).

6 Maintain the speed sensor body alignment

(Figure 25), and tighten the lock nut to 8,5-14

Nm [75-125 lb-in.] (torque values are for

clean dry threads).

7 Check the speed sensor body for correct

alignment (Figure 25), reinstall the sensor if it

is not correct.

Reassembly —

Speed Sensor

2000 Series Disc Valve Motors

104-1007

104-1001 -1002 -1003 -1004 -1005 -1006 -1007 -1143

1 inch Straight

2 Bolt

SAE A

Flange

Displacement cm

/r [ in

/r ] and Product Number

ShaftMounting 100

[ 6.2] 130

[ 8.0] 160

[ 9.6] 195

[11.9] 245

[14.9] 305

[18.7] 395

[24.0]

[ 4.9] 490

[29.8]

104-1037 -1038 -1039 -1040 -1041 -1042 -1043 -1044

7/8-14 O-ring Staggered

Ports

1-1/16—12 O-ring 180° Apart

104-1022 -1023 -1024 -1025 -1026 -1027 -1028 -1228 -1420

1-1/4 Inch Straight 104-1061 -1062 -1063 -1064 -1065 -1066 -1067 -1068 -1421

7/8-14 O-ring Staggered

1-1/16—12 O-ring 180° Apart

104-1029 -1030 -1031 -1032 -1033 -1034 -1035 -1229 -1422

1-1/4 Inch

14 T Splined 104-1087 -1088 -1089 -1090 -1091 -1092 -1093 -1094 -1423

7/8-14 O-ring Staggered

1-1/16—12 O-ring 180° Apart

32 mm Straight 104-1384 -1385 -1386 -1387 -1388 -1389 -1390 -1391G 1/2 (BSP)

105-1001 -1002 -1003 -1004 -1005 -1006 -1007 -1060

104-1376 -1377 -1378 -1379 -1380 -1381 -1382 -1383G 1/2 (BSP)

1-1/4 Inch

14 T Splined

105-1071 -1072 -1073 -1074 -1075 -1076 -1077 -1078

Standard

with 4 Bolt

Square

Flange

105-1029 -1030 -1031 -1032 -1033 -1034 -1035 -1096

105-1079 -1080 -1081 -1082 -1083 -1084 -1085 -1086

7/8-14 O-ring Staggered

1-1/16—12 O-ring 180° Apart

7/8-14 O-ring Staggered

1-1/16—12 O-ring 180° Apart

Wheel

Motor

105-1134 -1135 -1136 -1137 -1138 -1139 -1140 -1141G 1/2 (BSP)

32 mm Straight

1-1/4 Inch

14 T Splined

1-1/4 Inch

Tapered

106-1008 -1009 -1010 -1011 -1012 -1013 -1014 -1015 -1047

106-1038 -1039 -1040 -1041 -1042 -1043 -1044 -1045G 1/2 (BSP)

7/8-14 O-ring Staggered

Bearingless

2 Bolt

SAE B

Flange

104-1200 -1201 -1202 -1203 -1204 -1205 -1206 -1207

1-1/4 Inch Straight

104-1208 -1209 -1210 -1211 -1212 -1213 -1214 -1215

7/8-14 O-ring Staggered

104-1193 -1194 -1195 -1196 -1197 -1198 -1199

104-1216 -1217 -1218 -1219 -1220

7/8-14 O-ring Staggered

1-1/4 In. Involute SAE C Splined

1 Inch SAE 6B Splined

7/8 Inch SAE B Splined

7/8-14 O-ring Staggered

1-1/16—12 O-ring 180° Apart

1-1/4 Inch Straight — — — — — — —

— — — — — — —

-1148

-1149

-1152

—

— — —

—

105-

—

Use digit prefix —104-, 105-, or 106- plus four digit number from charts

for complete product number—Example 106-1039.

Product Numbers—2000 Series

Each Order Must Include the Following:

How to Order Replacement Parts

1. Product Number

2. Date Code

3. Part Name

4. Part Number

5. Quantity of Parts

For Additional Literature Contact Eaton Corp. Hydraulics

Division 15151 Highway 5 Eden Prairie, MN 55344.

Specifications and performance data, Catalog No. 11-878

Replacement part numbers and kit information — Parts

Information No. 6-129

Char-Lynn

Product number

Eaton Corp. Hydraulics Div.

Eden Prairie, MN 55344

Product Number

000 0000 000

Product Line

Identification

Number

Product

Identification

Number

Engineering

Change

Code

Week of

Year 01

Thru 52

Last

Number(s)

of Year

Date Code

00 00

Product Identification

2000 Series Disc Valve Motors

Notes:

Printed in USA

Form No. 7-124

Sumitomo Eaton

Hydraulic Company Ltd.

Ooi-Cho Kameoka-Shi

621-0017 Kyoto

Japan

Telephone: [+81] 771-22-9601

Fax: [+81] 771-29-2020

Eaton Corporation

Hydraulics Division

15151 Hwy. 5

Eden Prairie, MN 55344

Telephone: 612/937-7254

Fax: 612/937-7130

Eaton Ltd.

7th Floor, Woo Duk Building

832-2 Yeoksam-Dong, Kangnam-Ku

Soeul 135-750

Korea

Telephone: [+82] 2-557-0595

Fax: [+82] 2-557-1634

Eaton Ltd.

Hydraulics Division

Glenrothes, Fife

Scotland, KY7 4NW

Telephone: [+44] (0)1592-771-771

Fax: [+44] (0)1592-773-184

Eaton Hydraulics (Shanghai) Co. Ltd.

388 Aidu Road, Waigaogiao FTZ

Pudong New Area

Shanghai 200137

Peoples Republic of China

Telephone: [+86] 21-5046 0758

Fax: [+86] 21-5046 0767

Eaton B.V.

Boeing Avenue 11

1119 PC Schiphol-Rijk

The Netherlands

Telephone: [+31] (0)20-655 6776

Fax: [+31] (0)20-655 6800

Jining Eaton Hydraulic Co. Ltd.

6 Ji Da Road

Jining City

Shandong Province 272131

Peoples Republic of China

Telephone: [+86] 537-2221288

Fax: [+86] 537-2221557

Sumitomo Eaton Hydraulic Co.

8 Temasek Blvd.

42-01 Suntec Tower Three

Singapore 03988

Telephone: [+65] 832-7727

Fax: [+65] 832-7733

www.eatonhydraulics.com

ISO-9001 CERTIFICATED FIRM

DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS

ACCREDITED BY

THE DUTCH COUNCIL

FOR CERTIFICATION

Reg. No. 24

Qualitiy System Certified

Products in this catalog are manufactured

in an ISO-9001-certified site.

2000 Series Disc Valve Motors

Eaton®

Medium Duty Piston Pump

Repair Information

07-06-630

EN-0401

Model 70160 Variable Displacement Piston Pump

20,3 cm3/r [1.24 in3/r] or 23,6 cm3/r [1.44 in3/r] Displacements

Manual Controlled - 03

Model 70160

Table of Contents

Introduction .........................................................................................................2

Identification ........................................................................................................ 3

Tools Required .................................................................................................... 3

Parts Drawing ......................................................................................................4 - 5

Parts List ............................................................................................................. 6 - 7

Repair information

Disassembly ..................................................................................................8 - 10

Reassembly ...................................................................................................11 - 12

Fault - Logic Troubleshooting ..............................................................................13 - 17

Start-up Procedure .............................................................................................. 18

Introduction

This manual provides service information for Eaton Models 70160 variable displacement piston pumps. Step

by step instructions for the complete disassembly, inspection, and reassembly of the pump are given. The

following recommendations should be followed to insure successful repairs.

Remove the pump from the application.

Cleanliness is extremely important.

Clean the port areas thoroughly before disconnecting the hydraulic lines.

Plug the pump ports and cover the open hydraulic lines immediately after they're disconnected.

Drain the oil and clean the exterior of the pump before making repairs.

Wash all metal parts in clean solvent.

Use compressed air to dry the parts. Do not wipe them dry with paper towels or cloth.

Compressed air should be filtered and moisture free.

Always use new seals when reassembling hydraulic pumps.

Lubricate the new rubber seals with a petroleum jelly (Vaseline®) before installation.

Torque all bolts over gasketed joints, then repeat the torquing sequence to makeup for gasket

compression.

Verifying the accuracy of pump repairs on an authorized test stand is essential.

Introduction

Model 70160

Single Pump - Product Number:

7 0 1 6 0 - R A A - 03

Tandem Pumps - Product Number:

7 8 1 6 3 - R A B - 03

Serial Number Code:

A 99 01 31 JB

Tester's Initials

Day of Month (two digits)

Month (two digits)

Revision level of parts list.

Last two digits of year built.

( 98 for 1998 etc.)

Identification Numbers - Manually Variable Displacement Piston Pump

Stamped on each unit's mounting flange.

A - Product Number Description

70160 = Single Piston Pump

78162 = Single Piston Pump with Gear Pump

78161 = Tandem Piston Pumps

78163 = Tandem Piston Pumps with Gear Pump

B - Sequential Numbering

C - Engineering Design Code

Tools Required

1/2, 9/16, 7/8 & 1-1/8 in. sockets and/or end

wrenches

Torque wrench (136 N.m [100 lbf.ft] capacity)

Ratchet wrench

5/16 in. and 7/16 Allen wrenches or bit sockets

Internal and external retaining ring pliers

Small screwdrivers (2)

Hammer (soft face)

Light Petroleum Jelly

Seal driver or similar tool

Each order must include the following information.

1. Product and/or Part Number

2. Serial Number Code

3. Part Name

4. Quantity

Model 70160

Parts

Drawing

Pump drawn below is typical of a righthand rotation pump.

3-1

Press Fit

Shaft assembly for

rear pump of tandem.

Shaft assembly for

single pump

or front pump

of tandem.

910

Press Fit

50-1

22 Press Fit

51-1

Port

(D2)

Port

(D1)

Press Fit into

Cover plate

Model 70160

Parts

Drawing

2-1 2-2

(K4-4)

2-1 2-2

27A

27B

28A

55-1

49 55-2

55-3

55-4

49-1

55-5

55-1

55-2

55-4

55-5

49-1

34-1

(K2-1)

K2-2

K2-3

(K3-1)

(K3-2)

(K3-3)

(K4-1)

K4-2

K4-3

K1-1 32

(K2-2)

K2-3

K2-4

21-1

20-1

21-1

20-1

55-3

Model 70160

Item Qty. Description

1 1 Drive Shaft

2 1 Backplate Assembly

3 1 Housing Assembly

4 1 Rotating Kit Assembly

5 1 Camplate

6 1 Washer

+ 7 1 Retaining Ring

+ 8 2 Retaining Ring

9 1 Thrust Bearing

10 2 Bearing Race

+ 11 1 Shaft Seal, Drive

11 1 Viton Shaft Seal, Drive

11 1 Spacer

+ 12 1 Housing Gasket

13 1 Camplate Insert

14 6 Washer

+ 16 1 Shaft Seal, Trunnion

17 6 Screw, Cap

20 1 for Port "C" Relief Valve S/A

+ 20-1 1 O-ring, 2.95 mm Dia. x 23,46 mm ID. [.116 in. Dia. x .924 in. ID.]

