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Tennant 6400IC, Service Manual

The Tennant 6400IC Service Manual is the ultimate companion for users of the renowned Tennant 6400IC model. Providing step-by-step instructions and detailed insights, this comprehensive manual can easily be downloaded for free from our website. Maximize the efficiency and longevity of your cleaning equipment with this indispensable resource.

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GENERAL INFORMATION

1--19

6400IC MM433 (12--01)

MACHINE JACKING

Empty the hopper before jacking the machine.

The machine can be raised 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.

FOR SAFETY: Before leaving or

servicing machine, stop on level

surface, set parking brake, turn off

machine, and remove key.

The front jacking locations are on the flat bottom

edge of the front of the machine frame next to the

front tires.

The rear jacking location is the center of the rear

bumper.

FOR SAFETY: When servicing machine,

block machine tires before jacking up

machine.

FOR SAFETY: When servicing machine,

jack up machine at designated locations

only. Block machine up with jack

stands.

Summary of Contents for 6400IC

Page 1: ...MM433 Rev 02 MM433 Service Manual 6400IC ...

Page 2: ... Hydraulics Valve replacement repair motor replacement repair cylinder replacement repair pump replacement repair filter replacement schematics and hydraulics troubleshooting Engine G LPG air cooled Air filter replacement oil changing cooling system maintenance repair fuel system maintenance repair governor adjustment repair engine troubleshooting and engine repairs Engine G LPG liquid cooled Air ...

Page 3: ...WING AND TRANSPORTING THE MACHINE 1 16 PUSHING OR TOWING THE MACHINE 1 16 TRANSPORTING THE MACHINE 1 17 MACHINE JACKING 1 19 STORING MACHINE 1 20 TO STORE MACHINE UP TO 30 DAYS 1 20 TO STORE MACHINE 30 TO 90 DAYS 1 21 TO STORE MACHINE FOR MORE THAN 90 DAYS 1 21 HARDWARE INFORMATION 1 22 STANDARD BOLT TORQUE CHART 1 22 METRIC BOLT TORQUE CHART 1 22 BOLT IDENTIFICATION 1 22 THREAD SEALANT AND LOCKIN...

Page 4: ...GENERAL INFORMATION 1 2 6400IC MM433 8 94 ...

Page 5: ...faces Use care when reversing machine Move machine with care when hopper is raised Make sure adequate clearance is available before raising hopper Do not carry 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 brake Turn off machine and remove key 6 When servicing ma...

Page 6: ...ge or asphyxiation can result Provide adequate ventilation Consult with your regulatory authorities for exposure limits Keep engine properly tuned WARNING Lift arm pinch point Stay clear of hopper lift arms WARNING Raised hopper may fall Engage hopper support bar WARNING Moving belt and fan Keep away ...

Page 7: ...in its place EMISSIONS LABEL LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT FOR SAFETY LABEL LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT HOPPER LIFT ARMS LABEL LOCATED ON BOTH LIFT ARMS HOPPER SUPPORT LABEL LOCATED ON BOTH LIFT ARMS AND THE HOPPER SUPPORT BAR FAN AND BELT LABEL LOCATED ON THE SIDES OF THE RADIATOR SHROUD FAN AND BELT LABEL LOCATED ON THE VACUUM FAN HOUSING AND BELT SHROUD ...

Page 8: ...Sweeping path width 915 mm 36 in Sweeping path width with side brush 1270 mm 50 in Main sweeping brush pattern width 50 to 75 mm 2 to 3 in Hopper weight capacity 315 kg 700 lb Hopper volume capacity 315 L 11 25 ft3 Dust filter area 6 9 m2 74 ft2 GVWR 1542 kg 3400 lb Ceiling height minimum dumping clearance 2340 mm 92 in GENERAL MACHINE PERFORMANCE Item Measure Maximum forward speed 9 6 km h 6 mph ...

Page 9: ...m 0 0015 to 0 0030 in intake 0 050 to 0 088 mm 0 0020 to 0 0035 in exhaust 1 9 L 2 qt 10W30 SAE SG SH POWER TYPE GAS LIQUID COOLED Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke Kubota DG750 Piston Breakerless type spark 4 Natural 3 68 mm 2 68 in 68 mm 2 68 in Displacement Net power governed Net power maximum 740 cc 45 21 cu in 12 3 kw 16 5 hp 2500 rpm 18 3 kw 24 5 hp 3600 rpm Fuel Co...

Page 10: ...ed under load Engine lubricating oil with filter 1400 rpm 50 rpm 2450 rpm 25 rpm 5 1 L 5 4 qt SAE CD CE STEERING Type Power source Emergency steering Rear wheel hydraulic cylinder and rotary valve controlled Hydraulic accessory pump Manual HYDRAULIC SYSTEM System Capacity Fluid Type Hydraulic reservoir 19 3 L 5 12 gal TENNANT part no 65869 above 7_ C 45_ F Hydraulic total 20 8 L 5 5 gal p TENNANT ...

Page 11: ...TION 1 9 6400IC MM433 12 01 TOP VIEW SIDE VIEW 930 mm 2085 mm 82 in 1230 mm 48 4 in 2260 mm 89 in 1135 mm 44 7 in 1135 mm 44 7 in 1395 mm 55 in 1435 mm 56 5 in FRONT VIEW 2085 mm 82 in 350158 350165 MACHINE DIMENSIONS ...

Page 12: ...evel EO 1 y Check air intake and cooling areas for debris 1 5 Brush compartment skirts Check for damage wear and adjustment 5 11 Hopper lip skirts Check for damage wear and adjustment 3 8 Main brush Check for damage or wear 1 Check brush pattern 1 10 Side brush Check for damage or wear 1 Check brush pattern 1 9 Hopper dust filter Shake 1 25 Hours 3 Engine Clean air filter pre cleaner element 1 50 ...

Page 13: ...r 1 11 Side brush guard Rotate 90_ 1 7 Hopper lift arm pivots Lubricate SPL 2 11 Side brush pivot Check adjustment 1 400 Hours 6 Front wheel bearings Check for seal damage 2 800 Hours 14 Hydraulic fluid reservoir Replace filler cap 1 y Replace suction strainer 1 Change hydraulic fluid HYDO 1 15 Hydraulic fluid filter HChange filter element 1 Hydraulic hoses Check for wear and damage All 2 Propelli...

Page 14: ...gine Check oil level EO 1 y Empty air filter dust cap 1 Check optional air filter indicator 1 6 Brush compartment skirts Check for damage wear and adjustment 5 12 Hopper lip skirts Check for damage wear and adjustment 3 9 Main brush Check for damage or wear 1 Check brush pattern 1 11 Side brush Check for damage or wear 1 Check brush pattern 1 10 Hopper dust filter Shake 1 50 Hours 9 Main brush Rot...

Page 15: ...er lift arm pivots Lubricate SPL 2 12 Side brush pivot Check adjustment 1 400 Hours 4 Engine Clean or replace and adjust spark plugs 3 7 Front wheel bearings Check for seal damage 2 800 Hours 15 Hydraulic fluid reservoir Replace filler cap 1 y Replace suction strainer 1 Change hydraulic fluid HYDO 1 16 Hydraulic fluid filter Change filter element 1 Hydraulic hoses Check for wear and damage All 3 P...

Page 16: ...ir filter dust cap 1 Check optional air filter indicator 1 6 Brush compartment skirts Check for damage wear and adjustment 5 12 Hopper lip skirts Check for damage wear and adjustment 3 9 Main brush Check for damage or wear 1 Check brush pattern 1 11 Side brush Check for damage or wear 1 Check brush pattern 1 10 Hopper dust filter Shake 1 50 Hours 9 Main brush Rotate end for end 1 4 Fuel pipes and ...

Page 17: ...te 90_ 1 8 Hopper lift arm pivots Lubricate SPL 2 12 Side brush pivot Check adjustment 1 400 Hours 4 Fuel filter cartridge Replace element 1 7 Front wheel bearings Check for seal damage 2 800 Hours 15 Hydraulic fluid reservoir Replace filler cap 1 y Replace suction strainer 1 Change hydraulic fluid HYDO 1 16 Hydraulic fluid filter Change filter element 1 Hydraulic hoses Check for wear and damage A...

Page 18: ...ing 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 no...

Page 19: ...m 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 the holes in the sides of the machine frame near the rear bumper 4 Turn the bypass valve 90_ from the normal position before winching the machine onto the truck or trailer See PUSHING OR TOWING TH...

Page 20: ... in the wheel pockets at the front of the machine frame The rear tie down locations are the holes in the sides of the machine frame near the rear bumper 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 tra...

Page 21: ...e jacking up the machine FOR SAFETY Before leaving or servicing machine stop on level surface set parking brake turn off machine and remove key The front jacking locations are on the flat bottom edge of the front of the machine frame next to the front tires The rear jacking location is the center of the rear bumper FOR SAFETY When servicing machine block machine tires before jacking up machine FOR...

Page 22: ... from forming Contact TENNANT service personnel TO STORE MACHINE UP TO 30 DAYS 1 Dump the debris hopper 2 Change engine oil 3 Raise the main brush and side brush 4 Park the machine on a level surface in a cool dry area 5 Stop the engine and set the machine parking brake 6 Check the hydraulic fluid level It should be up to the FULL mark on the dipstick to prevent excessive condensation from forming...

Page 23: ...g temperature Oil adheres to cold metal surfaces much better than hot surfaces 5 Replace the high tension coil wire and spark plugs 6 Drain the gasoline from the carburetor TO STORE MACHINE FOR MORE THAN 90 DAYS 1 All of the above plus the following 2 Drain the engine oil from the engine oil pan 3 Drain the coolant from the radiator and engine block 4 Close the engine cooling system drain cocks 5 ...

Page 24: ... 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...

Page 25: ...9 ft lb 12 Nm 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 6 ft lb 8 Nm 9 ft lb 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 N...

Page 26: ...ped Reset Thermo Sentryt Hopper door partially or completely closed Open hopper door Poor sweeping performance Brush bristles worn Replace brushes Main and side brushes not adjusted properly Adjust main and side brushes Debris caught in main brush drive mechanism Remove debris from the drive mechanism Main brush drive failure Contact TENNANT service personnel Side brush drive failure Contact TENNA...

Page 27: ...T SEAT POSITION 2 6 STATIC DRAG CHAIN 2 6 FRONT TIRES AND WHEELS 2 7 TO REPLACE FRONT WHEEL BEARINGS 2 7 BRAKES AND TIRES 2 10 SERVICE BRAKES 2 10 TO REPLACE BRAKE SHOES 2 10 PARKING BRAKE 2 13 TO ADJUST BRAKES 2 14 REAR TIRE AND WHEEL AND WHEEL SUPPORT 2 16 TO REPLACE REAR WHEEL HOUSING PIVOT BEARINGS 2 16 ...

Page 28: ...CHASSIS 2 2 6400IC MM433 7 99 ...

Page 29: ...CHASSIS 2 3 6400IC MM433 7 99 INTRODUCTION This section includes information on the main chassis related components for example the seat steering brakes and tires ...

Page 30: ...he front of the right hand seat bracket TO REPLACE OPERATOR SEAT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Tilt the seat shroud back against the support cable 2 Remove the four hex nuts holding the seat brackets to the seat shroud 3 Remove the seat assembly from the seat shroud ...

Page 31: ...rientation of the brackets 5 Install the two seat brackets on the bottom of the new seat 6 Position the new seat and brackets on the seat shroud Line up the holes and install the hardware Tighten the hex screws to 18 5 24Nm 15 20 ft lb 7 Close the seat shroud and adjust the seat to a comfortable position ...

Page 32: ...d grasp the lock lever 2 Move the lock lever to the left until the seat moves freely 3 Slide the seat forward or backward to a comfortable position Release the lock lever 4 The seat is now locked in the chosen position STATIC DRAG CHAIN The static drag chain prevents build up of static electricity in the machine The chain is attached near the rear of the brush compartment skirts The chain should b...

Page 33: ...SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Disengage the parking brake if activated 2 Jack up one front corner of the machine Place jack stands under machine frame FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands ...

Page 34: ... wheel off the axle 6 Press the old bearings out Press the new bearings in the wheel in the same orientation 7 Slide the wheel back on the axle 8 Slide the flat washer and nut on the shaft 9 Tighten the nut with a hand wrench until the wheel binds then back the nut off to nearest cotter pin hole 10 Insert a new cotter pin through nut and hole ...

Page 35: ...CHASSIS 2 9 6400IC MM433 7 99 11 After making sure the wheel spins freely carefully reinstall the hub cap 12 Remove the jackstands and lower the machine 13 Repeat the procedure on the other wheel ...

Page 36: ... should not travel more than 2 inches to fully engage the brakes TO REPLACE BRAKE SHOES FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Disengage the parking brake if activated 2 Jack up one front corner of the machine Place jack stands under machine frame FOR SAFETY Block machine tires before jacking machine up Jack machine ...