21 1 for Port "D" Relief Valve S/A

+ 21-1 1 O-ring, 2.95 mm Dia. x 23,46 mm ID. [.116 in. Dia. x .924 in. ID.]

22 2 Cone Bearing

23 1 Coverplate Sub Assembly

24 1 Coverplate Sub Assembly

26 2 Dowel Pin

27 2 Cap Screws, 5/16-18, 50.8 mm [2 in.] Long

27A 2 Cap Screws, 5/16-18, 82.6 mm [3.25 in.] Long

27B 2 Cap Screws, 5/16-18, 88.9 mm [3.5 in.] Long

28 2 Cap Screws, 5/16-18, 63.5 mm [2.5 in.] Long

28A 2 Cap Screws, 5/16-18, 95.3 mm [3.75 in.] Long

28B 2 Cap Screws, 5/16-18, 101.6 mm [4.00 in.] Long

29 1 Key, Drive Shaft

30 1 Key, Tapered Arm

31 1 Cover Plate (In K3 kit)

+ 32 1 O-ring (In K1, K2, K3, & K4 kit)

33 2 Cap Screws, Cover Plate (In K3 kit)

34 1 Plug Assembly

+ 34-1 1 O-ring, 2.21 mm Dia. x 16.36 mm ID. [.087 in. Dia. x .644 in. ID.]

+ 35 1 Molded O-ring

36 1 Charge Pump Adaptor

37 1 Gerotor set and coupler sub-assembly

37 1 9 tooth coupler (In Kit 4)

37 1 11 tooth coupler (In Kit 5)

39 2 Cup, Bearing

40 1 Ring, Crush

41 2 O-ring, 2.38 mm Dia. x 66.68 mm I.D. [.0937 in. Dia. x 2.625 in. I.D.]

42 4 Washer

46 1 Mounting Bracket, Square shaped

46 1 Mounting Bracket, "V" shaped

48 1 Valve Plate

Parts List

Model 70160

Parts List

Righthand (CW) Rotation

Lefthand (CCW) Rotation

49 1 Plug Assembly

49-1 1 Plug Assembly

+ 50-1 1 O-ring, 1.98 mm Dia. x 11.89 mm ID. [.078 in. Dia. x .468 in. ID.]

51 1 Plug Assembly

+ 51-1 1 O-ring, 1.98 mm Dia. x 11.89 mm ID. [.078 in. Dia. x .468 in. ID.]

55 1 Bypass Valve sub-assembly

+ 55-1 1 Retaining Ring

55-2 1 Separator Plug

55-3 1 Separator

+ 55-4 1 O-ring, 1.59 mm Dia. x 9.53 mm I.D. [.0625 in. Dia. x .375 in. I.D.]

+ 55-5 1 O-ring, 2.46 mm Dia. x 19.18 mm I.D. [.097 in. Dia. x .755 in. I.D.]

Mounting Kits

K1 1 Tandem Piston Pump Mounting Kit

K1-1 1 35T Coupler, 36.8 mm [1.45 in.] long

K1-2 1 O-ring, 1.59 mm Dia. x 101.6 mm ID. [.0625 in. Dia. x 4 in. ID.]

K1-3 2 Cap Screws

K1-4 2 Washer

K2 1 Gear Pump Mounting Kit

K2-1 1 O-ring, 1.59 mm Dia. x 82.55 mm ID. [.0625 in. Dia. x 3.25 in. ID.]

K2-2 2 Washer

K2-3 2 Cap Screws

K3 1 Cover Plate Kit

K3-1 1 O-ring, 1.59 mm Dia. x 82.55 mm ID. [.0625 in. Dia. x 3.25 in. ID.]

K3-2 1 Cover Plate

K3-3 2 Cap Screws

K4 1 Gear Pump Mounting Kit with Coupler

K4-1 1 O-ring, 1.59 mm Dia. x 101.6 mm ID. [.0625 in. Dia. x 4 in. ID.]

K4-2 2 Washer

K4-3 2 Cap Screws

K4-4 1 9T Coupler

Seal Repair Kit

•1 Seal Repair Kit (see Parts Manual for part numbers)

Legend + Included in seal repair kit.

Item Qty. Description

Model 70160

Disassembly

The following disassembly procedure applies to a single pump

with or without gear pump The

repair procedure for tandem

pumps, once they are separated, is

basically the same. The basic

configuration differences between

a single and tandem pumps are the

backplates, pump shafts and

housing assemblies. In most

cases, only the rear pump of

tandem units contain a charge pump, which is common to

both the front and rear pump. The rear tandem pump does not

incorporate a shaft seal.

Thoroughly clean the Eaton Model 70160 or 78162 variable

displacement pump before any

repairs are attempted. When

working on tandem pumps,

separate the front and rear pumps

first.

1Support the pump with the

input shaft down. Use a 1/2 in.

socket or end wrench to remove

the pump adapter cover plate or

gear pump (see Figure 2).

2Use a pick or similar tool to

remove the adapter cover plate or

gear pump o-ring. (See Figure 3)

3Use a 7/16 in. Allen wrench or

bit socket remover to remove the

charge pressure relief valve spring

retainer from the pump adaptor

assembly (see Figure 4).

4Use a pencil magnet or similar

tool to carefully remove the charge

pressure spring and poppet from

the pump adaptor assembly. (See

Figure 5) Use caution not to drop

the charge pump poppet into the

pump adaptor assembly.

5The charge pressure relief

valve and poppet may be of the

standard or high pressure type. The

(6.9 to 10.3 bar [100 to 150 PSI])

standard spring and poppet are

shown on the bottom and the

optional high pressure (13.7 to

20.7 bar [200 to 300 PSI]) spring

and poppet is shown on the top.

The same charge pressure relief valve spring retainer is used

with either the standard or high

pressure (see Figure 6).

6Use a 7/8 in. socket or end

wrench to remove the optional

bypass valve assembly from the

backplate (see Figure 7).

7The internal seal may be

replaced by first removing the

small retaining ring on the end of

the bypass valve. Remove and

replace the o-rings (see Figure 8).

8Use a 9/16 in. hex key to

remove the two high pressure relief

valves from the pumps backplate

assembly (see Figure 9). Remove

relief valve as shown from each

side (see Figure 10). Each system

relief valve S/A is identified by both

its part number and relief valve

setting as shown in Parts Information manual.

9Firmly support the pump assembly. Use a 1/2 in. socket or

end wrench to remove the four cap screws retaining the charge

pump adapter assembly.

10 With the cap screws removed,

remove the charge pump adaptor

assembly from the backplate (see

Figure 11).

Note: The front pump assemblies

do not have charge pump adapter

assemblies.

11 Turn the adapter assembly

over. Use an o-ring pick or similar

tool remove the o-ring seal (see

Figure 12).

12 Inspect the gerotor pocket and

needle bearing located in the

charge pump adapter. The needles in the needle bearing must

remain intact in the bearing cage.

Repair Information - Disassembly

Figure 1

Figure 2

Figure 3

Figure 5

Figure 4

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Model 70160

13 When the needle bearing

assembly is replaced, the

numbered end of the bearing must

face toward the flange side of the

adapter to the dimension as shown

(see Figure 13).

14 With the charge pump adapter

removed, remove the charge pump

outerring and inner gerotor ring

assembly (see Figure 14 and 15).

15 Charge pumps are available in

two different displacements Charge

pump displacements are based on

the thickness of the gerotor

assembly and the depth of the

pocket located in the charge pump adapter. To determine the

displacement, refer to the table below.

Gerotor Pocket Depth

Displacement Depth of Pocket

cm3/r [in3/r] mm [in.]

6.9 [.42] 6.35 [.25]

13.8 [.84] 12.7 [.50]

16 To separate the backplate

assembly from the dowel pins in

the pump housing assembly, insert

two screwdrivers between

backplate and housing assembly

and pry upward (see Figure 16).

17 After separation, remove the

backplate from the housing

assembly.

18 Turn the backplate assembly

over and inspect the needle

bearing. The needles in the needle

bearing must remain intact in the

bearing cage (see Figure 17).

19 When the needle bearing

assembly is replaced, the

numbered end of the bearing must

face the valve plate side of the

backplate to the dimension as

shown (see Figure 18).

20 With the backplate removed,

remove the gasket from the pump

housing assembly and discard (see

Figure 19).

21 Remove the valve plate from the piston block assembly.

Note: This valve plate may have stuck to the backplate

assembly that was previously removed.

22 Valveplate directional rotation (CW or CCW) is identified

by the location of the metering slots located on the face of the

valve plates. Pump input

rotation should always turn

into the metering slots (see

Figure 20). A clockwise

valve plate is shown on the

left and a counter clockwise

valveplate is on the right.

Note: Whenever pump

input rotation is changed, the valve plate must be replaced

along with the desired rotation charge pump adapter.

23 Remove the rotating kit assembly

by carefully retaining it in the housing

assembly (see Figure 21). Lift the

housing and rotating kit assembly and

turn over assemblies allowing the

rotating kit assembly to slide down the

input shaft and out of the pump

housing.

24 With the rotating kit

assembly removed, remove the

piston assemblies, spider and

spider pivot from the piston

barrel.(see Figure 22).

25 Inspect the piston

assemblies, spider, spider pivot

and piston block. The piston block assembly usually requires

no further disassembly unless the pins or block spring are

damaged.

26 When any excessive wear or

scratches are noted on the face of

the piston block, the block

assembly must be replaced (see

Figure 23).

DO NOT LAP THE FACE OF PISTON

BLOCK ASSEMBLY.

27 To remove the input shaft

assembly, use a pair of internal

snap ring pliers and remove the

shaft seal retaining ring from the

housing assembly (see Figure 24).

Numbered End

Gerotor Pocket

2.41 mm

[.095 in.]

Flange

Figure 13

Figure 17

2.79 mm

[.110 in.]

1.91 mm

[.075 in.]

Numbered End

Figure 18

Figure 20

Figure 22

Figure 23

Figure 24

Figure 15

Figure 16

Figure 14

Figure 19

Figure 21

Repair Information - Disassembly

Model 70160

28 With the retaining ring

removed, use a small press to

press the shaft seal and input shaft

assembly from the housing

assembly.

29 With the input shaft assembly

removed, disassemble the

assembly for inspection by

removing the shaft seal, washer,

retaining ring thrust washers and

bearing (see Figure 26).

Note: The rear pump on tandem

units uses a spacer in place of

shaft seals.

30 To remove the camplate from

the housing assembly, use a 9/16

in. socket or end wrench and

remove the three cap screws and

washers retaining the control arm cover plate assembly. Start

at the cover plate with control arm (see Figure 27).

31 With the retaining cap screws removed, insert two small

screwdrivers in the notches located

in the cover plate assembly and pry

upward. Make sure bearing cup

comes off with the cover plate (see

Figure 28).