Page 37: ...d flat washer 5 Slide the wheel off the axle 6 Remove the one large C shaped tension spring holding the old brake shoes together Remove the old brake shoes 7 Replace the old brake shoes with new brake shoes 8 Reinstall the one large C shaped brake tension spring on the new brake shoes 9 Slide the wheel back on the axle ...

Page 38: ...t with a hand wrench until the wheel binds then back the nut off to nearest cotter pin hole 12 Insert a new cotter pin through nut and hole 13 After making sure the wheel spins freely carefully reinstall the hub cap 14 Remove the jackstands and lower the machine 15 Repeat the procedure on the other wheel ...

Page 39: ... when the machine rolls after setting the parking brake and after every 200 hours of operation The parking brake may be tightened by adjusting the brake rod clevis on the ends of the brake cross shaft See TO ADJUST BRAKES instructions Adjust the parking brake so it will hold the Machine on a smooth 8 degree incline The brake pedal should not travel more than 2 inches to fully engage the brakes ...

Page 40: ...achine And Remove Key 1 Raise the hopper and engage the support bar 2 Disengage the parking brake if activated FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 3 Remove the cotter pin and the clevis pin holding the brake rod clevis to the brake assembly lever ...

Page 41: ...tment and pedal travel The pedal should move no more than 1 before engaging the brakes 6 Reinstall the cotter pin and the clevis pin in the brake rod clevis and the brake assembly lever 7 Repeat the procedure on both sides 8 Drive the machine and operate the brakes Check for equal engagement of the brakes on both wheels ...

Page 42: ...0 hours of operation The proper tire air pressure is 790 35 kPa 115 5 psi Torque the rear wheel nuts in a star pattern to 122 to 150 Nm 90 to 110 ft lb after the first 50 hours of operation and every 800 hours there after TO REPLACE REAR WHEEL HOUSING PIVOT BEARINGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Engage parki...

Page 43: ...otted nut from drive wheel shaft 5 Use a puller to remove the drive hub from the tapered motor shaft 6 Disconnect the hydraulic hoses from the drive motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 7 Remove the rear drive motor mounting bolts 8 Slide the rear drive motor out of the wheel housing ...

Page 44: ...move the hex screw and nyloc nut attaching the rod end of steering cylinder to rear wheel housing 11 Loosen the two socket head bolts holding the drive housing pivot pin in the frame 12 Remove the cotter pin from the large slotted nut on top of the rear housing pivot pin Remove the slotted nut ...

Page 45: ... the wheel housing out of the main frame NOTE Make sure to retain the thrust washer from on top of the upper bearing cone 15 Replace the pressed in bearing cups 16 Pack the new bearing cones with Lubriplate EMB grease Coat the bearing cups with grease 17 Position the bearings in the housing ...

Page 46: ...upper bearing cone 19 Slide the wheel housing in position in main frame 20 Slide the pivot pin up through the frame hole 21 Thread castle nut on the pin Tighten to 34 40 Nm 25 30 ft lb Check for any play If the pin is not seated tap with rubber mallet and re torque castle nut ...

Page 47: ...ft lb 24 Check the wheel housing to see if it rocks or binds If it does loosen the top socket screw move the casting to seat bearing and re tighten socket screw to 100 115 Nm 73 85 ft lb 25 Tighten the lower socket screw to 100 115 Nm 73 85 ft lb 26 Re connect the rod end of the steering cylinder to the wheel housing using the 750x3 25 hex screw nyloc nut and flat washers Tighten to 270 300 Nm 200...

Page 48: ...ighten to 88 115 Nm 65 85 ft lb 29 Reconnect the hydraulic hoses See schematic in the HYDRAULICS section 30 Reinstall the hose clamp to the wheel housing Tighten the hex screws to 18 5 24Nm 15 20 ft lb 31 Mount the hub to the tapered motor shaft Tighten the slotted nut to 250 ft lb Install the cotter pin NOTE Make sure the key is installed on the tapered shaft of the drive motor ...

Page 49: ...he rear wheel nuts to 122 150 Nm 90 110 ft lb 33 Re connect the battery cables and start the engine Run the propelling in both directions Check for any leaks 34 Remove the jack stands and lower the machine to the ground 35 Operate the machine Check the rear drive for proper operation ...

Page 50: ...CHASSIS 2 24 6400IC MM433 7 99 ...

Page 51: ...IDE BRUSH PIVOT 3 37 Page SKIRTS AND SEALS 3 38 HOPPER LIP SKIRTS 3 38 TO REPLACE HOPPER LIP SKIRTS 3 38 BRUSH DOOR SKIRTS 3 40 TO REPLACE AND ADJUST RIGHT HAND BRUSH DOOR SKIRT 3 40 TO REPLACE AND ADJUST LEFT HAND BRUSH DOOR SKIRT 3 42 RIGHT BRUSH DOOR SEAL 3 44 REAR SKIRT AND DEFLECTOR BLADE 3 44 TO REPLACE AND ADJUST THE REAR SKIRT AND DEFLECTOR BLADE 3 45 HOPPER SIDE SEALS 3 48 HOPPER TOP SEAL...

Page 52: ...SWEEPING 3 2 6400IC MM433 7 99 ...

Page 53: ...CTION This section includes information on the sweeping operation The side brush sweeps debris in front of the machine and the main brush sweeps the debris into the hopper The vacuum fan pulls air from the hopper and through the dust filter ...

Page 54: ...y and require no regular maintenance If hopper components are repaired or replaced some components may need to be readjusted for best performance The hopper may need to be removed from the machine for some repair or service work TO REMOVE HOPPER 1 Start the machine and raise the hopper Engage the support bar 2 Remove the hopper level adjustment bolt nut and washers 3 Cut the plastic ties holding t...

Page 55: ... Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 6 Disconnect the hydraulic hoses leading to the side brush motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 7 Disconnect the side brush lift cable at the hydraulic motor 8 Remove the four hex screws holding the hopper bumper to the sides of the hopper ...

Page 56: ... hopper 10 Remove the bumper and side brush assembly from the machine 11 Remove the two hex screws and nyloc nuts holding the pivot bearings to each side of the hopper lift arm 12 The hopper can now be pulled away from the machine 13 Disconnect and plug the hydraulic hoses leading to the hopper dump door cylinder 14 The hopper can now be removed from the machine ...

Page 57: ... careful not to pinch hydraulic hoses or electrical wires during this procedure 2 Reconnect the hydraulic hoses to the dump door cylinder See the schematic in the HYDRAULICS section of this manual for proper hose connections NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 3 Line up the holes in the hopper pivot bearing flanges with the holes in the hopper lift arms Ins...

Page 58: ... hex screws and tighten to 18 24 Nm 15 20 ft lb 6 Reconnect the hydraulic hoses to the side brush motor See the schematic in the HYDRAULICS section of this manual for proper hose connections 7 Reconnect the side brush lift cable at the side brush assembly 8 Reconnect the hopper harness to the main harness 9 See the schematic in the ELECTRICAL section of this manual for proper harness connections 1...

Page 59: ...400IC MM433 7 99 11 Reinstall the lip height adjustment bolt on the back of the hopper 12 Start the machine and check for proper operation of hopper vacuum fan dump door side brush rotation and side brush up and down ...

Page 60: ...nt adjust the length of the adjustment bolt on the back of the hopper TO ADJUST HOPPER BUMPER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Loosen the four hex screws and nyloc nuts holding the hopper bumper to the sides of the hopper 2 Loosen the three hex screws holding the hopper bumper to the front of the hopper 3 Adjus...

Page 61: ...ns TO REMOVE HOPPER LIFT ARM 1 Park the machine on a smooth level surface 2 Stop the machine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Remove the debris hopper See TO REMOVE HOPPER FROM MACHINE instructions 4 Remove the cotter pins from the upper hopper lift cylinder pin ...

Page 62: ...e the hex hardware holding the hopper pivot pins to the frame towers 7 Raise up slightly on the lift arm to take pressure off the pins Remove the pins and washers and remove the lift arm from the machine 8 If the large self aligning bearing needs to be changed remove retaining rings and press the old bearing out of the lift arm ...

Page 63: ...he machine aligning the upper bearings in the lift arm with the holes in the towers of the machine NOTE Make sure the side brush lift cable is looped over the plastic pulley on the right hand lift arm pin 4 Install the lift arm pins in the bearings from the inside of the machine Make sure to reinstall the spacer washers that were removed when the pins were removed 5 Align the hole in lift arm pin ...

Page 64: ... 6 Align the small fiberglide bearing in the lift arm cylinder lug with the hole in the clevis on the hopper lift cylinder Reinstall the cylinder pin and cotter pins 7 Reinstall the hopper assembly See TO INSTALL HOPPER instructions ...

Page 65: ...R DUMP DOOR 1 Make sure the hopper is emptied of all debris Engage the parking brake 2 Raise the hopper and engage the prop rod WARNING Raised Hopper May Fall Engage Hopper Support Bar 3 Open the dump door Shut off the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Disconnect the rod end of dump door cylinder from th...

Page 66: ...ack off the hopper 6 Remove the five hex screws holding the seal on the front of the dump door to the back of the hopper 7 Use a razer knife to remove the RTV from the two dump door pivot bolts on each side of the hopper Remove the two hex screws 8 Drop the dump door down and out of the hopper ...

Page 67: ...g Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Position the dump door in the hopper Line up the pivot holes in the dump door with the mount holes in each side of the hopper 4 Install the two hex screws and nuts Hand tighten tight 5 Put a small amount of RTV around the two hex screws 6 Reinstall the seal on the front of the dump door Hand tighten th...

Page 68: ...nt bracket on the center of the dump door 8 Reconnect the two tension springs to the mount bracket 9 Start the machine and open and close hopper door a few times Check for proper operation NOTE Make sure the seals on the dump door are adjusted so they contact the inside wall of the hopper ...

Page 69: ...the Filter shaker position D TAPPING Tap the filter gently on a flat surface with the dirty side down Do not damage the edges of the filter element and seals or the filter will not seat properly in the filter frame D AIR Blow air through the dust filter opposite the direction of the arrows This may be done with the dust filter in the machine Always wear eye protection when using compressed air FOR...

Page 70: ... open the hopper cover Support the hopper with the hopper cover prop rod 3 Lift the dust filter element out of the hopper insert 4 Clean or discard the dust filter as required 5 Clean and inspect the filter sealing surfaces Make sure the foam element centering strips attached to the hopper and intact Put the cleaned or new dust filter in the hopper insert with the arrows pointing up 6 Lower the ho...

Page 71: ...h in the lowered position Adjust the main brush pattern by turning the main brush down pressure knob and moving the brush stop Rotate the main brush end for end after every 50 hours of operation for maximum brush life and best sweeping performance Replace the main brush when the remaining bristles measure 25 mm 1 in in length TO REPLACE MAIN BRUSH 1 Stop the machine and set the parking brake FOR S...

Page 72: ...ment 6 Put the new or rotated end for end main brush on the floor next to the access door 7 Slide the main brush onto the drive plug Rotate the brush until it engages the drive plug and push it all the way onto the plug 8 Slide the main brush idler plate plug in the main brush 9 Reinstall the attachment bolt 10 Close the right side main brush access door Check the main brush pattern ...

Page 73: ...on the main brush over the chalked area 3 Lower and start the main brush for 15 to 20 seconds while keeping a foot on the brakes to keep the machine from moving This will lower the rotating main brush NOTE If chalk or other material is not available allow the brushes to spin on the floor for two minutes A polish mark will remain on the floor 4 Raise and stop the main brush 5 Drive the machine off ...

Page 74: ...ot To decrease the width of the main brush pattern loosen the main brush pattern adjustment handle and slide backward in the slot If the main brush pattern is tapered more than 15 mm 0 5 in on one end than the other adjust taper 1 Loosen the brush shaft bearing bracket mounting bolts A Move the brush shaft bearing bracket up or down in the slots B Re check the main brush pattern and readjust as ne...

Page 75: ...p On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Remove the main brush idler arm from the machine 2 Remove the plastic cap from the idler plug 3 Clean the area around where the cap was mounted in the idler plug 4 Remove the M12 flat screw nyloc hex nut and washer holding the idler plug to the idler arm ...

Page 76: ... Place a new bearing the old seal plate and the retainer on the idler 8 Reinstall the four hex screws that hold the bearing seal plate and retainer in place Leave screws loose for now 9 Install the idler shaft in the new bearing Tighten the four hex screws to 8 10 Nm 6 8 ft lb 10 Position the idler plug on the idler arm shaft Reinstall the long flat screw Tighten to 68 81 Nm 50 60 ft lb ...

Page 77: ... 6400IC MM433 7 99 11 Put a small amount of RTV on the lip of the plastic cap and install in the end of the idler plug 12 Reinstall the idler arm on the machine 13 Operate the machine and check for proper operation ...

Page 78: ...et Parking Brake Turn Off Machine And Remove Key 1 Remove the main brush idler arm and brush from the right side of the machine 2 Remove the main brush motor arm assembly from the left side of the machine 3 Remove the large hex screw and nyloc nut holding the brush arm to the pivot bearings 4 Let the brush arm drop down and out of the way ...

Page 79: ...earings on the mount brackets Make sure to have the lock collars pointing to the outside of the machine 8 Reinstall the two bolts holding each of the two brush shaft bearings and retainers to the bearing brackets Tighten to 18 24 Nm 15 20 ft lb 9 Reinstall the main brush motor plate and idler plate 10 Check main brush pattern for taper and width Adjust as necessary See TO CHECK AND ADJUST MAIN BRU...

Page 80: ...er counter clockwise to increase the brush contact with the sweeping surface and clockwise to decrease the brush contact with the sweeping surface The side brush should be replaced when it no longer sweeps effectively for your application A guideline length is when the remaining bristles measure 50 mm 2 in in length You may change the side brush sooner if you are sweeping light litter or wear the ...

Page 81: ...e pin Remove the pin 5 Slide the side brush off the side brush motor shaft NOTE Remove the drive hub and put it on the new brush if one is not installed 6 Slide the new side brush on the side brush motor shaft 7 Reinstall the side brush retaining pin through the side brush hub and shaft 8 Secure the pin by clipping the pin keeper over the end of the pin ...

Page 82: ...SWEEPING 3 32 6400IC MM433 7 99 9 Disengage the hopper support bar and lower the hopper 10 Adjust the side brush pattern with the side brush down pressure lever ...

Page 83: ...On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Lower the side brush 2 Turn the side brush lever clockwise to decrease side brush pattern Turn the side brush lever counter clockwise to increase side brush pattern One half of the bristles should normally contact the floor 3 Raise the side brush ...

Page 84: ...Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Lower the side brush 2 Raise the hopper slightly and shut off the machine 3 Loosen the two hex screws on the back of the hopper bumper near the side brush assembly 4 Tilt the side brush in either direction ...

Page 85: ...SWEEPING 3 35 6400IC MM433 7 99 5 Tighten the hardware firmly 6 Lower the hopper 7 Start the machine and turn on the side brush Check the side brush pattern 8 Raise the side brush ...

Page 86: ...lace the brush guard after all four sides have been used TO ROTATE OR REPLACE SIDE BRUSH GUARD FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Remove the side brush 2 Remove the four bolts holding the side brush guard to the side brush motor 3 Rotate or replace the side brush guard 4 Reinstall the four bolts in the side brush...

Page 87: ...ould be checked for excessive movement after every 200 hours of operation Torque the front and rear compression springs to reduce excessive movement The side brush tilt is adjusted with the side brush cable Turn the clevis on the cable to get the desired side brush pattern ...

Page 88: ...the hopper lip skirts for wear or damage daily Replace the hopper lip skirts when they no longer touch the floor TO REPLACE HOPPER LIP SKIRTS 1 Dump the machine debris hopper 2 Set the machine parking brake 3 Raise the hopper engage the hopper support bar Shut off the machine WARNING Raised Hopper May Fall Engage Hopper Support Bar FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surfa...

Page 89: ...trip hopper lip and the back up strip Discard the hopper lip 6 Thread the retaining strip mounting bolts through the retaining strip the new hopper lip and the back up strip 7 Tighten the mounting hardware to 8 14 Nm 6 10 ft lb 8 Start the machine and lower the hopper ...

Page 90: ...or otherwise Check the skirts for wear or damage and adjustment daily NOTE The brush door skirts have slotted holes to allow for a ground clearance adjustment The door must be closed for proper adjustment TO REPLACE AND ADJUST RIGHT HAND BRUSH DOOR SKIRT 1 Park the machine on a smooth level surface 2 Stop the machine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine ...

Page 91: ...ead the skirt retaining bolts through the brush door the door skirt and in the skirt retaining strip NOTE The brush door skirts have slotted holes to allow for a ground clearance adjustment The door must be closed for proper adjustment 9 Slide the brush door skirt up or down so it will clear the floor by 3 5 mm 0 12 to 0 25 in Hand tighten the hex screws firmly 10 Operate the machine and check the...

Page 92: ...face 2 Stop the machine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the left hand brush door 4 Remove the four hex screws holding the skirt mount plate to the machine 5 Remove the brush skirt retaining bolts ...

Page 93: ...rt retaining strip NOTE The brush skirts have slotted holes to allow for a ground clearance adjustment The skirt plate must be mounted on the machine for proper adjustment 10 Reinstall the skirt mount plate on the machine Tighten the hex screws to 18 24 Nm 15 20 ft lb 11 Slide the brush door skirt up or down so it will clear the floor by 3 5 mm 0 12 to 0 25 in Hand tighten the hex screws firmly 12...

Page 94: ...ear or damage every 100 hours of operation REAR SKIRT AND DEFLECTOR BLADE The rear skirt and the deflector blade are located on the bottom rear of the main brush compartment The rear skirt should clear the floor up to 5 mm 0 25 in in dusty conditions and touch the floor otherwise The deflector blade is spring loaded Check the skirt and blade for wear or damage and adjustment daily NOTE Rear tire p...

Page 95: ... on a smooth level surface 2 Stop the machine and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the main brush doors 4 Remove the main brush 5 Remove the retaining strip and floor skirt Discard the old skirt ...

Page 96: ...t and the retaining strip toward the rear wheel 8 Slide the rear floor skirt up or down so that the skirt clears the floor up to a maximum of 5 mm 0 25 in 9 Tighten the rear floor skirt mounting bolts to 8 14 Nm 6 10 ft lb 10 Remove the brush contact blade retaining strip and the brush contact blade Discard the old blade up to 5 mm up to 0 25 in ...

Page 97: ...ad the mounting bolts through the mounting bracket the brush contact blade and the retaining strip 13 Tighten the brush contact blade mounting bolts to 8 14 Nm 6 10 ft lb 14 Reinstall the main brush 15 Close the main brush doors 16 Operate the machine and check for proper operation ...

Page 98: ... hardware to 4 5 Nm 3 4 ft lb Inspect the seals for wear or damage every 100 hours of operation HOPPER TOP SEAL The hopper dust seal is located under the front of the machine frame in the area of the machine that is contacted when the hopper is in the down position Check the seal for wear or damage every 100 hours of operation You can reach the seal by lifting the hopper and engaging the prop arm ...

Page 99: ...Engage Hopper Support Bar FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Remove the skirt retainer and skirt from each side of the machine Remove the plastic hardware by prying under the head 5 Position the new skirt and existing retainer on the front of the machine frame Secure with plastic push in hardware 6 Repeat on the ...

Page 100: ...AN SEAL The hopper vacuum fan seal is mounted on the front the vacuum fan inlet assembly Check the seal for wear or damage every 100 hours of operation You can reach the seal by removing the hopper insert HOPPER DUMP DOOR SEALS The hopper door seals are located on the hopper door They seal the hopper when the hopper door is closed Tighten hardware to 3 4 Nm 2 5 3 5 ft lb Check the seals for wear o...

Page 101: ...engage hopper support bar WARNING Raised Hopper May Fall Engage Hopper Support Bar FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Remove the six hex screws holding the dump door seal retainer and sponge cord to dump door Discard the old seal 5 Remove the three hex screws holding each side seal to the dump door Discard the ol...

Page 102: ...en to 3 3 4 4 Nm 30 39 In lb 7 Align the holes in the new side seal with holes on the edge of the dump door and retainer Reinstall the three hex screws Tighten to 3 3 4 4 Nm 30 39 In lb Make sure the seals are lined up with edge of hopper when tightening 8 Start machine and lower hopper 9 Operate the machine and check the dump door for proper operation ...

Page 103: ...cuum fan is used during sweeping to control dusting by pulling air from the main brush area through the hopper to the dust filters On the air cooled machine the vacuum fan is located in front of the engine On the water cooled machine the vacuum fan is located under the radiator AIR COOLED LIQUID COOLED ...

Page 104: ...ce 2 Stop the engine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Jack up the rear of the machine and install jack stands under the machine frame 4 Remove the rear tire and wheel assembly 5 Open the seat shroud ...

Page 105: ...ly to the bottom mount bracket 8 Move the vacuum fan assembly up far enough to remove the V belt from the sheave Remove the V belt 9 Remove the four hex screws holding the vacuum fan assembly to the bottom mount bracket 10 Remove the vacuum fan assembly from the bottom of the machine NOTE The vacuum fan assembly must be removed out the bottom of the machine ...

Page 106: ...ce 2 Stop the engine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Jack up the rear of the machine and install jack stands under the machine frame 4 Remove the rear tire and wheel assembly 5 Open the seat shroud ...

Page 107: ...ount bracket with the bracket on the machine Reinstall the four hex screws and nuts Leave loose for now 8 Reinstall the V belt on the vacuum fan sheave and engine sheave 9 Pull down lightly on the vacuum fan assembly to tighten the V belt The belt spec is 20 3 lb tension Apply 1 5 lb at the middle of the belt span to obtain 17 inch of deflection 10 Firmly tighten the four hex screws ...

Page 108: ...acuum hoses to the vacuum fan housing 12 Reinstall the rear tire and wheel assembly Tighten the wheel nuts to 122 150 Nm 90 110 ft lb 13 Remove the jack stands and lower the machine 14 Start the machine and operate the vacuum fan Check for proper operation ...

Page 109: ... level surface 2 Stop the engine and set the machine parking brake Open the engine shroud FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Remove the vacuum fan belt guard 4 Remove the vacuum hose connected to the vacuum fan assembly ...

Page 110: ...an assembly mount bracket to the machine frame 6 Move the vacuum fan assembly toward the engine and remove the V belt from the sheave Remove the V belt 7 Remove the three hex screws holding the vacuum fan assembly to the machine frame 8 Remove the vacuum fan assembly from the machine ...

Page 111: ...e machine parking brake Open the engine shroud FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Position the vacuum fan assembly in the machine 4 Align the holes in vacuum fan mount bracket with the holes in the machine frame Reinstall the three hex screws Leave loose for now ...

Page 112: ... 20 3 lb tension Apply 1 5 lb at the middle of the belt span to obtain 28 inch of deflection NOTE Use a straight edge to make sure the sheave on the engine is in line with the sheave on the vacuum fan assembly 7 Firmly tighten the hex screws 8 Reinstall the fan belt guard 9 Reconnect the vacuum hose to the vacuum fan housing 10 Start the machine and operate the vacuum fan Check for proper operatio...

Page 113: ...ake Turn Off Machine And Remove Key 3 Remove the vacuum fan assembly from the machine See TO REMOVE VACUUM FAN ASSEMBLY instructions in this section 4 Remove the nine thread cutting screws holding the fan housing to the fan assembly Remove the housing 5 Hold the impeller from turning and remove the hex nut from the end of the fan impeller shaft Pull the impeller straight off the shaft NOTE Make su...

Page 114: ... are in place on the impeller shaft 7 Reinstall the hex nut on the end of the impeller shaft 8 Hold the new impeller from turning and firmly tighten the flex lock nut 9 Reinstall the fan housing on the fan assembly 10 Reinstall the nine thread cutting screws in the fan housing Hand tighten 11 Reinstall the vacuum fan assembly in the machine See TO INSTALL VACUUM FAN ASSEMBLY instructions in this s...

Page 115: ...ng Brake Turn Off Machine And Remove Key 3 Remove the vacuum fan assembly from the machine See TO REMOVE VACUUM FAN ASSEMBLY instructions in this section 4 Remove the nine thread cutting screws holding the fan housing to the fan assembly Remove the housing 5 Hold the impeller from turning and remove the hex nut from the end of the fan impeller shaft Pull the impeller straight off the shaft NOTE Ma...

Page 116: ...e four hex screws holding the bearing assembly to the fan mount bracket and fan assembly back plate Remove the bearing assembly 8 Use a small press to remove the impeller shaft and two bearings from the bearing housing NOTE Make sure to note the orientation of the bearings and impeller shaft in relation to the bearing housing 9 Press two new bearings in the bearing housing ...

Page 117: ...ate on the fan mount plate Tighten the four M6 hex screws and nyloc nuts to 7 6 9 9 Nm 5 6 ft lb 12 Reinstall the spacer key and impeller on the shaft NOTE Place a small amount of grease on the impeller shaft to ease installation 13 Reinstall the fan impeller housing using the nine thread cutting screws Tighten to 223 290 Ncm 20 25 in lb ...

Page 118: ...the other side and reinstall the square key and sheave Push the sheave all the way on and hand tighten the two set screws tight 15 Reinstall the vacuum fan assembly in the machine See TO INSTALL VACUUM FAN ASSEMBLY instructions in this section ...

Page 119: ...ff Machine And Remove Key 1 Loosen the four hex screws holding the vacuum fan assembly to the mount bracket under the radiator 2 Use a static 20lbs or 3lbs to tension the V belt 3 Tighten the four hex screws 4 Apply 1 1 2 lbs of force to the middle of the V belt 1 2 way between the two sheaves There should be approximately 5 32 of deflection 5 Re check belt tension ...

Page 120: ...ing Brake Turn Off Machine And Remove Key 1 Loosen the hex screws holding the vacuum fan assembly mount plate to the engine mount bracket 2 Use a static 20lbs or 3lbs to tension the V belt 3 Tighten the hex screws 4 Apply 1 1 2 lbs of force to the middle of the V belt 1 2 way between the two sheaves There should be approximately 1 4 of deflection ...