Note: The crush ring in the control

arm trunnion cover does not need

to be removed (see Figure 29). The

only time the crush ring needs to

be removed is when either the

trunnion cover, the camplate

assembly or the housing assembly

is replaced. A shim kit is then

required in the crush ring’s place.

32 Reposition the pump assembly

to remove opposite cover plate.

The bearing cup in this cover plate

is press fit and not removable.

Repeat steps 30 through 31.

32b Remove the slip fit bearing on

the non-control arm side of the

camplate.

33 With housing in the upright

position, slide the camplate toward the control side and lift it

from the pump housing (see Figure 30).

Note: The camplate control shaft will fit out either side of the

pump housing. Be sure to note on which side of the housing

the control shaft protrudes before removing camplate from

housing for correct reassembly orientation.

34 Use an o-ring pick or similar tool to remove the o-ring

seals from the two counter-bores in the housing or the cover

plates (see Figure 31).

35 To remove the control side cover plate lip seal, use a small

press and press the lip seal inward

(see Figure 32).

36 Remove the thrust plate from

the camplate. The thrust plate is

reversible and either side may face

the camplate (see Figure 33).

37 Inspect the housing

assembly's front needle bearing. If

the needles remain in their cage

and move freely, replacement

usually is not required (see Figure

34).

38 When the needle bearing is

replaced, the numbered end of the

needle bearing must face away

from the housing and pressed to

the dimension as shown (see

Figure 35).

Figure 26

Figure 27

Repair Information - Disassembly

Figure 32

Figure 34

1.78 mm

[.07 in.]

Numbered End Flange End of Housing

Figure 35

Figure 25

Figure 28

Figure 29

Figure 30

Figure 33

Figure 31

Model 70160

Reassembly

1Before reassembling the pump, replace all worn and

damaged parts, assemblies, seals and o-rings. Lubricate the

seals and o-rings with petroleum jelly to help retain them

during reassembly and to provide lubrication to the input and

control shaft seals. Lubricate all finished part surfaces freely

with clean hydraulic fluid to help provide start up lubrication

between all rotating parts.

2To reassemble the camplate

assembly into the pump housing,

tilt the camplate slightly and install

the control side of the camplate

through the previously noted or

marked side of the housing

assembly (see Figure 36).

3Lubricate the tapered bearing

and reassemble it on the non-

control arm side of the camplate

(see Figure 37).

4Lubricate and install the o-ring

seal into counter-bore of housing

(see Figure 37).

5Install the trunnion cover over

bearing and onto pump housing.

Install the three cap screws and

washers, torque screws to 39,3 Nm

[29 ft-lb] (see Figure 38).

6Lubricate and install the

control arm shaft seal into the

control arm cover plate. Install with the lip of the seal facing

upward or to the inside of the pump (see Figure 39).

7If the housing, trunnion covers or camplate assembly have

not been replaced, the existing crush ring may be re-used. If

you have replaced anyone of the above a shim kit must replace

the crush ring. See Parts Information manual for number.

8Place the bearing cup into trunnion cover over the crush

ring or shims (see Figure 40).

9Lubricate and install the o-ring

seal into counter-bore of housing

(see Figure 41).

10 Install the trunnion cover over

the control shaft and into the pump

housing. Install the three retaining

cap screws and washers, torque

screws to 39,3 Nm [29 ft-lb] (see

Figure 42).

11 Using your fingers, tilt the

camplate back and forth to check

the trunnion bearing preload.

Proper preload is achieved when

the camplate has a very slight

tilting resistance. The camplate

must not have any or very little side

clearance.

12 Reassemble the input shaft

assembly by installing the thrust

washer, thrust bearing, second

thrust washer, retaining ring,

washer and shaft seal (see Figure

43).

Note: The lip of the shaft seal must

point toward the center of the input

shaft.

13 Install the input shaft

assembly into the housing

assembly. Push the shaft seal in

just far enough so you can start the

shaft seal retaining ring.

14 Use a pair of snap ring pliers

to install retaining snap ring into

the housing assembly (see Figure

44).

15 Use a seal driver or similar

tool to press or drive the snap ring and seal into the housing

assembly (see Figure 45).

CAUTION! Press or drive inward

until the snap ring snaps into the

snap ring groove located in the

pump housing assembly.

16 The thrust plate is reversible.

Either side will fit into the camplate.

In most cases if any irregularities

are noted it is best to replace the thrust plate (see Figure 46).

Figure 38

Figure 42

Figure 43

Figure 44

Figure 45

Repair Information - Reassembly

Figure 36

Figure 37

Figure 39 Figure 40

Figure 41

Figure 46

Model 70160

18 Lubricate and install the

thrustplate over the input shaft

assembly and into the camplate.

The thrustplate must rest firmly in

its pocket located in the camplate.

19 Reassemble the rotating kit

assembly by first aligning the

splines in the pivot with the splines

in the block. Install the pivot on the

block assembly pins (see Figure 47).

20 Use a small socket or similar

tool to help retain the pivot in the

centered position. Lubricate and

install the spider and piston

assemblies onto the pivot and

pistons into the piston block

assembly (see Figure 48).

21 Hold the housing assembly in

the vertical position then carefully

install the rotating kit by first

aligning with the splines on the

input shaft. With splines aligned,

install the rotating kit into the

pump housing (see Figure 50). Use

caution to ensure all parts are kept

in their proper position.

22 With the rotating kit installed,

reposition the housing assembly in

the input shaft down position and

install a new housing gasket (see

Figure 50).

23 Lightly coat the backplate side

of the valve plate with petroleum

jelly for retention during assembly.

Install the valve plate over the

needle bearing, aligning the small

slot on the outside of the valve

plate with the dowel pin in the

backplate (see Figure 51).

24 Carefully install the backplate

assembly by aligning it with the

dowel pins located in the pump

housing. Use caution not to

dislodge the valve plate (see Figure 54).

25 Align the spline of the

gerotor’s inner ring, then lubricate

and install the inner ring and outer

ring over the input shaft and onto

the backplate assembly (see Figure

53).

Note: Before installing the charge pump adaptor plate, offset

the outer ring of the geroter as

shown.

26 With the gerotor assembly

installed, install new o-ring into

charge pump adapter plate and

place adapter onto backplate over

gerotor. Retain with cap screws.

Torque cap screws to 25 N•m [18.5

lbf•ft] (see Figure 54).

27 Install the two high pressure

relief valves. Torque valves 128,8

to 142,4 Nm [95 to105 lb-ft] (see

Figure 55).

29 Lubricate and reassemble the

bypass valve assembly. Install the

bypass valve into the backplate.

Torque valve to 30,5±2 Nm

[22.5±1.5 lb-ft] (see Figure 56).

30 Coat the charge pressure

poppet with petroleum jelly and

place poppet onto spring and install

into the adapter plate (see Figure

57).

31 Install the hollow charge

pressure relief valve retainer into

the adapter plate. Torque retainer

to 6,8 to 9,5 Nm [5 to 7 lb-ft].

32 Lubricate and install the o-ring

on the cover plate or gear pump.

Install the cover plate or gear pump

and two cap screws. Torque cap screws to 36,6 to 40 Nm [27

to 31 lb-ft].

The Model 70160 or 78162 variable displacement pump is now

ready for test and reinstallation.

Figure 48

Figure 49

Figure 51

Figure 54

Figure 55

Figure 56

Figure 57

Repair Information - Reassembly

Figure 47

Figure 50

Figure 52

Figure 53

Model 70160

Inspect

Repair

Replace

Defective

Action

Step

Comment

Number

Decision

Solution

Symptom:

Gauges Recommended

Inlet vacuum gauge: 2 bar to 1 bar [30 PSI to 30 inHg]

System pressure gauge: 700 bar [10,000 PSI]

Charge pressure gauge: 0 to 50 bar [0 to 600 PSI]

Case pressure gauge: 0 to 25 bar [0 to 300 PSI]

Explanatory

Diagram

This fault - logic troubleshooting guide is a

diagnostic aid in locating transmission problems.

Match the transmission symptoms with the problem

statements and follow the action steps shown in the

box diagrams. This will provide help in correcting

minor problems eliminating unnecessary machine

down time.

Following the fault - logic diagrams are diagram

action comments of the action steps shown in the

diagrams. Where applicable, the comment number of

the statement appears in the action block of the

diagrams.

Recommended Gauge Locations

Figure 58

Pressure Ports

Tee In Line to Check

System Pressure

Charge Pump Suction Port

Tee In Line to Check Inlet

Vacuum

Drain Port

Tee In Line to Check

Case Pressure

Auxiliary Port

Check Charge Pressure

Fault - Logic Troubleshooting

Bypass Valve

Location

Model 70160

Fault - Logic Troubleshooting

Inspect

Servo Control

(If used)

Inspect

External Control

Linkage

Defective

Repair

Replace

Defective

Repair

Replace

Symptom: Neutral Difficult or Impossible to Find

Inspect

Heat

Exchanger

OKOK OK

456

Check

Oil Level in

Reservoir

Fill to

Proper

Level

DefectiveBelow Level

Repair

Replace

Check

System

Pressure

Reduce

System

Load

High

Inspect

Charge Relief

Valve

Inspect

Charge

Pump 13

Inspect

Motor 12

Inspect

Inlet Screen

or Filter

Replace

Clogged

Check

Charge

Pressure

Low OK

Replace

Pump &

Motor

Inspect Pump

Bypass Valve

(If used)

Inspect Heat

Exchanger

Bypass Valve

(If used)

Defective

Repair

Replace

Defective

Repair

Replace

Defective

Repair

Replace

Defective

Repair

Replace

Defective

Repair

Replace

Symptom: System Operating Hot

Model 70160

Inspect

Servo Control

(If used)

OK OK

123

Inspect

External Control

Linkage

Defective

Repair

Replace

Inspect

System Relief

Valves

Defective

Repair

Replace

Defective

Repair

Replace

Symptom: Operates in One Direction Only

Inspect

Servo Control

(If used)

OKOK OK

Defective

Repair

Replace

Inspect

Motor

Replace

Clogged

Check

Charge

Pressure

Low OK

Inspect Pump

Bypass Valve

(If used)

Replace

Pump &

Motor

Defective

Repair

Replace

Inspect

Inlet Screen

or Filter

OK OK

813

Defective

Repair

Replace

Inspect

Charge Relief

Valve

Inspect

Charge

Pump

Defective

Repair

Replace

Defective

Repair

Replace

Symptom: System Response Sluggish

Fault - Logic Troubleshooting

Model 70160

Check External

Control

Linkage

OKOK OK

417

Check

Oil Level in

Reservoir

Fill to

Proper

Level

DefectiveBelow Level

Repair

Replace

Check

System

Pressure

Inspect

Charge Relief

Valve

Inspect

Charge

Pump 13

Inspect

Motor 12

Inspect

Inlet Screen

or Filter

Replace

Clogged

Check

Charge

Pressure

Low OK

Replace

Pump &

Motor

Inspect

Servo Control

(If used)