Page 121: ...Open the hopper door Thermo Sentryt tripped Reset Thermo Sentryt Poor sweeping performance Brush bristles worn Replace brushes Main and side brushes not adjusted properly Adjust main and side brushes Debris caught in main brush drive mechanism Free drive mechanism of debris Main brush drive failure Contact TENNANT service personnel Side brush drive failure Contact TENNANT service personnel Hopper ...

Page 122: ...SWEEPING 3 72 6400IC MM433 7 99 ...

Page 123: ...ICAL RELAY 4 22 ELECTRICAL SCHEMATIC GAS LP LIQUID COOLED 4 26 ELECTRICAL SCHEMATIC DIESEL 4 28 ELECTRICAL SCHEMATIC GAS LP AIR COOLED 4 30 WIRE HARNESS GROUP GAS LP LIQUID COOLED 4 32 WIRE HARNESS GROUP DIESEL 4 34 WIRE HARNESS GROUP GAS LP AIR COOLED 4 36 Page TROUBLESHOOTING 4 39 LIQUID COOLED GAS LP ENGINE WILL NOT START 4 40 LIQUID COOLED GAS LP ENGINE STARTS BUT WILL NOT STAY RUNNING 4 42 DI...

Page 124: ...ELECTRICAL 4 2 6400IC MM433 7 99 ...

Page 125: ...ELECTRICAL 4 3 6400IC MM433 12 01 INTRODUCTION The machines electrical system consists of the battery instrument panel switches relays and circuit breakers ...

Page 126: ...ours after that clean and tighten the battery connections Periodically clean the top surface of the batteries and the terminals and check for loose connections Use a strong solution of baking soda and water Brush the solution sparingly over the battery tops terminals and cable clamps Do not allow any baking soda solution to enter the batteries Use a wire brush to clean the terminal posts and the c...

Page 127: ... are not thoroughly mixed the readings may not be accurate Check the hydrometer readings against the following chart to determine the remaining battery charge level SPECIFIC GRAVITY BATTERY at 27_ C 80_ F CHARGE 1 260 1 280 100 Charged 1 230 1 250 75 Charged 1 200 1 220 50 Charged 1 170 1 190 25 Charged 1 110 1 160 Discharged NOTE If the readings are taken when the battery electrolyte is any tempe...

Page 128: ...re Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Tilt the seat support Locate the battery on the left side of the machine in front of the engine 2 Disconnect the battery cables 3 Remove the battery hold down strap ...

Page 129: ...tery lifting device 5 Make sure that both posts are clean on the new battery Position the new battery in the machine 6 Reinstall the battery hold down strap 7 Reconnect the positive then the negative battery cables 8 Lower the seat support and start the machine to test the new battery ...

Page 130: ...o Sentryt stops the vacuum fan and cuts off the air flow TO REPLACE THERMO SENTRYt FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the hopper cover and engage prop rod 2 Locate the Thermo Sentryton the back of the filter shaker motor bracket Unplug the two wires leading to the Thermo Sentryt ...

Page 131: ...3 12 01 3 Remove the hex screws holding the Thermo Sentryt to the bracket Remove from the hopper 4 Install the new Thermo Sentryton the bracket Reinstall the hardware and tighten 5 Reconnect the wires and close the hopper cover ...

Page 132: ...Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Cut the plastic wire tie holding the Thermo Sentrytsolenoid wire to the machine Disconnect the Thermo Sentrytsolenoid wire harness from hopper harness 3 Remove the pin connecting the rod of the Thermo Sentrytsolenoid to the lever ...

Page 133: ...nut holding Thermo Sentrytsolenoid to the bracket Remove the Thermo Sentrytsolenoid from the machine 5 Mount the new Thermo Sentrytsolenoid on the bracket with existing hardware 6 Reconnect the wires to the Thermo Sentryt solenoid 7 Close the seat support ...

Page 134: ... meter fuel gauge horn button circuit breakers and indicator light panel TO REPLACE INDICATOR LIGHT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the hopper and engage the support bar 2 Open the seat support and disconnect the battery ...

Page 135: ...ount plate back away from the instrument panel 5 Unplug the two wires leading to the light that needs to be changed 6 Squeeze the sides of the light and push the light out of the mount plate 7 Install the new light in the mount plate Snap in place 8 Reconnect the wires to the new light See schematic in this section 9 Position the mount plate back on the instrument panel Reinstall the two nyloc nut...

Page 136: ...ELECTRICAL 4 14 6400IC MM433 12 01 10 Reconnect the battery cable 11 Close the seat support 12 Start the machine and lower the hopper Check the indicator lights for proper operation ...

Page 137: ... 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 breakers are located in the operator compartment The chart lists the circuit breakers and the electrical components they protect Circuit Breaker Rating Circuit Protected CB 1 15 A Thermo Sentryt CB 2 15 A H...

Page 138: ...rn Off Machine And Remove Key 1 Raise the hopper and engage the support bar 2 Open the seat support and disconnect the battery 3 Locate the circuit breakers below the indicator light panel 4 Use the electrical schematic in this section to locate the circuit breaker that needs to be replaced 5 Disconnect the wires leading to the faulty circuit breaker ...

Page 139: ...ut off 7 Remove the old circuit breaker and discard 8 Position the new circuit breaker in the hole in the panel Install the metal lock ring NOTE The circuit breaker will only fit in the hole in one direction 9 Plug the main harness wires into the new circuit breaker See the schematic in this section 10 Reconnect the battery cables ...

Page 140: ...ELECTRICAL 4 18 6400IC MM433 12 01 11 Close the seat support 12 Start the machine and lower the hopper Check the new circuit breaker for proper operation ...

Page 141: ... Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the hopper cover and engage the prop rod 2 Locate the filter shaker motor on the top side of the filter shaker assembly 3 Unplug the filter shaker motor from the hopper harness ...

Page 142: ...wo hex screws holding the shaker motor bracket to the motor assembly Remove the motor from the assembly 6 Loosen the two set screws on the eccentric weight Pull the weight off the motor shaft 7 Install the eccentric weight on the new shaker motor Position the weight flush with the guard plate 8 Install the new shaker motor on the assembly mount plate Tighten the two hex screws to 18 24 Nm 15 20 ft...

Page 143: ...e shaker motor support bracket Make sure the sleeves are in place on the two hex screws tighten to 18 24 Nm 15 20 ft lb 10 Plug the shaker motor into the hopper harness 11 Test the shaker motor for proper operation 12 Disengage the hopper cover prop rod and lower the cover ...

Page 144: ... SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the hopper and engage the support bar 2 Open the seat support and remove the battery cables from battery 3 Locate the relays under the circuit breakers ...

Page 145: ...s to be replaced 5 Push the two tabs on the electrical plug of the main harness and remove it from the faulty relay 6 Remove the hex nut holding the relay to the panel Remove and discard the relay 7 Position the new relay on the instrument panel Reinstall the hex screw and nyloc nut Hand tighten ...

Page 146: ... in the new relay See the schematic in this section NOTE The harness plug will only fit in the new relay in one direction 9 Reconnect the battery cables 10 Close the seat support 11 Start the engine and lower the hopper Check the new relay for proper operation ...

Page 147: ...ELECTRICAL 4 25 6400IC MM433 12 01 ...

Page 148: ...ELECTRICAL 4 26 6400IC MM433 12 01 ELECTRICAL SCHEMATIC GAS LP LIQUID COOLED 1 2 3 4 5 6 7 ...

Page 149: ...ELECTRICAL 4 27 6400IC MM433 12 01 ELECTRICAL SCHEMATIC GAS LP LIQUID COOLED 1 2 3 4 5 6 7 350167 G LP LIQ ...

Page 150: ...ELECTRICAL 4 28 6400IC MM433 12 01 ELECTRICAL SCHEMATIC DIESEL 2 1 2 ...

Page 151: ...ELECTRICAL 4 29 6400IC MM433 12 01 ELECTRICAL SCHEMATIC DIESEL 1 2 350169 D ...

Page 152: ...SED CONTACT START RUN OFF PREHEAT X X X X X X X IGN 19 30 BATT 50 17 N U 20 BLU N U RUN ACC 40 AMPS MAX ALT OUTPUT AT 2500 RPM TURNS ON LIGHT AT LESS THAN 12 3 3 VOLTS ENG TEMP IND LIGHT 19 GRN ENGINE TEMP SWITCH AIR FLOW SHUT OFF SOLENOID 57B PUR 57A PUR 57 PUR 7A GRY 7 GRY 13D BLK 5 PUR 30 GRY 30A GRY 1B RED RED GRN RED FUEL SHUT OFF SOLENOID OPTION WHT WHT WHT RED WHT RUN DIODE START DIODE NOT ...

Page 153: ...OR CLOSED IND LIGHT OPTION DUST FILTER SWITCH WILL CLOSE AT 11 H2O OF DIFFERENTIAL VACUUM HYDR FILTER SWITCH WILL CLOSE WHEN DIFFERENTIAL PRESSURE IS 40 P S I OR GREATER PLUGGED FILTER IND LIGHT OPTION CLOGGED FILTER IND LIGHT OPTION HYDR CLOGGED FILTER SWITCH OPTION N O 13AB BLK 52A BRN 52 BRN HOPPER DOOR CLOSED SWITCH OPTION PLUGGED DUST FILTER SWITCH OPTION HOPPER DOOR CLOSED N O 54 YEL N O 75C...

Page 154: ...ELECTRICAL 4 32 6400IC MM433 12 01 WIRE HARNESS GROUP GAS LP LIQUID COOLED ...

Page 155: ...D FROM THE REAR LOW FUEL LPG ONLY 74C YEL 74B YEL 18E ORA 18F ORA 25 GRN 72A GRN 18D ORA 1C RED 1C RED 1B RED 18A ORA CIRCUIT BREAKERS CB 1 15 AMP HOPPER TEMP VAC FAN CB 2 15 AMP FUEL PUMP OIL PRESSURE ENGINE TEMP CB 3 15 AMP SHAKER MOTOR HOPPER DOOR HOPPER POSITION CLOGGED HYD PLUGGED DUST FILTER BRUSHES CB 4 15 AMP LIGHTS CB 5 15 AMP HORN 85 COIL 86 COIL 30 COMMON CONTACT 87 N O CONTACT 87A N C ...

Page 156: ...ELECTRICAL 4 34 6400IC MM433 12 01 WIRE HARNESS GROUP DIESEL ...

Page 157: ...RICAL 4 35 6400IC MM433 12 01 WIRE HARNESS GROUP DIESEL 18C ORA CB1 STARTING MODE DIODE 1 14B YEL 14A YEL 12A BRN 12 BRN 72A GRN 20C BLU 20B BLU 4D YEL 20B BLU 20A BLU 7 GRY 1B RED 1A RED 1B RED 4 5 350137 D ...

Page 158: ... YEL 74A YEL 75 74E YEL C A A C C C A A C A A C AB LPG LOW FUEL PRESSURE SWITCH LPG ONLY A B 34 BRN 74 YEL 74D YEL 74C YEL 74D YEL 13G BLK 13F BLK 13F BLK 13E BLK MAIN SIDE BRUSHES SV 1 60A ORA 31 BLU 75C ORA 75C ORA 13DA BLK 13DA BLK 3 2 1 HOUR METER 18 ORA ENGINE HOPPER HARNESS MAIN HARNESS SECTION D D D D SECTION C C C C SENDING UNIT HYD FILTER INDICATOR SWITCH 53 BRN LIGHTING SWITCH 75B ORA 75...

Page 159: ... FOR REFERENCE ONLY SECTION G G DETAIL B B CONTROL PANEL VIEWED FROM THE REAR 21 GRY 14 YEL 23 YEL M2 34 BRN 9 BLU 21 GRY 13C BLK 13D BLK 18B ORA 18A ORA 19 GRN 57A PUR 57 PUR 13E BLK 13D BLK 54 YEL 53 BRN 52 BRN CLOGGED HYDR FILTER HOPPER DOOR OPEN CLOSE PLUGGED DUST FILTER HOPPER TEMP LIGHT OIL PRESSURE LIGHT ENGINE TEMP LIGHT CHARGE FAULT LIGHT LOW FUEL LPG ONLY 74C YEL 74B YEL 72A GRN 1C RED 1...

Page 160: ...ELECTRICAL 4 38 6400IC MM433 12 01 ...

Page 161: ...400IC MM433 10 93 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 ...

Page 162: ...NTACT START RUN OFF PREHEAT X X X X X X X 30 BATT 50 20 BLU 13D BLK START DIODE M2 30 21 GRY 85 86 OIL PRESSURE SWITCH 20A BLU 15 AMP STARTER MOTOR STARTER RELAY STARTER SOLENOID MTR 13 BLK ACC LINE M1 BATTERY M1 SW4 18C ORA 23 YEL 13L BLK FUEL PUMP 14E YEL 18E ORA 18F ORA MOTOR 12A BRN D1 15 21 GRY L3 LOW OIL PRESSURE 14B YEL 14D YEL CARB SHUTOFF SOLENOID VALVE SV3 GRND SV4 IGNITION COIL COIL WIR...