Inspect Pump

Bypass Valve

(If used)

Defective

Repair

Replace

Defective

Repair

Replace

Defective

Repair

Replace

Defective

Repair

Replace

Defective

Repair

Replace

High

Reduce

System

Load

Symptom: System Will Not Operate In Either Direction

Fault - Logic Troubleshooting

Model 70160

Diagram Action Step Comments

1 Inspect External Control Linkage for:

a. misadjustment or disconnection

b. binding, bending or breakage

c. misadjusted, damaged or broken neutral return spring

2 Inspect Servo Control Valve for: (if used)

a. proper inlet pressure

b. misadjusted, damaged or broken neutral return spring

c. galled or stuck control spool

d. galled or stuck servo piston

3 Inspect System Relief Valves* for:

a. improper pressure relief setting

b. damaged or broken spring

c. valve held off seat

d. damaged valve seat

4 Check Oil Level in Reservoir:

a. consult owner/operators manual for the proper type

fluid and level

5 Inspect Heat Exchanger for:

a. obstructed air flow (air cooled)

b. obstructed water flow (water cooled)

c. improper plumbing (inlet to outlet)

d. obstructed fluid flow

6 Inspect Heat Exchanger Bypass Valve for: (if used)

a. improper pressure adjustment

b. stuck or broken valve

7 Inspect Pump Bypass Valve for: (if used)

a. held in a partial or full open position

8 Inspect Inlet Screen or Filter for:

a. plugged or clogged screen or filter element

b. obstructed inlet or outlet

c. open inlet to charge pump

9 Check System Pressure:

a. See figure 60 for location of pressure gauge installation.

b. consult owner/operators manual for maximum system

relief valve settings

10 Check Charge Pressure:

a. See figure 60 for location of pressure gauge installation.

b. consult owner/operators manual for maximum charge

relief valve settings

11 Inspect Charge Relief Valve for:

a. improper charge relief pressure setting *

b. damaged or broken spring

c. poppet valve held off seat

12 Inspect Motor for:

a. disconnected coupling

13 Inspect Charge Pump for:

a. broken or missing drive key

b. damaged or missing o-ring

c. excessive gerotor clearance

d. galled or broken gerotor set

* System/Charge Relief Valve Pressure Settings for Eaton’s

Variable Displacement Controlled Piston Pumps

Inlet Vacuum 6 inHg max.

Case Pressure 25 PSI maximum

Charge Pressure 100 to 150 PSI Standard

200 to 250 PSI Optional

250 to 300 PSI Optional

System Pressure 5000 PSI maximum

3000 PSI continuous

The high pressure relief valves are all factory preset and

cannot be readjusted.

The pressure setting and assembly number is stamped on

each high pressure relief valve cartridge.

Valve Identification Example:

110603-500 5000

Relief Valve Setting

Relief Valve Assembly Number

Fault - Logic Troubleshooting

Model 70160

When starting a new or rebuilt transmission system, it is

extremely important to follow the start-up procedure. It

prevents the chance of damaging the unit which might occur if

the system was not properly purged of air before start-up.

1After the transmission components have been properly

installed, fill the pump housing at least half full with filtered

system oil. Connect all hydraulic lines and check to be sure

they are tight.

2Install and adjust all control linkage.

3Fill the reservoir with an approved oil that has been filtered

through a 10 micron filter. Refer to Eaton Hydraulics

Technical Data Sheet number 3-401 titled Hydraulic Fluid

Recommendations.

4For Gasoline engines or L.P. engines remove the coil wire

and turn the engine over for 15 seconds. For Diesel engines

shut off the fuel flow to the injectors and turn the engine

over for 15 seconds.

5Replace the coil wire or return the fuel flow to the injectors.

Place the transmission unit in the neutral position, start the

engine and run it at a low idle. The charge pump should

immediately pick up oil and fill the system. If there is no

indication of fill in 30 seconds, stop the engine and

determine the cause.

6After the system starts to show signs of fill, slowly move

pump camplate to a slight cam angle. Continue to operate

system slowly with no load on motors until system

responds fully.

7Check fluid level in the reservoir and refill if necessary to

the proper level with an approved filtered oil.

8Check all line connections for leaks and tighten if

necessary.

The machine is now ready to be put into operation.

Frequent filter changes are recommended for the first two

changes after placing the machine back into operation. Change

the first filter in 3-5 hours and the second in approximately 50

hours. Routinely scheduled filter changes are recommended

for maximum life of the hydraulic system.

Start-up Procedure

Model 70160

Notes:

Model 70160

Printed in U.S.A

Eaton Hydraulics

14615 Lone Oak Road

Eden Prairie, MN 55344

Telephone: 652 937-7254

Fax: 652 937-7130

www.eatonhydraulics.com

46 New Lane, Havant

Hampshire PO9 2NB

England

Telephone: (44) 23 92 486 451

Fax: (44) 23 92 487 110

ISO-9001 CERTIFICATED FIRM

DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS

ACCREDITED BY

THE DUTCH COUNCIL

FOR CERTIFICATION

Reg. No. 24

Quality System Certified

Products in this catalog are

manufactured in an

ISO-9001-certified site.

Information contained in this catalog is accurate as of the publication date and is subject to

change without notice. Performance values are typical values. Customers are responsible for

selecting products for their applications using normal engineering methods.

No. 7-310

January, 1995

Char-Lynn®

Power Steering

2 Series

Steering Control Unit 001

Repair Information

Dust

Seal

Housing Quad

Seal

Thrust

Bearing

Sleeve

Spool

Centerin

Springs

Bearing Race (2)

O-ring

Seal

O-ring

Seal

Wear

Plate

Drive

Gerotor

Spacer

Manual Steering

Relief Valve

O-ring

O-ring Seal

Ring

End

Cap

Screw

(7)

Plug

Check

Ball

Spring

Retaining

Ring

Power Steering

2 Series

Steering Control Units

Tools Required

• 10 mm Socket

• 7/8 in. Socket

• Torque Wrench (18 Nm [160 lb-in] Capacity)

• Small Blade Screwdriver

Power Steering

2 Series

Steering Control Units

Disassembly

Cleanliness is extremely important when repairing hydraulic

Steering Control Units (SCU). Work in a clean area. Before

disconnecting the hydraulic lines, clean the port area of the

SCU. Before disassembly, drain the oil, then plug the ports and

thoroughly clean the exterior of the SCU. During repairs,

always protect machined surfaces.

1 Remove the seven cap screws and disassemble the SCU as

shown in Figure 1.

2 Remove the plug and manual steering check as shown in

Figure 1.

Note: The manual steering check may be a check ball or a

check/relief valve.

3 Slide the spool and sleeve from the housing (see Figure 2).

4 Remove the thrust bearing and bearing races.

5 Remove the quad seal.

6 Using a small blade screwdriver, carefully pry the dust seal

from the housing.

Important: Do not damage the dust seal seat.

O-ring

Seal

O-ring

Seal

Wear

Plate Drive

Gerotor

Seal

Ring

Spacer

Manual Steering

Check/Relief Valve

O-ring

O-ring O-ring

End

Cap

Screw

(7)

Figure 1

Plug

Dust

Seal

Housing Quad

Seal

Thrust

Bearing

Bearing Race (2)

Spool and Sleeve

Figure 2

Power Steering

2 Series

Steering Control Units

7 Remove the pin that holds the spool and sleeve together

(see Figure 3).

8 Carefully slide the spool out of the sleeve. The springs

and retaining ring will stay with the spool as it's removed.

Reassembly

Check all mating surfaces. Replace any parts with

scratches or burrs that could cause leakage. Wash all

metal parts in clean solvent. Blow them dry with pressur-

ized air. Do not wipe parts dry with paper towels or cloth

as lint in a hydraulic system will cause damage.

Note: Always use new seals when reassembling

hydraulic steering control units. Refer to parts list 6-323

for seal kit part numbers, replacement parts, and

ordering information.

Important: During reassembly lubricate the new seals

with a petroleum jelly such as Vaseline®. Also lubricate

machined surfaces and bearings with clean hydraulic

fluid.

9 Remove the retaining ring and springs.

Caution: The centering springs are under tension. Remove

the retaining ring carefully.

10 Install the quad seal:

• Put one of the bearing races and sleeve into

the housing.

• Together, the housing and bearing race create

a groove into which the quad seal will be

installed.

• Hold the bearing race tightly against the input

end of the housing by pushing on the gerotor

end of the sleeve.

• Fit the quad seal into its seat through the input

end of the housing. Be sure the seal is not

twisted.

• Remove the sleeve and bearing race.

Centering

Springs and

Spacers

Sleeve

Spool

Figure 3

Spring

Retaining

Ring

Power Steering

2 Series

Steering Control Units

20 Lubricate and install a new o-ring seal in the groove in

the housing.

21 Install the wear plate and align the holes in the wear

plate with threaded holes in the housing.

Note: The holes in the wear plate are symmetrical.

22 Install the drive, be sure the slot in the drive engages

the pin.

23 Lubricate and install a new o-ring seal in the groove in

the wear plate.

24 Install the gerotor and align the screw holes.

25 Lubricate and install a new o-ring seal in the groove in

the gerotor ring.

26 Lubricate and install a new o-ring and seal ring in the

groove in the gerotor star.

27 Install the spacer.

28 Install end cap and seven cap screws. Tighten cap screws,

in a crisscross pattern, to 16 -18 Nm [140 -160 lb-in].

29 Remove the SCU from the vise.

30 Install the relief valve/check or check ball and plug. Use

a new o-ring and tighten the plug to 17 Nm [150 lb-in].

Quad Seal

Figure 4

Dust Seal Thrust Bearing

and Race (2)

Figure 5

11 Lubricate and install the dust seal (see Figure 4 for

correct seal orientation).

12 Install the centering springs in the spool. It is best to

install the two flat pieces first. Next, install the curved

pieces, three at a time.

13 Fit the retaining ring over the centering springs.

14 Apply a light coating of clean hydraulic fluid to the

spool and slide it into the sleeve. Be sure the centering

springs fit into the notches in the sleeve.

15 Install the pin (see Figure 3).

16 Apply a light coating of petroleum jelly to the inner

edge of the dust and quad seals.

17 Put the thrust bearing and races into the housing. The

thrust bearing goes between the two races (see Figure 2).

18 Apply a light coating of clean hydraulic fluid to the

spool and sleeve assembly and slide it into the housing.

Important: Do not damage the dust or quad seals.

19 Clamp the housing in a vise as shown in Figure 5. Use

just enough clamping force to hold the housing securely.

System

Product Numbers 2 Series (Standard — 69 Bar [1000 PSI])

Product Numbers 2 Series (High Pressure — 103 Bar [1500 PSI])

Ports Relief Valve

Setting

Bar [PSI] 31 [1.9] 39 [2.4] 63 [3.8] 74 [4.5] 100 [6.1]51 [3.1]

Displacement cm

/r [in

/r] and Product Number

291-1001-001None 291-1002-001 291-1003-001 291-1004-001 291-1005-001 291-1006-001

291-1001-04140 [ 580] 291-1002-041 291-1003-041 291-1004-041 291-1005-041 291-1006-041

291-1001-05150 [ 725] 291-1002-051 291-1003-051 291-1004-051 291-1005-051 291-1006-051

291-1001-06163 [ 914] 291-1002-061 291-1003-061 291-1004-061 291-1005-061 291-1006-061

291-1001-07170 [1015] 291-1002-071 291-1003-071 291-1004-071 291-1005-071 291-1006-071

293-4001-001None 293-4002-001 293-4003-001 293-4004-001 293-4005-001 293-4006-001

293-4007-001None 293-4008-001 293-4009-001 293-4010-001 293-4011-001 293-4012-001

Open

Center

Non-

Load

Reaction

Power

Beyond

Non-

Load

Reaction

Dynamic

Signal

Load

Sensing

9/16 Inch

Plug-O (4)

9/16 Inch

Plug-O (5)

9/16 Inch

Plug-O (5)

9/16 -18

Inch

SAE (4)

9/16 -18

Inch

SAE (5)

9/16 -18

Inch

SAE (5)

None

40 [ 580]

50 [ 725]

63 [ 914]

70 [1015]

None

40 [ 580]

50 [ 725]

63 [ 914]

70 [1015]

None

40 [ 580]

50 [ 725]

63 [ 914]

70 [1015]

291-1007-001 291-1008-001 291-1009-001 291-1010-001 291-1011-001 291-1012-001

291-1007-041 291-1008-041 291-1009-041 291-1010-041 291-1011-041 291-1012-041

291-1007-051 291-1008-051 291-1009-051 291-1010-051 291-1011-051 291-1012-051

291-1007-061 291-1008-061 291-1009-061 291-1010-061 291-1011-061 291-1012-061

291-1007-071 291-1008-071 291-1009-071 291-1010-071 291-1011-071 291-1012-071

291-5001-001 291-5002-001 291-5003-001 291-5004-001 291-5005-001 291-5006-001

291-5001-041 291-5002-041 291-5003-041 291-5004-041 291-5005-041 291-5006-041

291-5001-051 291-5002-051 291-5003-051 291-5004-051 291-5005-051 291-5006-051

291-5001-061 291-5002-061 291-5003-061 291-5004-061 291-5005-061 291-5006-061

291-5001-071 291-5002-071 291-5003-071 291-5004-071 291-5005-071 291-5006-071

291-5007-001 291-5008-001 291-5009-001 291-5010-001 291-5011-001 291-5012-001

291-5007-041 291-5008-041 291-5009-041 291-5010-041 291-5011-041 291-5012-041

291-5007-051 291-5008-051 291-5009-051 291-5010-051 291-5011-051 291-5012-051

291-5007-061 291-5008-061 291-5009-061 291-5010-061 291-5011-061 291-5012-061

291-5007-071 291-5008-071 291-5009-071 291-5010-071 291-5011-071 291-5012-071

291-1001-121None 291-1002-121 291-1003-121 291-1004-121 291-1005-121 291-1006-121

291-1001-081 80 [1160] 291-1002-081 291-1003-081 291-1004-081 291-1005-081 291-1006-081

291-1001-091 90 [1305] 291-1002-091 291-1003-091 291-1004-091 291-1005-091 291-1006-091

291-1001-101100 [1450] 291-1002-101 291-1003-101 291-1004-101 291-1005-101 291-1006-101

293-4001-121None 293-4002-121 293-4003-121 293-4004-121 293-4005-121 293-4006-121

293-4007-121None 293-4008-121 293-4009-121 293-4010-121 293-4011-121 293-4012-121

Open

Center

Non-

Load

Reaction

Power

Beyond

Non-

Load

Reaction

Dynamic

Signal

Load

Sensing

9/16 Inch

Plug-O

(4)

9/16 Inch

Plug-O

(5)

9/16 Inch

Plug-O (5)

9/16 -18

Inch

SAE

(4)

9/16 -18

Inch

SAE

(5)

9/16 -18

Inch

SAE (5)

None

80 [1160]

90 [1305]

100 [1450]

None

80 [1160]

90 [1305]

100 [1450]

None

80 [1160]

90 [1305]

100 [1450]

291-1007-121 291-1008-121 291-1009-121 291-1010-121 291-1011-121 291-1012-121

291-1007-081 291-1008-081 291-1009-081 291-1010-081 291-1011-081 291-1012-081

291-1007-091 291-1008-091 291-1009-091 291-1010-091 291-1011-091 291-1012-091

291-1007-101 291-1008-101 291-1009-101 291-1010-101 291-1011-101 291-1012-101

291-5001-121 291-5002-121 291-5003-121 291-5004-121 291-5005-121 291-5006-121

291-5001-081 291-5002-081 291-5003-081 291-5004-081 291-5005-081 291-5006-081

291-5001-091 291-5002-091 291-5003-091 291-5004-091 291-5005-091 291-5006-091

291-5001-101 291-5002-101 291-5003-101 291-5004-101 291-5005-101 291-5006-101

291-5007-121 291-5008-121 291-5009-121 291-5010-121 291-5011-121 291-5012-121

291-5007-081 291-5008-081 291-5009-081 291-5010-081 291-5011-081 291-5012-081

291-5007-091 291-5008-091 291-5009-091 291-5010-091 291-5011-091 291-5012-091

291-5007-101 291-5008-101 291-5009-101 291-5010-101 291-5011-101 291-5012-101

Power Steering

2 Series Steering Control Units

Power Steering

2 Series

Steering Control Units

Printed in USA

Form No. 7-310

Char-Lynn

Eaton Corp. Hydraulics Div.Hydraulics Div.

Eden Prairie, MN 55344

Product number

000 0000 000

000

Product Number

000 0000 000

Product Line

Identification

Number

Product

Identification

Number

Engineering

Change

Code

Week of

Year

01 Thru 52

Last Number(s)

of Year

Date Code

00 00

Relief Valve Pressure Code

00 = None

04 = 40 Bar [ 580 PSI]

05 = 50 Bar [ 725 PSI]

06 = 63 Bar [ 914 PSI]

07 = 70 Bar [1015 PSI]

08 = 80 Bar [1160 PSI]

09 = 90 Bar [1305 PSI]

10 = 100 Bar [1450 PSI]

Each Order Must Include the Following:

How to Order Replacement Parts

1. Product Number

2. Date Code

3. Part Name

4. Part Number

5. Quantity of Parts

For More Detailed Information Contact Eaton Corp. Hydraulics

Division 15151 Highway 5 Eden Prairie, MN 55344.

Specifications and performance data, Catalog No. 11-872

Replacement part numbers and kit information — Parts

Information No. 7-310.

Power Steering

2 Series

Steering Control Units

Eaton Corporation

Hydraulics Division

15151 Hwy. 5

Eden Prairie, MN 55344

Telephone 612/937-9800

Fax 612/937-7130

Eaton Ltd.

Hydraulics Division

Glenrothes, Fife

Scotland, KY7 4NW

Telephone 01-592-771-771

Fax 01-592-773-184

Eaton GmbH

Hydraulics Products

Am Schimmersfeld 7

40880 Ratingen, Germany

Telephone 02102-406-830

Fax 02102-406-800

ISO-9001 CERTIFICATED FIRM

DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS

ACCREDITED BY

THE DUTCH COUNCIL

FOR CERTIFICATION

Reg. No. 24

Quality System Certified

Products in this catalog are manufactured

in an ISO-9001-certified site.

No. 7-624

October,1995

Eaton®

Gear Pumps

Repair Information

Series 26

Model 26000 Single Gear Pumps

Series 26 - Model 26000 Single Gear Pumps

Introduction

Table of Contents

Introduction ................................................................................................................................ 2

Identification............................................................................................................................... 3

Tools Required ........................................................................................................................... 3

Exploded View Drawing .............................................................................................................. 4

Parts List .................................................................................................................................... 5

Disassembly ............................................................................................................................... 5 & 6

Reversibility ................................................................................................................................ 7

Inspection................................................................................................................................... 8

Reassembly ................................................................................................................................9 & 10

Specific Backplate Parts List.......................................................................................................11 &12

Placing Pump Back into Operation ............................................................................................. 13

Trouble Shooting ........................................................................................................................ 14

Ordering Information .................................................................................................................. 16

Introduction

This manual provides service information for the Eaton model 26000 single gear pumps. Step by step

instructions for the complete disassembly, inspection, and reassembly of the pumps are included.

The following recommendations should be followed to insure successful repairs.

Remove the pump from the application.

Cleanliness is extremely important.

Clean the port areas thoroughly before disconnecting the hydraulic lines.

Plug the pump ports and cover the open hydraulic lines immediately after they're disconnected.

Drain the oil and clean the exterior of the pump before making repairs.

Wash all metal parts in clean solvent.

Use compressed air to dry the parts. Do not wipe them dry with paper towels or cloth.

The compressed air should be filtered and moisture free.

Always use new seals when reassembling hydraulic pumps.

For replacement parts and ordering information refer to parts list 6-634.

Lubricate the new rubber seals with a petroleum jelly (vaseline) before installation.

Torque all bolts over gasket joints, then repeat the torquing sequence to makeup for gasket

compression.

Verifying the accuracy of pump repairs on an authorized test stand is essential.

Series 26 - Model 26000 Single Gear Pumps

Identification and Tools

Required

B 95 01 31 JB Serial Number Code:

Series

26 = Gear Pump

( SAE "A" Mount )

Features

0 = Standard Single Pump

1 = Standard Single W/ Relief

2 = Flow Divider Backplate

3 = Flow Divider W/ Load Sense

4 = Tandem Backplate

5 = Multiple Pumps

Displacement cm3/r [ in3 /r]

01 = 6.6 [.40] 08 = 22.5 [1.37]

02 = 8.2 [.50] 09 = 24.3 [1.48]

03 = 9.5 [.58] 10 = 25.2 [1.54]

04 = 10.8 [.66] 11 = 27.7 [1.69]

05 = 13.8 [.84] 12 = 29.0 [1.77]

06 = 16.7 [1.02] 13 = 30.6 [1.87]

07 = 19.7 [1.20]

Input Rotation

R = Right-hand (clockwise)

L = Left-hand (Counterclockwise)

Catalog / Non-Catalog

Z = Cataloged Pump

A-Y = Non-Cataloged Pump

Shafts , Porting Size and Location

Side Ports

A = 3/4 in. 11 Tooth, 1 5/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

C = 3/4 in. Str. Keyed, 1 5/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

E = 3/4 in. 9 Tooth, 1 5/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

G = 5/8 in. Str. Keyed, 1 1/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

J = 5/8 in. 9 Tooth, 1 1/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

L = 5/8 in. Str. Keyed, 1 5/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

N = 3/4 in. 11 Tooth, 1 1/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

R = 3/4 in. Str. Keyed, 1 1/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

Rear Ports

B = 3/4 in. 11 Tooth, 1 5/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

D = 3/4 in. Str. Keyed, 1 5/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

F = 3/4 in. 9 Tooth, 1 5/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

H = 5/8 in. Str. Keyed, 1 1/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

K = 5/8 in. 9 Tooth, 1 1/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

M = 5/8 in. Str. Keyed, 1 5/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

P = 3/4 in. 11 Tooth, 1 1/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

S = 3/4 in. Str. Keyed, 1 1/16-12 UN-2B Suction, 7/8-14 UNF-2B Pressure

Product Number: 26 0 01 - R Z A

Tools Required

3/8 in. socket and ratchet wrench

Internal Retaining Ring Pliers

(straight .090 tip)

O-ring Pick

Thread 3/8 dia. UNC bolt/screw

Torque Wrench

(135.6 N.m [100 lbf.ft] capacity)

Hammer (soft face)

Light Petroleum Jelly

Seal Driver

Arbor Press

Testers Initials

Day of Month (two digits)

Month (two digits)

Last two digits of year built.