Page 163: ...ES ENGINE WILL NOT START ENGINE WILL NOT TURN OVER ENGINE TURNS OVER BUT WILL NOT START CHECK BATTERY KEY SWITCH STARTER MOTOR AND THEIR WIRE CONNECTIONS DOES 14 YEL HAVE BATTERY VOLTAGE TO GROUND WHEN THE KEY SWITCH IS IN THE START POSITION OK EITHER NOT WORKING NO SPARK CHECK TO SEE IF THERE IS SPARK AT THE SPARK PLUGS DURING CRANKING CHECK THE IGNITION COIL AND DISTRIBUTOR REPLACE DEFECTIVE COM...

Page 164: ... 20 BLU 13D BLK START DIODE M2 30 21 GRY 85 86 OIL PRESSURE SWITCH 20A BLU 15 AMP STARTER MOTOR STARTER RELAY STARTER SOLENOID MTR 13 BLK ACC LINE M1 BATTERY M1 SW4 18C ORA 23 YEL 13L BLK FUEL PUMP 14E YEL 18E ORA 18F ORA MOTOR 12A BRN D1 15 21 GRY L3 LOW OIL PRESSURE 14B YEL 14D YEL CARB SHUTOFF SOLENOID VALVE SV3 GRND SV4 IGNITION COIL COIL WIRE DISTRIBUTOR SPARK PLUGS LIQUID COOLED GAS LP ENGIN...

Page 165: ...RTS BUT WILL NOT STAY RUNNING RESET OR REPLACE CB2 IF DEFECTIVE WHEN THE KEY SWITCH IS IN THE ON POSITION WITH THE ENGINE STOPPED IS THERE BATTERY VOLTAGE BETWEEN 1 RED AND 21 GRY NO REPLACE THE OIL PRESSURE SWITCH YES IS THERE BATTERY VOLTAGE BETWEEN 14 YEL AND GROUND DURING ENGINE CRANKING AFTER THE OIL PRESSURE LIGHT HAS GONE OUT NO REPLACE M2 RELAY YES CHECK FUEL FILTER AND REPLACE IF DEFECTIV...

Page 166: ... LINE M1 BATTERY M1 NORMAL MOTOR STARTER CURRENT 75 AMPS SW4 18C ORA 23 YEL 13N BLK SOL 3 FUEL PUMP 14D YEL 18D ORA 18E ORA L4 AC 90 GRY 90A GRY GRND 90D GRY GLOW PLUGS MOTOR 12A BRN 14C YEL 12B BRN 13J BLK WHT RED HOLD SOL 2 PULL IN FUEL SOLENOID D1 GLOW PLUG LAMP TIMER 4 5 6 3 13H BLK 90C GRY 12C BRN 91 BLU 90B GRY GLOW PLUG LAMP GLOW PLUG LAMP INDICATES HOW LONG TO PRE HEAT GLOW PLUGS TOTAL CUR...

Page 167: ...LS OF THE FUEL SOLENOID ARE WORKING PROPERLY CHECK DIODE D1 AND REPLACE IF DEFECTIVE DIESEL ENGINE WILL NOT START NO YES ENGINE WILL NOT START ENGINE WILL NOT TURN OVER ENGINE TURNS OVER BUT WILL NOT START CHECK BATTERY KEY SWITCH STARTER MOTOR AND THEIR WIRE CONNECTIONS DOES 14 YEL HAVE BATTERY VOLTAGE TO GROUND WHEN THE KEY SWITCH IS IN THE START POSITION OK CHECK WITH AN AMMETER TO SEE THAT THE...

Page 168: ...ER CURRENT 75 AMPS SW4 18C ORA 23 YEL 13N BLK SOL 3 FUEL PUMP 14D YEL 18D ORA 18E ORA L4 AC 90 GRY 90A GRY GRND 90D GRY GLOW PLUGS MOTOR 12A BRN 14C YEL 12B BRN 13J BLK WHT RED HOLD SOL 2 PULL IN FUEL SOLENOID D1 GLOW PLUG LAMP TIMER 4 5 6 3 13H BLK 90C GRY 12C BRN 91 BLU 90B GRY GLOW PLUG LAMP GLOW PLUG LAMP INDICATES HOW LONG TO PRE HEAT GLOW PLUGS TOTAL CURRENT DRAW FOR ALL GLOW PLUGS 20 25 AMP...

Page 169: ... WILL NOT STAY RUNNING RESET OR REPLACE CB2 IF DEFECTIVE WHEN THE KEY SWITCH IS IN THE ON POSITION WITH THE ENGINE STOPPED IS THERE BATTERY VOLTAGE BETWEEN 1 RED AND 21 GRY NO REPLACE THE OIL PRESSURE SWITCH YES IS THERE BATTERY VOLTAGE BETWEEN 14 YEL AND GROUND DURING ENGINE CRANKING AFTER THE OIL PRESSURE LIGHT HAS GONE OUT NO REPLACE M2 RELAY YES CHECK FUEL FILTER AND REPLACE IF DEFECTIVE ...

Page 170: ...INDICATES A CLOSED CONTACT START RUN OFF PREHEAT X X X X X X X IGN 19 30 BATT 50 17 N U 20 BLU N U RUN ACC 40 AMPS MAX ALT OUTPUT AT 2500 RPM 13D BLK RED GRN RED FUEL SHUT OFF SOLENOID OPTION WHT WHT WHT RED WHT RUN DIODE START DIODE NOT USED OIL PRESSURE IND LIGHT M3 M2 30 RECTIFIER REGULATOR 21 GRY 85 86 OIL PRESSURE SWITCH SPARK PLUG 20A BLU 87 30 86 85 87A 15 AMP STATOR FLYWHEEL ALTERNATOR 1 2...

Page 171: ...E HARNESS MAY BE OPEN REPLACE ENGINE HARNESS YES YES REPLACE THE ENGINE IGNITION COIL NO REPLACE THE ENGINE SHUTDOWN RELAY NO IS THERE BATTERY VOLTAGE ON THE BATTERY POST OF THE STARTER SOLENOID WITH RESPECT TO GROUND YES NO CHECK BATTERY CABLE CONNECTIONS AND BATTERY IS THERE BATTERY VOLTAGE AT THE STARTER SOLENOID COIL TERMINAL WITH RESPECT TO GROUND WHEN THE KEY SWITCH IS IN THE START POSITION ...

Page 172: ...CH S 3 X INDICATES A CLOSED CONTACT START RUN OFF PREHEAT X X X X X X X IGN 19 30 BATT 50 17 N U 20 BLU N U RUN ACC 40 AMPS MAX ALT OUTPUT AT 2500 RPM 13D BLK RED GRN RED FUEL SHUT OFF SOLENOID OPTION WHT WHT WHT RED WHT RUN DIODE START DIODE NOT USED OIL PRESSURE IND LIGHT M3 M2 30 RECTIFIER REGULATOR 21 GRY 85 86 OIL PRESSURE SWITCH SPARK PLUG 20A BLU 87 30 86 85 87A 15 AMP STATOR FLYWHEEL ALTER...

Page 173: ...NG YES ENGINE STARTS BUT WILL NOT STAY RUNNING NO NO YES THE RUN DIODE IN THE ENGINE HARNESS MAY BE OPEN REPLACE THE ENGINE WIRE HARNESS CHECK FOR BATTERY VOLTAGE TO GROUND AT ANY 18 ORA WIRE WITH THE KEY SWITCH IN THE RUN POSITION NO CHECK THE 15AMP CIRCUIT BREAKER CB1 AND RESET OR REPLACE IF DEFECTIVE IS THERE NOW BATTERY VOLTAGE TO GROUND AT ANY 18 ORA WIRE NO CHECK KEY SWITCH AND THE CIRCUIT B...

Page 174: ...ELECTRICAL 4 52 6400IC MM433 7 99 ...

Page 175: ...EPLACE HOPPER DUMP DOOR CYLINDER 5 55 TO REPLACE STEERING CYLINDER 5 58 TO REPLACE STEERING VALVE 5 62 HYDRAULIC CONTROL VALVE 5 66 TO REPLACE CONTROL VALVE 5 66 HYDRAULIC SOLENOID VALVE 5 69 TO REPLACE SOLENOID VALVE 5 69 TO REPLACE MAIN BRUSH MOTOR 5 73 TO REPLACE SIDE BRUSH MOTOR 5 77 TO REPLACE REAR DRIVE MOTOR 5 80 HYDRAULIC SCHEMATIC 5 85 HYDRAULIC HOSE GROUP 5 87 Page TROUBLESHOOTING 5 90 M...

Page 176: ...HYDRAULICS 5 2 6400IC MM433 7 99 ...

Page 177: ...HYDRAULICS 5 3 6400IC MM433 7 99 INTRODUCTION The hydraulic system consists of the propel pump accessory pump control valve and drive motors ...

Page 178: ...e 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 The hydraulic fluid filter is located at the bottom of the engine compartment...

Page 179: ...er 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 contaminant...

Page 180: ...e machine Drain the fluid into a pan Properly discard the old fluid 4 Open the seat support and locate the hydraulic oil filter at the back left hand side of the machine under the radiator 5 Unthread and discard the hydraulic fluid filter element Hydraulic fluid will drain through the filter head Discard the used hydraulic fluid Loosen the breather filler cap NOTE Be aware the hydraulic filter is ...

Page 181: ...3 8 94 6 Apply a thin coat of hydraulic fluid to the seal of the new hydraulic fluid filter element 7 Thread and hand tighten the new hydraulic fluid filter element on the filter head 8 Refill the hydraulic reservoir AIR COOLED ...

Page 182: ...fill the hydraulic fluid reservoir Do not overfill 4 Check the hydraulic fluid level in the reservoir with the fluid level dipstick 5 Add hydraulic fluid until the level in the reservoir is between the ADD and the FULL range Do not overfill NOTE Do not overfill the hydraulic fluid reservoir Hydraulic fluid expands as it reaches its normal operating temperature Always allow for expansion when filli...

Page 183: ...a variable displacement hydraulic piston pump The machine accessory pump is a hydraulic gear pump After repairing or replacing a hydraulic pump or when system contamination is likely change the hydraulic fluid in the reservoir and the hydraulic fluid filter AIR COOLED LIQUID COOLED ...

Page 184: ...age the support bar Remove the front rubber firewall FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Open the seat support and disconnect the battery cables 3 Remove the hose leading from the air cleaner to the machine lintel ...

Page 185: ...e propel pump bracket to the engine bellhousing bracket 6 Disconnect and plug the hydraulic charge line leading to the back of the propel pump 7 Remove the two hex screws holding the accessory pump and directional bracket to the propel pump Move the directional spring assembly out of the way NOTE Do not disconnect the hydraulic hoses leading to the accessory pump ...

Page 186: ... hydraulic cleanliness requirements when opening hydraulic lines 9 Mark disconnect and plug the hydraulic hoses leading to the propel pump 10 Remove the two hex screws holding the propel pump to the bellhousing Pull the propel pump out of the bellhousing and remove it from the machine 11 Remove the hydraulic fittings from the old pump and install in the new pump in the same orientation ...

Page 187: ... tighten to 36 40 Nm 27 30 ft lb Use loctite 242 blue on the threads 14 Reconnect the hydraulic hoses to the new propel pump See the hose pictorial in this section NOTE Do not reconnect the charge line to the propel pump until after the accessory pump and directional spring mount bracket are installed 15 Position the accessory pump in the back of the new propel pump Make sure the O ring is in plac...

Page 188: ...mp mount bracket with the mount holes in the accessory pump Reinstall the two hex screws and tighten to 36 40 Nm 27 30 ft lb Use loctite 242 blue on the threads 18 Reconnect the charge line to the propel pump 19 Reinstall the directional arm to the propel pump Leave the three hex screws loose for now 20 Reinstall the hose to the air cleaner and machine lintel ...

Page 189: ...connect the battery cables Reinstall the front rubber firewall 22 Raise the rear drive tire off the floor Place jack stands under the frame 23 Adjust the neutral centering of the new propel pump See TO ADJUST DIRECTIONAL SPRING instructions ...

Page 190: ...ngage the support bar Remove the front rubber firewall FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Open the seat support and disconnect the battery cables 3 Remove the hose leading from the air cleaner to the machine lintel ...

Page 191: ...g the hydraulic charge line leading to the back of the propel pump NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 6 Disconnect and plug the hydraulic hoses leading to the accessory pump 7 Remove the two hex screws holding the accessory pump and directional bracket to the propel pump Move the directional spring assembly out of the way ...

Page 192: ...ry pump and propel pump 9 Remove the fittings from the old accessory and install in the new accessory pump in the same orientation 10 Position the new accessory pump in the back of the propel pump Make sure the O ring is in place on the accessory pump 11 Position the directional spring mount bracket over the mounting flange on the new accessory pump ...

Page 193: ...e two hex screws and tighten to 36 40 Nm 27 30 ft lb Use loctite 242 blue on the threads 13 Reconnect the charge line to the propel pump NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 14 Reinstall the hose to the air cleaner and machine lintel 15 Reconnect the battery cables Reinstall the front rubber firewall ...