( 95 for 1995 etc.)

Revision level of parts list.

Series 26 - Model 26000 Single Gear Pumps

Parts

Drawing

Righthand (CW)

Rotation Pump

Lefthand (CCW)

Rotation Pump

Body

Front Plate

Cap Screws

Washer

O- ring

O-ring

Plug

Backup Gasket

Seal

Wear Plate

Drive Gear

Assembly

Idler Gear

Assembly

Washer

Shaft seal

Optional

Retaining

Ring

Drive Gear

Assembly

Drive Gear

Assembly

Drive Gear

Assembly

14a

Key

14b

Key

Backplate

Body

Front Plate

Cap Screws

Washer

O- ring

O-ring

Plug

Backup Gasket

Seal

Wear Plate

Drive Gear

Assembly

Idler Gear

Assembly

Washer

Shaft seal

Optional

Retaining

Ring

14a

Key

Backplate

Series 26 - Model 26000 Single Gear Pumps

Disassembly Parts List

Item

No. Description Qty.

1 Front plate Assembly 1

2 Backplate 1

3 Body Assembly 1

4 Drive Gear Assembly 1

5 Idler Gear Assembly 1

~ 7 Wear Plate 1

~ 8 O-ring 2

~ 9 Shaft Seal 1

~ 10 Washer 1

11 Cap Screw 8

~ 12 Backup Gasket 1

~ 13 Seal 1

14 Key for Straight Shaft 1

~ 17 Washer 4

25 Retaining Ring (optional) 1

40 Plug 1

~ Seal Kit 26000-901 for Single Pumps

6 Remove

o-ring

seal from backplate.

7 To disassemble the

relief valve backplate, flow divider

backplate, and tandem flow divider backplate

see page 11 &

12.

Repair Information - Model 26000

Work in a clean area; cleanliness is extremely important when

repairing hydraulic pumps. Before disconnecting the lines,

clean port area of pump. Disconnect hydraulic lines, removing

pump assembly from vehicle and plugging ports. Thoroughly

clean the outside of pump. After cleaning, remove port plugs

and drain oil.

Disassembly

1 Remove

key

from drive shaft if keyed drive gear assembly

is used.

2 Put a

location mark

across front plate, body and backplate

to assure proper reassembly.

3 Clamp pump in vise, shaft end up.

4 Remove

cap screws

(eight each) and washer (four each).

5 Remove pump from vise, hold pump in hands and tap

shaft with plastic hammer or rawhide mallet to separate front

plate from backplate. Body will remain with either front plate or

backplate.

Series 26 - Model 26000 Single Gear Pumps

Disassembly

8 Remove

idler gear assembly

from body.

9 To separate

body

from the plate it remained with, place

drive gear assembly

in gear pocket and tap protruding end with

plastic hammer or rawhide mallet. Remove drive gear

assembly.

10 Remove wear plate and o-ring seal, noting position of

open side of wear plate.

11 Remove

back-up gasket and seal

from wear plate by

extracting with a o-ring tool.

12 Remove snap ring (if applicable) from the front of the front

plate shaft seal area.

13 Remove

shaft seal

and

washer

from front plate with a

blunt punch from the back side.

14 Removing the

plug

in front plate is not necessary, unless

you intend to change rotation. See Reversibility - Changing

Input Rotation of Pump.

Series 26 - Model 26000 Single Gear Pumps

Reversibility

Changing Input Rotation of Pump

1 Place pump in a protected jaw vise with shaft end up.

Remove the eight cap screws.

2 Remove front plate, noting orientation of drive shaft

through bearing in reference to the backplate.

3 Notice the location of the open side of wear plate and

remove wear plate.

4 Switch

drive gear and idler gear

within gear pockets. Do

not flip idler gear end for end.

Note: Gear housing body and backplate do not need altering.

5 Re-install wear plate into gear pockets over the gears with

seal and backup gasket up. (Same orientation as removed)

6 Front plate disassembly and assembly:

- Thread 3/8 UNC threaded bolt into

plug

cavity. Start

with fingers, then place bolt head in vise and turn front

plate to engage threads 2-3 turns.

- Holding bolt in vise, tap front plate with rubber

hammer to disengage

plug

- Remove

plug

from bolt.

- Install plug in the other casting cavity and tap flush

with rubber hammer. Note L or R at bottom of cavity.

Plug

Open for

righthand

rotation

Open for

lefthand

rotation

- Ensure that bearing drain holes are free of debris.

- Note proper placement of o-ring in groove of front

plate.

7 Hold o-ring in groove of front plate with petroleum jelly.

Reassemble front plate over drive shaft end, being careful not

to damage shaft seal.

8 Torque 8 cap screws 34 to 38 N•m [25 to 28 lbf•ft].

9 Lubricate gears and mating surfaces with hydraulic oil

through ports.

10 Rotate shaft (manually) to ensure proper assembly of

components.

Series 26 - Model 26000 Single Gear Pumps

Inspection

Model Number 26001 26002 26003 26004 26005 26006 26007 26008 26009 26010 26011 26012 26013

Pump Disp. 6,6 8,2 9,5 10,8 13,8 16,7 19,7 22,5 24,3 25,2 27,7 29,0 30,6

cm3/r [in3/r] [.40] [.50] [.58] [.66] [.84] [1.02] [1.20] [1.37] [1.48] [1.54] [1.69] [1.77] [1.87]

Gear Width 7,85 9,75 11,20 12,95 16,15 19,35 22,56 25,76 28,12 28,96 32,16 33,78 35,36

mm [in] [.309] [.384] [.441] [.510] [.636] [.762] [.888] [1.014] [1.107] [1.140] [1.266] [1.330] [1.392]

Front plate and Backplate Inspection

1Oil groove in bushings in front plate should be in line with

dowel pin holes and 180° apart. The oil grooves in the

backplate bushings should be at approximately 37° to the

pressure side.

2Replace the backplate or front plate if I.D. of bushings

exceed 19,2 mm [.755 in] (Bushings are not available as

separate items).

3Bushings in front plate should be at 3,20 mm [.126 in]

above surface of front plate.

4Check for scoring on face of backplate. Replace if wear

exceeds ,038 mm [.0015 in.].

Body Inspection

1Check body inside gear pockets for excessive scoring or

wear.

2 Replace body if I.D. of gear pockets exceeds 43,7 mm

[1.719 in].

Inspect Parts for Wear

General

1 Clean and dry all parts.

2 Remove all nicks and burrs from all parts with emery

cloth.

Gear Assembly Inspection

1 Check spline drive shaft for twisted or broken teeth or

check keyed drive shaft for broken or chipped keyway.

2Inspect both the drive gear and idler gear shafts at

bushing points and seal area for rough surfaces and excessive

wear.

3Replace gear assembly if shaft measures less than 19 mm

[ .748 in] in bushing area. (One gear assembly may be replaced

separately; shafts and gears are available as assemblies only.)

4Inspect gear for scoring and excessive wear.

5Replace gear assembly if gear width is below the following

dimensions. Refer to chart on this page.

6Assure that snap rings are in grooves on either side of

drive and idler gears.

7If edge of gear teeth are sharp, break edge with emery

cloth.

Series 26 - Model 26000 Single Gear Pumps

4 Install new

seal

and new

backup gasket

into wear plate.

Note in the middle of the backup gasket a flat section or

support. This area must face away from the wear plate inside

the seal.

5 Place new

wear plate, seal,

and

backup gasket

into gear

pocket with seal and backup gasket next to front plate. The side

of the wear plate with the mid section cut-away must be on the

suction side of pump.

6 Dip

gear assemblies

into oil and slip into front plate

bushings and gears into pockets of body.

Reassembly

General Information

It is important that the relationship of the backplate, body, wear

plate and front plate is correct. You will note two half moon

cavities in the body. Note: The smaller half moon port cavity

must be on the pressure side of the pump. The side of wear

plate with midsection cut out must be on suction side of pump.

Suction side of backplate is always side with larger port boss.

Reassembly

1 During the reassembly replace the

wear plate, seal, back-up

gasket, shaft seal and o-rings

as new parts.

2 Install

o-ring

in groove of front plate.

3 Apply a thin coat of petroleum jelly or hydraulic oil to both

milled gear pockets of body. Slip body onto front plate with half

moon port cavities in body facing away from front plate.

Note: The small half moon port cavity must be on the pressure

side (the plugged side of the front plate) of pump.

Series 26 - Model 26000 Single Gear Pumps

Reassembly

7 Install new

o-ring

in groove of backplate.

8 Make sure port orientation is correct and then slide

backplate

over gear shafts until dowel pins are engaged.

9 Secure with

cap screws

and new

washers

. Tighten cap

screws evenly in a crisscross pattern 34 to 38 N•m [25 to 28

lbf•ft] torque.

10 Place washer over drive shaft into housing. Liberally oil

shaft seal and install over drive shaft, carefully so that rubber

sealing lips are not cut.

11 Place 1-5/16 in. O.D. sleeve over shaft and press in shaft

seal until flush with front surface of front plate.

13 Install key on keyed shaft.

Note: Refer to Start-up Procedure and Trouble Shooting

Procedure.

Series 26 - Model 26000 Single Gear Pumps

Specific Backplate Parts List

Item

No. Description Qty.

2 Relief Valve Backplate 1

18 O-ring 3

19A Relief Valve Assembly 1

19A1 Relief Valve 1

~ 19A2 O-ring 1

~ 19A3 Backup Ring 1

~ 19A4 O-ring 1

19B Plug Assembly 1

19B1 Plug 1

Item

No. Description Qty.