Page 194: ...ULICS 5 20 6400IC MM433 7 99 16 Raise the rear drive tire off the floor Place jack stands under the frame 17 Adjust the neutral centering of the new propel pump See TO ADJUST DIRECTIONAL SPRING instructions ...

Page 195: ...arking Brake Turn Off Machine And Remove Key 1 Open the seat support and disconnect the battery cables 2 Remove the three hex screws holding the directional arm to the propel pump 3 Disconnect and plug the hydraulic charge line leading to the back of the propel pump NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines ...

Page 196: ...ccessory pump 5 Pull the accessory pump out of the back of the propel pump Do not loose the rubber O ring from between the accessory pump and propel pump 6 Disconnect and plug the hydraulic hoses leading to the propel pump NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 7 Remove the two hex screws holding the propel pump to the bellhousing Pull the propel pump out of t...

Page 197: ...ump in the same orientation 10 Position the new propel pump in the bellhousing Reinstall the two hex screws and tighten to 36 40 Nm 27 30 ft lb Use loctite 242 blue on the threads 11 Reconnect the hydraulic hoses to the new propel pump See the hose pictorial in this section NOTE Do not reconnect the charge line to the propel pump until after the accessory pump and directional spring mount bracket ...

Page 198: ...on the accessory pump 14 Line up the holes in the pump mount bracket with the mount holes in the accessory pump Reinstall the two hex screws and tighten to 36 40 Nm 27 30 ft lb Use loctite 242 blue on the threads 15 Reconnect the charge line to the propel pump NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 16 Reinstall the directional arm to the propel pump Leave the ...

Page 199: ...C MM433 7 99 17 Reconnect the battery cables 18 Raise the rear drive tire off the floor Place jack stands under the frame 19 Adjust the neutral centering of the new propel pump See TO ADJUST DIRECTIONAL SPRING instructions ...

Page 200: ...et Parking Brake Turn Off Machine And Remove Key 1 Open the seat support and disconnect the battery cables 2 Disconnect and plug the hydraulic charge line leading to the back of the propel pump NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 3 Disconnect and plug the hydraulic hoses leading to the accessory pump ...

Page 201: ...he way 5 Pull the accessory pump out of the back of the propel pump Do not loose the rubber O ring from between the accessory pump and propel pump 6 Remove the fittings from the old accessory pump and install in the new accessory pump in the same orientation 7 Position the new accessory pump in the back of the propel pump Make sure the O ring is in place on the accessory pump ...

Page 202: ...w accessory pump Reinstall the two hex screws and tighten to 36 40 Nm 27 30 ft lb Use loctite 242 blue on the threads 10 Reconnect the charge line to the propel pump 11 Reconnect the battery cables Reinstall the front rubber firewall 12 Raise the rear drive tire off the floor Place jack stands under the frame 13 Adjust the neutral centering of the new propel pump See TO ADJUST DIRECTIONAL SPRING i...

Page 203: ... move when the pedal neutral position is adjusted correctly The pedal linkages should also be adjusted whenever the reverse is faster or slower than machine specification TO REPLACE DIRECTIONAL SPRING Liquid cooled 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 disconnect the battery cables 2 Remove...

Page 204: ...st jam nut washer propel cable bracket and 2nd jam nut from the end of the directional cable NOTE Make note of the location of the 2nd jam nut for proper re assembly 6 Loosen the large jam nut holding the directional spring to the directional spring mount bracket Pull the directional spring up out of the slot NOTE Mark the directional cable before removing the directional spring to make sure the n...

Page 205: ...Position the new spring in the same location on the cable as the old one 9 Place the new directional spring in the mount slot Tighten the large jam nut firmly 10 Reinstall the 1st jam nut cable bracket rubber washer 2nd jam nut and ball end Tighten the jam nuts in the same location as they were removed 11 Install a new plastic wire tie around the cable bracket ...

Page 206: ...00IC MM433 7 99 12 Reconnect the cable ball end to the propel pump arm Tighten the hex screw to 11 14 Nm 7 10 ft lb 13 Reinstall the lower hose on the air cleaner assembly 14 See TO ADJUST DIRECTIONAL SPRING instructions ...

Page 207: ... On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the hopper and engage the support bar Remove the front rubber firewall 2 Open the seat support and disconnect the battery cables 3 Remove the two hydraulic tank straps Lift the tank up far enough to access the cable Do not disconnect the hydraulic hoses ...

Page 208: ...he hex screw spacer and nyloc nut holding the directional spring ball end to the propel pump arm 6 Cut the plastic tie from around the propel cable bracket 7 Remove the ball end 1st jam nut washer propel cable bracket and 2nd jam nut from the end of the directional cable NOTE Make note of the location of the 2nd jam nut for proper re assembly ...

Page 209: ... the slot NOTE Mark the directional cable before removing the directional spring to make sure the new spring is install in the same location 9 Un screw the directional spring from the directional cable 10 Push the directional cable through the large cable clamp under the hydraulic accessory pump 11 Go to the operators compartment and remove the floor plate access panel ...

Page 210: ...emove the clamp holding the directional cable to the side panel of the operators compartment 15 Remove the old directional cable from the machine Remove the rod end from the old cable and install on the new cable in the same location NOTE One end of the new cable has 1 inch of thread and the other end has 1 1 2 inch of thread The end with 1 inch of thread goes toward the directional pedal and the ...

Page 211: ...f the operators compartment Tighten the large jam nut tight 19 Reconnect the cable clevis to the directional pedal Tighten the hex screw and nyloc to 11 14 Nm 7 10 ft lb 20 Reinstall the floor access plate 21 Position the hydraulic tank back down on the frame Reinstall the two tank straps ...

Page 212: ... Reinstall the 1st jam nut cable bracket rubber washer 2nd jam nut and ball end Tighten the jam nuts in the same location as they were removed NOTE Make note of the location of the 2nd jam nut for proper re assembly 25 Install a new plastic wire tie around the cable bracket Reinstall the front rubber firewall 26 Reconnect the cable ball end to the propel pump arm Tighten the hex screw to 11 14 Nm ...

Page 213: ...e Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the rear of the machine and install jack stands under the machine frame 2 Open the seat support 3 Start the machine and check the rear tire for any rotation If the tire is rotating in either direction the centering spring needs to be adjusted ...

Page 214: ...the directional arm either clockwise or counter clockwise to achieve neutral centering 6 Check to make sure the rear tire is not turning with the engine running If the tire is not turning tighten the three hex screws on the directional arm Tighten to 18 24 Nm 15 20 ft lb 7 Remove the jack stands and lower the machine Check to make sure the machine does not creep ...

Page 215: ...chine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support and disconnect the battery cables 2 Remove the hex screw and nyloc nut holding the directional spring ball end to the propel pump arm Retain the two spacers 3 Cut the plastic tie from around the propel cable bracket ...

Page 216: ...mount bracket Pull the directional spring up out of the slot NOTE Mark the directional cable before removing the directional spring to make sure the new spring is install in the same location 6 Un screw the directional spring from the directional cable 7 Install the new directional spring on the old directional cable thread it on completely Position the new spring in the same location on the cable...

Page 217: ...ut and ball end Tighten the jam nuts in the same location as they were removed 10 Install a new plastic wire tie around the cable bracket 11 Reconnect the cable ball end to the propel pump arm Tighten the hex screw to 11 14 Nm 7 10 ft lb 12 See TO ADJUST DIRECTIONAL SPRING instructions ...

Page 218: ...arking Brake Turn Off Machine And Remove Key 1 Open the seat support and disconnect the battery cables 2 Remove the hex screw and nyloc nut holding the directional spring ball end to the propel pump arm Retain the two spacers 3 Remove the two hydraulic tank straps Lift the tank up far enough to access the cable Do not disconnect the hydraulic hoses ...

Page 219: ...E Make note of the location of the 2nd jam nut for proper re assembly 6 Loosen the large jam nut holding the directional spring to the directional spring mount bracket Pull the directional spring up out of the slot NOTE Mark the directional cable before removing the directional spring to make sure the new spring is install in the same location 7 Un screw the directional spring from the directional...

Page 220: ...d 9 Reach in through the access hole and remove the hex screw and nyloc nut holding the clevis on the end of the directional cable to the directional pedal assembly 10 Loosen the large jam nut holding the directional cable to the floor plate Drop the directional cable out of the slot 11 Remove the old directional cable from the machine Remove the clevis from the old cable and install on the new ca...

Page 221: ... The end with 1 inch of thread goes toward the directional pedal and the end with 1 1 2 inch of thread goes toward the propel pump 13 Position the new cable in the slot on the bottom of the operators compartment Tighten the large jam nut tight 14 Reconnect the cable clevis to the directional pedal Tighten the hex screw and nyloc to 11 14 Nm 7 10 ft lb 15 Reinstall the floor access plate ...

Page 222: ...irectional spring on the new directional cable Position it in the new cable in the same location as it was removed from the old cable 18 Place the old directional spring and new cable in the mount slot Tighten the large jam nut firmly 19 Reinstall the 1st jam nut cable bracket 2nd jam nut and ball end Tighten the jam nuts in the same location as they were removed ...

Page 223: ...new plastic wire tie around the cable bracket 21 Reconnect the cable ball end to the propel pump arm Tighten the hex screw to 11 14 Nm 7 10 ft lb NOTE Make sure the spacer in place under the ball end 22 See TO ADJUST DIRECTIONAL SPRING instructions ...

Page 224: ...Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the rear of the machine and install jack stands under the machine frame 2 Open the seat support 3 Start the machine and check the rear tire for any rotation If the tire is rotating in either direction the centering spring needs to be adjusted ...

Page 225: ...the directional arm either clockwise or counter clockwise to achieve neutral centering 6 Check to make sure the rear tire is not turning with the engine running If the tire is not turning tighten the three hex screws on the directional arm Tighten to 18 24 Nm 15 20 ft lb 7 Remove the jack stands and lower the machine Check to make sure the machine does not creep ...

Page 226: ...s Remove the front rubber firewall FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Disconnect and cap the two hydraulic hoses leading to the hopper lift cylinder NOTE Always observe hydraulic cleanliness requirements when opening hydraulic lines 5 Remove the inside cotter pin from the upper clevis pin on the upper end of the ...

Page 227: ...emove the hopper lift cylinder from the machine 8 Remove the fittings from the old cylinder and install in the new cylinder in the same orientation 9 Position the new cylinder in the machine with the rod end pointing to the front of the machine 10 Align the bottom of the lift cylinder with the hole in the frame mount lug Reinstall the clevis pin and cotter pin ...

Page 228: ...hole in the lift arm cylinder mount lug Reinstall the clevis pin and cotter pin 12 Reconnect the hydraulic hoses to the new cylinder See schematic in this section 13 Start the machine and operate the hopper Check for any leaks and proper operation Reinstall the front rubber firewall ...

Page 229: ...3 Set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Disconnect and plug the two hoses leading to the hopper dump door cylinder 5 Remove the cotter pin and clevis pin from the top of the dump door cylinder were it attaches to the center rear of the debris hopper ...

Page 230: ...door cylinder were it attaches to the center of the dump door 7 Remove the old cylinder from the hopper 8 Remove the fittings from the old cylinder and install in the new cylinder in the same orientation 9 Position the new cylinder in the machine with the rod end pointing to the center of the dump door ...

Page 231: ...er 11 Reinstall the clevis pin and cotter pin in the upper end of the dump door cylinder 12 Reconnect the hydraulic hoses to the dump door cylinder See the schematic in this section 13 Start the machine and open and close the hopper dump door Check for any leaks and proper operation Reinstall the front rubber firewall ...

Page 232: ... Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the rear of the machine with a hoist or floor jack Put jack stands under the rear frame 2 Open the seat support 3 Turn the steering wheel to the left so the rear drive casting can be accessed from the fuel tank area of the machine ...

Page 233: ... drive motor hydraulic hoses to rear casting Move the hoses to gain access to the steering cylinder 6 Remove the hex screw and nut holding the steering cylinder rod end balljoint to the rear drive casting 7 Disconnect and cap the two hydraulic hoses leading to the steering cylinder NOTE Always observe hydraulic cleanliness requirements when opening hydraulic lines ...

Page 234: ...ylinder in the same orientation 10 Remove the ball joint ends from the old cylinder and install on the new cylinder Make sure that the balljoints are pointed down and the center line distance between them is 18 75 in 11 Position the new steering cylinder and balljoint assembly in the machine with the rod part of the cylinder toward the rear of the machine ...

Page 235: ...the steering cylinder See schematic in this section NOTE Always observe hydraulic cleanliness requirements when opening hydraulic lines 14 Reinstall the clamp holding the drive motor hydraulic hoses to rear casting 15 Remove the jack stands from machine and lower 16 Start machine and turn steering wheel in both directions Observe the steering cylinder for any leaks ...

Page 236: ...the front rubber firewall FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Turn off the engine and engage the parking brake Open the seat support 3 Remove battery cables from battery 4 Remove the rubber cap in the center of the steering wheel ...