2C Flow Divider Backplate 1

19A Relief Valve Assembly 1

19A1 Relief Valve 1

~ 19A2 O-ring 1

~ 19A3 Backup Ring 1

~ 19A4 O-ring 1

19B Plug Assembly 1

19B1 Plug 1

20 Flow Divider Spool 1

21 Plug/O-ring Assembly 1

21A Plug 1

~ 21B O-ring 2

22 Plug/O-ring Assembly 1

22A Plug 1

23 Spring 1

24 Shim (.0239 inch thick) A/R

A/R – As Required

3 Remove flow divider

plugs, shims, spring, and spool

from

backplate. (Notice orientation of spool with cavity in backplate)

4 Install new plug

seals

on plugs. Install

spool, spring,

shims, and plug assemblies

into backplate. Torque plugs 29 to

33 N•m [21 to 24 lbf•ft]

21B

22A

19A4

21A

19A319A2

19B1

19B

21B

19A4

19A2

19A3

19A1

19A

Flow Divider Backplate

Disasembly and Reassembly

1 After removing

relief valve or plug

, remove and replace o-

ring and backup ring with new parts.

2 Install

relief valve or plug

and torque 41 to 46 N•m [30 to

34 lbf•ft]

19A4

19A2

19A3

19A1

19A

Relief Valve Backplate

Disasembly and Reassembly

1 After removing

relief valve

, remove and replace o-rings

and backup ring with new parts.

2 Install

relief valve

and torque 41 to 46 N•m [30 to 34 lbf•ft]

Series 26 - Model 26000 Single Gear Pumps

Specific Backplate Parts List

29A

29B

27 26

20A

23A

28B28A

Tandem Flow Divider Backplate

Item

No. Description Qty.

2D Tandem Flow Divider Backplate 1

2E Tandem Backplate 1

18 O-ring 3

20A Spool for Tandem Flow Divider Backplate

23A Spring for Tandem Flow Divider Backplate 1

24 Shim (.0239 inch thick) A/R

~ 26 O-ring 1

27 Plug 1

28 Plug/O-ring Assembly 1

28A Plug 1

~ 28B O-ring 2

29 Plug/O-ring Assembly 1

29A Plug 1

~ 29B O-ring 1

30 Relief Valve Spring 1

32 Sleeve 1

33 Spring 1

34 Poppet 1

35 Shim Washer (.010 inch thick) A/R

36 Tandem Cover Plate 1

37 O-ring 1

38 Cap Screw 2

A/R – As Required

Tandem Backplate

Disasembly and Reassembly

1 Remove

relief valve plug, shim, spring, and poppet

from

backplate. Do not remove internal relief valve seat. Seat is

loctited to a predetermined depth. Remove o-ring from plug

and replace with new o-ring.

2 Install

poppet, spring, shim, and relief valve plug

and

torque 14 to 16 N•m [10 to 12 lbf•ft]

3 Remove flow divider

plugs, shims, springs, spool, and

sleeve

from backplate. (Notice orientation of spool with cavity

in backplate) Remove

o-rings

from sleeve and replace with new

o-rings

4 Install

sleeve, spool, springs, shims, and plug assemblies

into backplate. Torque plug #27 48 to 54 N•m [35 to 40 lbf•ft]

and plug #28 29 to 33 N•m [21 to 24 lbf•ft]

Series 26 - Model 26000 Single Gear Pumps

Placing Series 26 Gear Pump

Back into Operation

Connect

Fluid Supply

Mount Pump

Machine

Check

for

Leaks

Pump

Ready for

Service

Start Pump

and

Run For

3 Minutes

Each

At 1/2 Speed At 1/2 Speed At Full Speed

Zero

Pressure

Load

Intermittently

to 1000 lbf/in

Load

Intermittently

to 500 lbf/in

When test stand is

not available

When test stand is

available

Connect

Fluid Supply

Mount Pump

Test Stand

Check

for

Leaks

Pump

Ready for

Service

Start Pump

and

Run For

3 Minutes

Each

Zero

Pressure

Load

Intermittently

to 1000 lbf/in

Load

Intermittently

to 500 lbf/in

Remove

from

Test Stand

Load

Intermittently

to 2000 lbf/in

Series 26 - Model 26000 Single Gear Pumps

Trouble Shooting

Problem Possible Cause Correction

Cavitation a. Oil too heavy. a. Change to proper viscosity

b. Oil filter plugged. b. Clean filter.

c. Suction line plugged or too small. c. Clean line and check size of line.

Oil heating a. Oil supply low. a. Fill reservoir.

b. Contaminated oil. b. Drain reservoir and refill with clean oil.

c. Setting of relief valve too high or

too low. c. Set to correct pressure.

d. Oil in system too light. d. Drain reservoir and refill with proper

viscosity oil.

Shaft seal leakage a. Worn shaft seal. a. Replace shaft seal.

b. Worn shaft in seal area. b. Replace drive assembly.

c. Debris in shaft seal suction side

drain holes. c. Disassemble pump and inspect.

Foaming oil a. Low oil level a. Fill reservoir.

b. Air leaking into suction line b. Tighten fittings.

c. Wrong kind of oil. c. Drain and fill reservoir with

non-foaming oil.

Series 26 - Model 26000 Single Gear Pumps

Note

Wear Plate Identification

A product improvement has been made to the Model 26000 gear pump with a new designed wear plate. To identify the new wear

plate, look for grooves placed in the seal side of the wear plate as shown below.

This new wear plate enables better pressure clamping with aerated oil in pumps 1.37 cubic inch or smaller. Aerated oil

may occur during a cold start-up in applications with long suction lines or when the mouth of the inlet line is temporarily

exposed to air.

New Groove

OLD

Wear Plate

NEW

Wear Plate

Eaton Corporation

Hydraulics Division

15151 Hwy. 5

Eden Prairie, MN 55344

Telephone 612/937-9800

Fax 612/937-7130

Eaton Ltd.

Hydraulics Division

Glenrothes, Fife

Scotland, KY7 4NW

Telephone 01-592-771-771

Fax 01-592-773-184

Eaton GmbH

Hydraulics Products

Am Schimmersfeld 7

40880 Ratingen, Germany

Telephone 02102-406-830

Fax 02102-406-800

ISO-9001 CERTIFICATED FIRM

DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS

ACCREDITED BY

THE DUTCH COUNCIL

FOR CERTIFICATION

Reg. No. 24

Quality System Certified

Products in this catalog are manufactured

in an ISO-9001-certified site.

Printed in USA

Order parts from 6-634 Parts Information booklet.

Each order must include the following information.

1. Product and/or Part Number

2. Serial Number Code

3. Part Name

4. Quantity

ENGINE--DIESEL

6-1

ATLV 4300 330495 (12--01)

CONTENTS

Page

INTRODUCTION 6-3......................

COOLING SYSTEM 6-4.............

ENGINE OIL 6-5....................

ENGINE OIL FILTER 6-5............

BELTS 6-5............................

ENGINE BELT 6-5..................

AIR FILTER 6-6.....................

AIR FILTER INDICATOR 6-6.........

FUEL FILTER/WATER SEPARATOR 6-7

TO REPLACE FUEL FILTER/WATER

SEPARATOR 6-7................

FUEL LINES 6-9....................

FUEL PUMP 6-9....................

PRIMING FUEL SYSTEM 6-10.......

TO PRIME FUEL SYSTEM 6-10......

TO REMOVE ENGINE 6-11..........

TO INSTALL ENGINE 6-14...........

ENGINE SPEEDS 6-16..............

DIESEL ENGINE SERVICE MANUAL

KUBOTA D1105 B (E)

TENNANT Part Number 84660

ENGINE--DIESEL

6-2 ATLV 4300 330495 (10--98)

ENGINE--DIESEL

6-3

ATLV 4300 330495 (10--98)

INTRODUCTION

This section includes repair information on the

engine and related systems, such as fuel,

electrical, and drive belts. Also, engine removal

and installation.

ENGINE--DIESEL

6-4 ATLV 4300 330495 (10--98)

COOLING SYSTEM

Check the radiator coolant level daily in the

overflow reservoir. Use clean water mixed with a

permanent-type, ethylene glycol antifreeze to a

-- 3 4 _C(--30_F) rating. Add coolant to the

overflow reservoir.

FOR SAFETY: When Servicing Machine,

Avoid Contact With Hot Engine Coolant.

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 daily. Blow or rinse all dust,

which may have collected on the radiator, in

through the radiator fins, and out the grill,

opposite the direction of normal air flow. 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

1600 hours of operation, using a dependable

cleaning compound.

ENGINE--DIESEL

6-5

ATLV 4300 330495 (10--98)

ENGINE OIL

Check the engine oil level daily. The engine oil

dipstick can be accessed by lifting up the engine

cover. Change the engine oil and oil filter after

every 100 hours of machine operation. Use

10W30 SAE--CD/SE rated engine oil.

ENGINE OIL FILTER

Open the seat support assembly. Locate the

engine oil filter to the right of the machine battery.

Change the engine oil and oil filter after every 100

hours of machine operation. Use 10W30

SAE--CD/SE rated engine oil.

BELTS

ENGINE BELT

The engine fan belt is driven by the engine

crankshaft pulley and drives the alternator pulley.

Proper belt tension is 10 mm (0.40 in) from a

forceof4to5kg(8to10lb)appliedatthe

mid-point of the longest span.

Check and adjust the belt tension every 100 hours

of operation.

ENGINE--DIESEL

6-6 ATLV 4300 330495 (10--98)

AIR FILTER

The engine air filter housing has a dust cap and a

dry cartridge-type air filter element. Empty the

dust cap daily. Check the dust cap every 100

hours of operation to make sure it is expelling

dust. Replace the dust cap if the rubber is worn.

The air filter element must be replaced whenever

it 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.

To clean the filter element, remove it from the filter

housing. Carefully clean the end cap and the

interior of the housing with a damp cloth. Clean

the housing sealing surfaces.

Using an air hose, direct clean, dry air, maximum

205 kPa (30 psi), up and down the pleats on the

inside of the element. 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.

After cleaning the air filter element, inspect it for

damage by placing a bright light inside. The

slightest rupture requires replacement of the

element. Inspect the seals on the ends of the

element, they should be flexible and undamaged.

Install the dust cap on the air filter housing with

the arrows pointing up.

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

5kPa(20inH

2O) 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.

ENGINE--DIESEL

6-7

ATLV 4300 330495 (10--98)

FUEL FILTER/WATER SEPARATOR

The fuel filter/water separator cartridge filters

impurities from the diesel fuel. It is located on the

back side of the engine, to the right of the larger

hydraulic fluid filter.

Replace the fuel filter element every 200 hours of

operation.

NOTE: Check the fuel filter water trap daily for

water. Drain any water that has collected in the

cartridge.

TO REPLACE FUEL FILTER/WATER

SEPARATOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, And Turn

Off Machine.

1. Open the hopper cover and tilt the hopper

back.

2. Open the top engine cover.

3. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

4. Locate the fuel filter/water separator in the

center of the upper machine frame. Remove

the air cleaner hose from the engine and air

cleaner. Place a drain pan under the filter.

5. Open the pet--cock on the bottom of the filter

cartridge. Let any water drain from the filter.

6. Un--screw the filter from the filter head.

Properly discard the old filter.

7. Place a small amount of oil on the rubber

O--ring on the new filter.

8. Screw the new filter onto the filter head.

Tighten until snug then 1/4 turn.

ENGINE--DIESEL

6-8 ATLV 4300 330495 (10--98)

9. Open the air breather on top of the filter

head and turn the engine over. Close the air

breather when the diesel fuel coming out of

the breather is free of air bubbles. The

engine may start at any time during this

procedure. Clean up any spilled diesel fuel.

10. Remove the drain pan. Reinstall the rear

engine cover.

11. Tilt the hopper forward and close the hopper

cover.

12. Start the machine and check the new filter

for any leaks.

ENGINE--DIESEL

6-9

ATLV 4300 330495 (10--98)

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.

Parts of the fuel line are made of rubber. The fuel

lines may become worn out whether the engine

has been used much or not. Replace the rubber

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.

FUEL PUMP

Check the fuel pump every 100 hours of

operation.

Check the clamps and fuel lines that connect to

the fuel pump every 50 hours of operation.

ENGINE--DIESEL

6-10 ATLV 4300 330495 (10--98)

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 the fuel filter, disconnecting the low

pressure fuel lines, or any part of the low pressure

fuel system leaks during engine operation.

TO PRIME FUEL SYSTEM

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, And Turn

Off Machine.

1. Open the seat support and engage the prop

rod. Make sure the fuel tank is full.

2. Open the breather vent on top of the fuel

filter/water separator.

3. Turn the key to the start position until fuel,

free from air, appears at the filter vent point.

Close the breather vent.

4. Loosen the bleed screw at the banjo fitting

on the injector pump.

5. Turn the key to the start position until fuel,

free from air, appears at the banjo fitting on

the injector pump. Tighten the connection.

6. Clean up any spilled fuel. Operate the

machine and check for proper operation.

ENGINE--DIESEL

6-11

ATLV 4300 330495 (10--98)

TO REMOVE ENGINE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, And Turn

Off Machine.

1. Open the hopper cover and tilt the hopper

back. Close the hopper cover.

2. Open the top engine cover.

3. Remove the five pan screws holding the rear

engine cover to the machine. Remove the

cover.

4. Pivot the seat assembly forward and engage

theproprod.

5. Disconnect the battery cables.

6. Remove both side fenders.

7. Remove the top engine cover and prop rod

at the hinges.

8. Remove the engine cover prop rod cross

brace.

9. Remove the black cross brace running

between the legs of the roll bar.

10. Remove the clamps holding the two air

hoses of the air cleaner assembly to the

engine and intake tube. Remove the two air

cleaner hoses.

11. Remove the two M10 hex screws holding

the air cleaner mounting bracket to the

bellhousing. Remove the air cleaner

assembly from the machine.

12. Drain the anti--freeze from the cooling

system. Remove the radiator hoses from the

engine. Disconnect the hose leading to the

overflow tank.

13. Remove the four M10 hex screws holding

the bottom of the radiator/cooler/shroud

assembly to the machine frame.

ENGINE--DIESEL

6-12 ATLV 4300 330495 (10--98)

14. Remove the two M8 hex screws holding the

top of the radiator to the two “L” brackets.

Move the radiator/cooler/shroud assembly

away from the front of the engine. Leave the

hydraulic hoses connected to the cooler and

engine oil cooler lines connected to the

lower cooler.

15. Remove the four M6 hex screws holding the

fan blade to the engine. Remove the fan

from the engine.

16. Disconnect the exhaust pipe at the exhaust

manifold.

17. Remove all of the fuel lines (rubber and

steel).

18. Remove the fuel filter/water separator from

the machine frame.

19. Remove the hardware holding the hydraulic

fluid filter to the machine frame. Move the

filter and filter head out of the way.

NOTE: Leave the hoses connected to the filter.

20. Pull the radiator overflow tank off the mount

bracket.

21. Disconnect the battery cables from the

engine starter and the ground cables from

the frame

22. Disconnect the main electrical harness from

the back of the alternator, starter, oil sender,

temp sender,glow plugs, ect. Pull the main

harness away from the engine.

23. Disconnect the engine throttle cable at the

engine lever. Loosen the throttle cable clamp

mount screw. Remove the throttle cable

from the mount clamp.

24. Drain the engine oil.

ENGINE--DIESEL

6-13

ATLV 4300 330495 (10--98)

25. Mark, disconnect, and plug the two remote

engine oil lines at the oil filter adaptor plate

on the engine.

NOTE: Make sure to mark the hoses for proper

re--assembly ! If the hoses are connected

incorrectly-- --engine damage may result !

26. Remove the hardware holding the directional

hydroback mount bracket to the side of the

engine.

27. Remove the two hex screws holding the

directional pump arm to the propel pump

hub. Pull the directional hydroback assembly

away from the engine.

28. Remove the propel pump and accessory

pump assembly from the back of the engine.

See TO REPLACE PROPEL PUMP

instructions in the HYDRAULIC section of

this manual. DO NOT DISCONNECT THE

HYDRAULIC HOSES. Pull the pump back

and out of the way for engine removal.

29. Remove the three M12 hex screws, nyloc

nuts, and washers holding the engine motor

mounts to the engine frame.

30. Using a overhead hoist, hook a chain in the

engine lift brackets and slowly lift the engine

out of the engine frame. Be careful not to

catch the engine on any hydraulic hoses or

electrical wires on the way out of the engine

compartment.

ENGINE--DIESEL

6-14 ATLV 4300 330495 (10--98)

TO INSTALL ENGINE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, And Turn

Off Machine.

1. Using a overhead hoist, hook a chain in the

engine lift brackets and slowly lift the engine

into the machine frame. Be careful not to

catch the engine on any hydraulic hoses or

electrical wires on the way into the engine

compartment.

2. Line up the three engine isolators in the

engine motor mounts with the holes in the

frame mounts. Make sure the four special

washers are in place between the frame and

isolator.

3. Install the three M12 hex screws, washers,

and nyloc nuts into the engine mounts.

Tighten to 64 -- 83 Nm (50 -- 60 ft lb).

4. Position the propel/accessory pump

assembly back in the bellhousing and drive

coupling. See TO REPLACE PROPEL

PUMP instructions in the HYDRAULIC

section of this manual. Make sure the

splines on the pump drive hub line up with

the splines in the flywheel drive flange.

Install the two hex screws and washers

holding the pump assembly to the

bellhousing. Tighten to 45 -- 58 Nm

(36 -- 47 ft lb).

5. Reinstall the propel pump arm onto the hub

on the side of the propel pump. Reinstall the

two hex screws. Leave loose for now.

6. Reinstall the propel hydroback mount

bracket onto the side of the engine. Reinstall

the two hex screws and tighten to

37 -- 48 Nm (26 -- 34 ft lb).

7. Reconnect the throttle cable to the engine

throttle lever. Tighten the cable clamp.

8. Reconnect the electrical harness to the

engine and related component (alternator,

starter, oil sender, temp sender,glow plugs,

ect.). See harness diagram or electrical

schematic in the ELECTRICAL section of

this manual.

ENGINE--DIESEL

6-15

ATLV 4300 330495 (10--98)

9. Reconnect the battery cables to the starter

and the ground cables to the machine

frame.

10. Reinstall the radiator over flow tank into the

mount bracket.

11. Reinstall the hydraulic fluid filter and head

assembly onto the machine frame. Reinstall

the two hex screws and tighten to

18 -- 24 Nm (15 -- 20 ft lb).

12. Reinstall the fuel filter/water separator onto

the machine frame. Reinstall the two hex

screws and tighten to 8 -- 10 Nm (6 -- 8 ft lb)

13. Reconnect the fuel lines (rubber and steel)

14. Reconnect the exhaust pipe to the exhaust

manifold. Tighten the two hex screws to

37 -- 48 Nm (26 -- 34 ft lb).

15. Position the engine fan back on the upper

engine sheave. Install the four M6 hex

screws and tighten to 11 -- 14 Nm

(7 -- 10 ft lb).

16. Pivot the radiator back in position and install

the two upper hex screws into the “L”

brackets. Tighten to 8 -- 10 Nm (6 -- 8 ft lb)

17. Reinstall the four hex screws into the lower

radiator mount brackets. Tighten the screws

to 37 -- 48 Nm (26 -- 34 ft lb).

18. Reinstall the radiator hoses to the engine

and fill the cooling system with 4 L

(1 gal) of antifreeze.

19. Reconnect the over flow hose from the top

of the radiator to the over flow tank.

20. Reconnect the two engine oil lines leading

from the remote oil filter to the adaptor on

the front, right side of the engine.

NOTE: Make sure to mark the hoses for proper

re--assembly! If the hoses are connected

incorrectly-- --engine damage may result!

ENGINE--DIESEL

6-16 ATLV 4300 330495 (10--98)

21. Fill the engine with 5.2 L (5.5 qt) 10W30

SAE--CD/SE rated engine oil with a new

filter.

22. Reinstall the air cleaner mounting bracket to

the rear of the bellhousing. Tighten the two

M10 hex screws to 52 -- 67 Nm

(39 -- 51 ft lb).

23. Reinstall the two air cleaner tubes onto the

air cleaner and engine intake.

24. Reinstall the black cross brace running

between the legs of the roll bar.

25. Reinstall the engine cover prop rod brace.

26. Reinstall the engine cover and prop rod at

the hinges.

27. Reinstall both side fenders.

28. Reconnect the battery cables.

29. See TO ADJUST PROPEL NEUTRAL

instructions in the CHASSIS section of this

manual before attempting to start the

machine.

30. Start the machine. The engine speed and

travel speeds must be checked and set at

this point.. See below for engine speed

setting. See TO SET TRAVEL SPEEDS

instructions in the CHASSIS section.

31. After the engine and travel speeds have

been set, close the seat assembly and

reinstall the rear engine cover. Tilt the

hopper in place and operate the machine.

Check all systems carefully for proper

operation

ENGINE SPEEDS

The idle speed of the model ATLV 4300 is set at

the factory at 1200±50 rpm. The top engine speed

should not exceed 3050±50 rpm. To set the

engine speed, use the position of the end of the

throttle cable in the cable clamp on the engine

bracket to set the upper engine speed. Use the

stop bolt on the engine injector pump to set the

engine idle speed.

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Technical Publications #15

701 North Lilac Drive

P.O. Box 1452

Minneapolis, MN 55440--9947

TENNANT COMPANY

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.

Thank you for helping us make zero defects a way of life at Tennant.

Manual No. Rev. No. Publish Date Page

Machine -Report Error -Suggestion

Name Date

Customer Number

Company

Address

City/State/Zip Code

Tape hereFold along dotted lines

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED SATES

BUSINESS REPLY MAIL

FIRST CLASS MAIL PERMIT NO. 94 MINNEAPOLIS, MN

POSTAGE WILL BE PAID BY ADDRESSEE

Technical Publications #15

701 North Lilac Drive

P.O. Box 1452

Minneapolis, MN 55440--9947

TENNANT COMPANY

ATLV 4300 Service Manual Tennant Rider Floor Sweeper

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