Page 237: ...he steering wheel from the steering valve shaft 6 Tilt the steering wheel to the lowest position 7 Remove and plug the five hydraulic hoses on the steering control motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 8 Remove the hex screws holding the hydraulic steering valve to the steering column ...

Page 238: ... motor Install the fittings in the new valve in the same orientation 11 Install the new hydraulic steering valve in the machine Position the ports in the same orientation as the old valve Reinstall the hex screws and tighten to 31 40 Nm 27 35 ft lb 12 Reconnect the hydraulic hoses to hydraulic steering valve See the schematic in this section ...

Page 239: ...on the steering column Tighten the wheel nut to 18 24 Nm 15 20 ft lb 14 Reinstall the rubber steering wheel cover 15 Reconnect the battery cables and start engine Turn the steering wheel and check for any leaks and proper operation Reinstall the front rubber firewall ...

Page 240: ...low to the main and side brushes The main and side brushes will only turn on when the hopper is in the down position TO REPLACE 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 seat support 2 Remove the hair pins C pins and tension spring holding the valve handles to the valve ...

Page 241: ...emove the two M6 hex screws and nyloc nuts holding the control valve to the valve mount bracket Remove the valve from the machine 5 Remove the fittings from the old valve and install in the new valve in the same orientation 6 Install the new valve back on the valve mount bracket Reinstall the two M6 hex screws and nyloc nuts Tighten to 115 225 Ncm 10 20 in lb OUT IN BYD B D OUT IN BYD B D ...

Page 242: ...ydraulic hoses See schematic in this section 8 Reinstall the two valve handles C pins and hair pins on the new valves 9 Reconnect the tension spring to the left handle 10 Start the machine and check the control valve for proper operation OUT IN BYD B D ...

Page 243: ...e brush or main brush handles are placed in the down position The solenoid valve also contains a relief valve to protect the hydraulic system from damage TO REPLACE SOLENOID VALVE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the hopper and engage the support bar Remove the front rubber firewall 2 Open the seat suppor...

Page 244: ... disconnect and plug the hydraulic hoses leading to the solenoid valve 5 Un plug the two electrical coils from the main harness 6 Go in front of the machine and down under the brush wrap Locate the two hex screws holding the solenoid valve to the machine frame Remove the valve from the machine T3 M1 M2 T2 P T1 T4 ...

Page 245: ...ation 8 Position the new valve in the machine Line up the holes in the frame with the two holes in the valve Reinstall the two hex screws and tighten to 18 24 Nm 15 20 ft lb 9 Reconnect the hydraulic hoses See schematic in this section 10 Reconnect the two electrical coils to the main harness T3 M1 M2 T2 P T1 T4 T3 M1 M2 T2 P T1 T4 ...

Page 246: ...YDRAULICS 5 72 6400IC MM433 7 99 11 Reinstall the battery and connect the battery cables 12 Start the machine and check the new valve for any leak and proper operation Reinstall the front rubber firewall ...

Page 247: ...vicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Remove the main brush from the machine 3 Remove the four hex screws holding the dust skirt assembly plate to the machine Remove the skirt assembly from the machine 4 Remove and plug the hydraulic hoses leading to the main brush motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines ...

Page 248: ...from turning and remove the castle nut 7 A puller must be used to remove the brush drive plug from tapered shaft on the main brush motor 8 Remove the four hex screws holding the main brush motor to the brush arm Remove the motor from the machine 9 Remove the hydraulic fittings from old motor and install in the new motor in the same orientation ...

Page 249: ...the hydraulic hoses to the new motor See schematic in this section 12 Reinstall the brush drive plug onto the tapered shaft of the new motor Make sure the key is in place 13 Reinstall the castle nut and tighten to 40 54 Nm 30 40 ft lb Continue to tighten castle nut until it lines up with hole in brush motor shaft Install a new cotter pin ...

Page 250: ...ULICS 5 76 6400IC MM433 8 94 14 Reinstall the dust skirt assembly on the machine Tighten the hex screws to 18 24 Nm 15 20 ft lb 15 Reinstall the main brush Operate the machine and check for proper operation ...

Page 251: ...cing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Remove the side brush retaining pin from the side brush drive shaft by pulling the pin keeper over the end of the pin 5 Remove the side brush from the side brush motor 6 Remove and plug the hydraulic hoses leading to the side brush motor Note Observe hydraulic cleanliness requirements when opening hydraulic line...

Page 252: ... side brush motor from machine 8 Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation 9 Install the new side brush motor and the side brush guard on the mount bracket Tighten the four hex screws to 27 35 ft lb 10 Reconnect the hydraulic hoses to the side brush motor See schematic in this section ...

Page 253: ...otor 12 Reinstall the side brush retaining pin through the side brush hub and shaft 13 Secure the pin by clipping the pin keeper over the end of the pin 14 Disengage the hopper support bar and lower the hopper 15 Adjust the side brush pattern with the side brush down pressure lever ...

Page 254: ...Engage the parking brake and block the front tires 2 Jack up the rear of the machine Use jack stands to support machine FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 3 Remove the rear tire and wheel assembly from the drive motor hub 4 Remove the cotter pin and slotted nut from drive wheel shaft ...

Page 255: ...connect the hydraulic hoses from the drive motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 7 Remove the four motor mounting bolts 8 Slide the motor out of the rear wheel housing 9 Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation ...

Page 256: ...g orientation 11 Reinstall the four hex head screws and tighten to 88 115 Nm 65 85 ft lb 12 Reconnect the hydraulic hoses See schematic in the HYDRAULICS section 13 Mount the drive hub to the tapered motor shaft Tighten the castle nut to 270 Nm 200 ft lb and put new 0 125 x 2 50 cotter pin through slotted nut ...

Page 257: ...HYDRAULICS 5 83 6400IC MM433 8 94 14 Install the rear tire Tighten the nuts to 122 150 Nm 90 110 ft lb 15 Remove the jack stands and lower the machine ...

Page 258: ...HYDRAULICS 5 84 6400IC MM433 12 01 Fig 1 Hydraulic Schematic Liquid cooled 350156 LIQ ...

Page 259: ...HYDRAULICS 5 85 6400IC MM433 12 01 Fig 1 Hydraulic Schematic Liquid cooled 350156 LIQ ...

Page 260: ...HYDRAULICS 5 86 6400IC MM433 12 01 Fig 2 Hydraulic Schematic Air Cooled ...

Page 261: ...HYDRAULICS 5 87 6400IC MM433 12 01 Fig 2 Hydraulic Schematic Air Cooled 350157 AIR ...

Page 262: ... T3 T1 M2 T2 P G R E P L T BYD C D B A IN OUT IN OUT STEERING CYLINDER REAR DRIVE MOTOR HYDRAULIC RESERVOIR HYDRAULIC FILTER MAIN BRUSH MOTOR HOPPER LIFT CYLINDER PROPEL PUMP SOLENOID CONTROL VALVE STEERING VALVE SIDE BRUSH MOTOR DUMP DOOR CYLINDER MAIN CONTROL VALVE ACCESSORY PUMP ...

Page 263: ...T3 T1 M2 T2 P G R E P L T BYD C D B A IN OUT IN OUT STEERING CYLINDER REAR DRIVE MOTOR HYDRAULIC RESERVOIR HYDRAULIC FILTER HOPPER LIFT CYLINDER PROPEL PUMP ACCESSORY PUMP SOLENOID CONTROL VALVE MAIN BRUSH MOTOR STEERING VALVE SIDE BRUSH MOTOR DUMP DOOR CYLINDER MAIN CONTROL VALVE ...

Page 264: ...6400IC MM433 4 94 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 ...

Page 265: ...AIN PRESSURE READINGS BASED ON 150 F MAIN BRUSH ON CIRCUIT STRAINER RV3 IN PROPEL PUMP 85 PSI 3 8 GPM 2400 RPM LIQUID COOLED SV1 SV2 RV4 2150 PSI M1 M2 T4 T3 T1 T2 G P RV6 25 PSI SIDE BRUSH MAIN BRUSH FILTER PUMP x 500 PSI 2700 RPM AIR COOLED W VAC FAN ON 400 20 RPM ...

Page 266: ...OR PLUMBING OK SV1 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV1 STEM CARTRIDGE YES NO PUMP OUTLET FLOW OK MAIN BRUSH DOES NOT TURN ON YES NO MOTOR INLET FLOW OK NO YES REPAIR OR REPLACE PLUMBING NO YES REPAIR OR REPLACE PUMP YES RV RELIEF CARTRIDGE OK NO REPAIR OR REPLACE RV RELIEF CARTRIDGE NO ...

Page 267: ...3 6400IC MM433 NIL SV1 STEM MAGNETIZED CHECK ELECTRICAL SYSTEM SV1 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV1 STEM CARTRIDGE YES NO MAIN BRUSH DOES NOT TURN OFF NO BRUSH SPEED LESS THAN 10 RPM SYSTEM OK YES NO ...

Page 268: ...ADINGS BASED ON 150 F MAIN BRUSH SIDE BRUSH ON CIRCUIT STRAINER RV3 IN PROPEL PUMP 85 PSI SV1 SV2 RV4 2150 PSI M1 M2 T4 T3 T1 T2 G P RV6 25 PSI SIDE BRUSH MAIN BRUSH FILTER PUMP x 700 PSI 200 PSI x 3 8 GPM 2400 RPM LIQUID COOLED 2700 RPM AIR COOLED W VAC FAN ON 400 20 RPM 90 5 RPM ...

Page 269: ...OR PLUMBING OK SV2 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV2 STEM CARTRIDGE YES NO PUMP OUTLET FLOW OK SIDE BRUSH DOES NOT TURN ON YES NO MOTOR INLET FLOW OK NO YES REPAIR OR REPLACE PLUMBING NO YES REPAIR OR REPLACE PUMP YES RV RELIEF CARTRIDGE OK NO REPAIR OR REPLACE RV RELIEF CARTRIDGE NO ...

Page 270: ...5 96 6400IC MM433 NIL SV2 STEM MAGNETIZED CHECK ELECTRICAL SYSTEM SV2 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV2 STEM CARTRIDGE YES NO SIDE BRUSH DOES NOT TURN OFF NO BRUSH SPEED 10 RPM SYSTEM NORMAL NO YES ...

Page 271: ...EADINGS BASED ON 150 F R L STEERING CIRCUIT RIGHT TURN FILTER RV6 25 PSI PUMP STRAINER RV3 IN PROPEL PUMP 85 PSI x 300 PSI STATIONARY P E T RV5 1500 PSI 650 PSI TURNING 1500 PSI HELD AT STOP ON STEERING WHEEL STRG CYL 3 2 GPM 2400 RPM LIQUID COOLED 2700 RPM AIR COOLED W VAC FAN ON ...

Page 272: ...EADINGS BASED ON 150 F R L STEERING CIRCUIT LEFT TURN FILTER RV6 25 PSI PUMP STRAINER RV3 IN PROPEL PUMP 85 PSI x 300 PSI STATIONARY P E T RV5 1500 PSI 650 PSI TURNING 1500 PSI HELD AT STOP ON STEERING WHEEL STRG CYL 3 2 GPM 2400 RPM LIQUID COOLED 2700 RPM AIR COOLED W VAC FAN ON ...

Page 273: ...R REPLACE PLUMBING PUMP OUTLET FLOW OK REPAIR OR REPLACE PUMP YES NO POWER STEERING IS NOT NORMAL NO STEER CYLINDER ROD ENDS SEALS OK REPAIR OR REPLACE STEER CYLINDER OR ROD ENDS NO YES STEERING INLET PRESSURE OK REPAIR OR REPLACE STEERING CONTROL NO YES ...

Page 274: ...AIN PRESSURE READINGS BASED ON 150 F HOPPER DOOR CIRCUIT PUMP STRAINER RV5 IN STEERING CIRCUIT 1500 PSI 3 2 GPM 2400 RPM LIQUID COOLED 2700 RPM AIR COOLED W VAC FAN ON CLOSED 1500 PSI DOOR HELD CLOSED C D A B DOOR LIFT CLOSE LIFT IN OUT BYD x RV3 IN PROPEL PUMP 85 PSI ...

Page 275: ...MANUAL CONTROL VALVE PLUMBING OK REPAIR OR REPLACE PLUMBING YES NO HOPPER DOOR DOES NOT OPEN NO DOOR CYLINDER CLEVIS PINS SEALS OK REPLACE DOOR CYLINDER OR CLEVIS PINS NO YES PUMP OUTLET FLOW OK REPAIR OR REPLACE PUMP NO YES STEERING INLET PRESSURE OK REPAIR OR REPLACE STEERING CONTROL YES NO ...

Page 276: ...TING OK REPAIR OR REPLACE MANUAL CONTROL VALVE PLUMBING OK REPAIR OR REPLACE PLUMBING YES NO NO DOOR CYLINDER CLEVIS PINS SEALS OK REPLACE DOOR CYLINDER OR CLEVIS PINS NO YES PUMP OUTLET FLOW OK REPAIR OR REPLACE PUMP NO YES STEERING INLET PRESSURE OK REPAIR OR REPLACE STEERING CONTROL YES NO ...

Page 277: ...OPPER DOOR DOES NOT STAY CLOSED MANUAL CONTROL VALVE SPOOL SHIFTING OK REPAIR OR REPLACE MANUAL CONTROL VALVE PLUMBING OK REPAIR OR REPLACE PLUMBING YES NO NO DOOR CYLINDER CLEVIS PINS SEALS OK REPLACE DOOR CYLINDER OR CLEVIS PINS NO YES ...

Page 278: ...E DRAIN PRESSURE READINGS BASED ON 150 F HOPPER LIFT CIRCUIT PUMP STRAINER RV3 IN PROPEL PUMP 85 PSI 3 2 GPM 2400 RPM LIQUID COOLED 2700 RPM AIR COOLED W VAC FAN ON 1500 PSI HOPPER UP FULL C D A B DOOR LIFT CLOSE LIFT IN OUT BYD RV5 IN STEERING CIRCUIT 1500 PSI x ...

Page 279: ...MANUAL CONTROL VALVE CYLINDER ORIFICE PLUMBING OK REPAIR OR REPLACE CYLINDER ORIFICE OR PLUMBING YES NO NO LIFT CYLINDER CLEVIS PINS SEALS OK REPAIR OR REPLACE LIFT CYLINDER OR CLEVIS PINS NO YES PUMP OUTLET FLOW OK REPAIR OR REPLACE PUMP NO YES STEERING INLET PRESSURE OK REPAIR OR REPLACE STEERING CONTROL YES NO ...

Page 280: ...ER MANUAL CONTROL VALVE SPOOL SHIFTING OK REPAIR OR REPLACE MANUAL CONTROL VALVE CYLINDER ORIFICE PLUMBING OK REPAIR OR REPLACE CYLINDER ORIFICE OR PLUMBING YES NO NO LIFT CYLINDER CLEVIS PINS SEALS OK REPAIR OR REPLACE LIFT CYLINDER OR CLEVIS PINS NO YES ...

Page 281: ...3 NIL HOPPER DOES NOT HOLD UP POSITION LIFT CYLINDER SEALS OK REPAIR OR REPLACE LIFT CYLINDER MANUAL CONTROL VALVE SPOOL SHIFTING OK REPAIR OR REPLACE MANUAL CONTROL VALVE YES NO NO CAN SAFETY LEG BE PUT IN PLACE SYSTEM OK NO YES ...

Page 282: ...0IC MM433 4 94 PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F PROPEL CIRCUIT STRAINER M RV2 2000 PSI RV1 2000 PSI RV3 85 PSI CV1 CK2 PROPEL MOTOR CK1 x LEVEL 400 PSI 8 RAMP 1800 PSI 9 GPM FULL FWD F R ...

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Page 331: ...CHANGE AN LPG FUEL TANK 6 12 REGULATOR 6 13 VAPORIZER 6 13 CARBURETOR 6 13 LPG FUEL TROUBLESHOOTING 6 14 CYLINDER HEAD 6 14 VALVE TAPPET CLEARANCE 6 14 CRANKCASE VENTILATION SYSTEM 6 14 GOVERNOR 6 14 IGNITION SYSTEM 6 15 SPARK PLUGS 6 15 TO REPLACE SPARK PLUGS 6 15 TO REPLACE ALTERNATOR 6 15 TO REPLACE STARTER 6 16 TO REMOVE ENGINE 6 18 TO INSTALL ENGINE 6 22 AIR COOLED GAS ENGINE SERVICE MANUAL K...

Page 332: ...ENG AIR COOLED 6 2 6400IC MM433 7 99 ...

Page 333: ...ENG AIR COOLED 6 3 6400IC MM433 7 99 INTRODUCTION This section includes repair information on the engine and related systems such as fuel electrical and engine removal ...

Page 334: ...ill the engine with oil to the level indicated on the oil dipstick The engine oil capacity is 1 9 L 2 qt including the oil filter COOLING SYSTEM This engine is air cooled and does not have any anti freeze coolant or a radiator The flywheel mounted fan blows air over the engine cylinders and head to remove engine heat The cooling fins should be cleaned every 100 hours by blowing compressed air acro...

Page 335: ... element nut and inner cover then remove the air filter element Carefully clean the covers 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 ...

Page 336: ...nts are idle fuel mixture and idle speed Check and adjust idle fuel mixture and idle speed every 100 hours of operation FOR SAFETY When Servicing Machine Keep Flames And Sparks Away From Fuel System Service Area Keep Area Well Ventilated The idle speed is controlled by a screw located on the side of the carburetor next to the throttle linkage Increase the engine speed by turning the screw clockwis...

Page 337: ...he LPG is operated with engine vacuum The vaporizer section of the vaporizer regulator converts the liquid LPG fuel into a gaseous LPG fuel From the vaporizer section the gaseous LPG fuel is sent to the primary regulator section of the vaporizer regulator The primary regulator section reduces the pressure of the LPG fuel The secondary regulator section reduces the LPG fuel pressure to the level re...

Page 338: ...ct this epoxy type sealant Be sure to follow application directions and apply proper torque when reconnecting fittings Never bypass safety components except to test If they are defective replace them before operating the machine Frosting does not occur before the engine reaches operating temperature Check after engine reaches operating temperature Check routings of all LPG hoses Keep them away fro...

Page 339: ...t paint or other debris in the valve openings The following specific checks must also be made Filler Valve Check the valve for proper functioning and the presence of the handwheel Valve must be closed except during filling Liquid Service Valves Check the valve for proper functioning and presence of the handwheel The valve must be closed except when in service Tank Service Valve Coupling Check for ...

Page 340: ...ence of the relief valve elbow and the proper direction of the elbow If the rain cap is missing check for foreign matter and replace the rain cap Do not tamper with the relief valve setting Magnetic Liquid Level Gauge Check the operation against the maximum filling point as determined by weight ...

Page 341: ... near combustible materials or high temperature sources such as ovens and furnaces since the heat may raise the pressure of the fuel to a point where the safety relief valves would function Store the tanks in a way that if the safety relief valves do function they will relieve vapor and not liquid Valves on empty tanks must be closed during storage and transportation Similar precautions should be ...

Page 342: ...ank and inspect it for damage or leaks NOTE Make sure the LPG fuel tank matches the fuel system liquid tank with liquid system 10 Carefully put the LPG tank in the machine so that the tank centering pin enters the aligning hole in the tank collar NOTE If you cannot line up the centering pin make sure you have the correct LPG fuel tank and then adjust the pin locator in or out 11 Fasten the tank ho...

Page 343: ... reassemble the regulator with the seal repair kit Check for proper operation VAPORIZER The vaporizer is mounted on the engine shroud The hot air from the engine flows over the vaporizer CARBURETOR If any malfunction is found completely disassemble the carburetor Clean all the parts in alcohol Inspect all the parts and replace where needed Carefully reassemble the carburetor with the seal repair k...

Page 344: ...evenly or lacks power Wrong type of fuel tank vapor withdrawal tank Replace vapor withdrawal tank with liquid withdrawal tank Plugged fuel filter Replace filter Kinked or restricted fuel line Straighten or replace fuel line Engine out of tune Tune up engine Restricted air filter Clean or replace air filter element Vaporizer regulator out of adjustment Adjust vaporizer regulator CYLINDER HEAD See K...

Page 345: ...LUGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set The Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Remove the spark plug wires from the two spark plugs NOTE Clean any dirt from the spark plug seat area before removing the spark plugs 3 Remove the spark plugs from the engine 4 Clean the spark plug seat in the cylinder head 5 Use a new seat gask...

Page 346: ...LACE STARTER 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 2 Disconnect the battery cables 3 Disconnect the wires leading to the back of the starter ...

Page 347: ... and remove it from the machine 6 Install the new starter in the machine Align the two holes in the starter with the holes in the block Reinstall the two hex screws and tighten to 7 Reconnect the wires to the back of the starter See the schematic in the ELECTRICAL section 8 Reconnect the battery cables and start the engine Check the starter for proper operation ...

Page 348: ...REMOVE ENGINE 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 2 Disconnect the battery cables 3 Remove the belt guard on the out side of the engine ...

Page 349: ...ngine and fan assembly 5 Disconnect the throttle cable and choke cable from the engine 6 Remove the muffler clamp holding the exhaust pipe to the engine manifold Slip the pipe down off the manifold 7 Disconnect the wire harness from the starter and engine Move the wires out of the way for engine removal ...

Page 350: ...r 9 Using an overhead hoist hook a chain through the two pick up points on the top of the engine Put a slight amount of tension on the chain 10 Remove the two hex screws holding the propel pump accessory pump assembly to the back of the engine 11 Remove the clamp holding the propel hoses to the back of the engine 12 Remove the four hex screws holding the engine to the engine mount plate ...

Page 351: ...M433 7 99 13 Pull the engine out of the propel pump accessory pump assembly 14 The engine can now be carefully removed from the machine NOTE Make sure the engine is clear of any wires or hoses before you lift it out of the machine ...

Page 352: ...rtment NOTE Make sure the hoses wire harness exhaust pipe and propel pump are pulled back out of the way when lowering engine assembly into place 2 Position the engine in the area of the propel pump accessory pump assembly Slip the pump assembly in the engine coupling Reinstall the two hex screws and tighten to 37 48 Nm 26 34 ft lb NOTE Make sure the splines on pump line up with splines in coupler...

Page 353: ...d under the front right engine mount screw 5 Remove the hoist from the engine 6 Reinstall exhaust pipe back on the engine manifold Reinstall the muffler clamp and hand tighten tight 7 Reconnect the gas line to the engine mounted fuel pump 8 Reconnect the LPG line to the fuel lock off 9 Reconnect the throttle cable and choke cable 10 Reinstall the clamp with the propel hoses on the back of the engi...

Page 354: ...t on the engine pulley leading to the vacuum fan assembly Align and tension the V belt See TO TENSION VACUUM FAN BELT air cooled instructions in the SWEEPING section NOTE Use a straight edge to make sure the sheave on the engine is in line with the sheave on the vacuum fan assembly 13 Reinstall the belt guard on the out side of the engine 14 Reconnect the battery cables to the battery ...

Page 355: ... the machine and place jack stands under the machine frame FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 16 Start the engine and check for any leaks and proper operation ...

Page 356: ...ENG AIR COOLED 6 26 6400IC MM433 7 99 ...

Page 357: ... 7 9 FUEL SYSTEM LPG 7 10 LP FUEL TANKS 7 12 TO CHANGE AN LPG FUEL TANK 7 15 FUEL FILTER LOCK 7 16 VAPORIZER REGULATOR 7 16 CARBURETOR 7 16 GOVERNOR 7 17 LPG FUEL TROUBLESHOOTING 7 18 CYLINDER HEAD 7 18 VALVE CLEARANCE 7 18 CRANKCASE VENTILATION SYSTEM 7 18 IGNITION SYSTEM 7 19 SPARK PLUGS 7 19 TO REPLACE SPARK PLUGS 7 19 TO REPLACE ALTERNATOR 7 20 TO REPLACE STARTER 7 24 TO REMOVE ENGINE 7 26 TO ...

Page 358: ...ENG LIQUID COOLED 7 2 6400IC MM433 7 99 ...

Page 359: ...ENG LIQUID COOLED 7 3 6400IC MM433 7 99 INTRODUCTION This section includes repair information on the engine and related systems such as fuel electrical and engine removal ...

Page 360: ...rs of operation Tighten the clamps if they are loose Replace the hoses and clamps if the hoses are cracked harden or swollen Check the radiator core exterior and hydraulic cooler fins for debris every 100 hours of operation Blow or rinse all dust which may have collected on the radiator in through the grille and radiator fins opposite the direction of normal air flow The grille and hydraulic coole...

Page 361: ...t 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 AIR FILTER INDICATOR OPTIONAL 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 repl...

Page 362: ... ELEMENT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set The Parking Brake Turn Off Machine And Remove Key 1 Start the engine and raise the debris hopper Engage the support bar 2 Unscrew the clamp ring on the filter 3 Remove the dust cap ...

Page 363: ... interior of the air cleaner housing with a camp cloth Clean the element housing sealing surfaces 8 Using an air hose direct dry clean air maximum 205 kPa 30 psi up and down pleats on the inside of the filter Do not rap tap or pound dust out of the element FOR SAFETY When Servicing Machine Wear Eye And Ear Protection When Using Pressurized Air Or Water ...

Page 364: ... to replace the element after cleaning it three times 10 Install the new or cleaned filter element so the fins on the element are at the intake end of the air cleaner Be careful not to damage the fins Make sure the element is seating evenly Tighten the element wing nut 11 Install the dust cap with the arrows pointing up Tighten the clamp ring to hold it in place Check all intake hose connections f...

Page 365: ...w engine to cool Keep flames and sparks away from fuel system service area Keep area well ventilated The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The high idle is set at the factory and cannot be adjusted The low idle fuel adjusting needle is also set at the factory and normally does not need adjustment FOR SAFETY When servicing...

Page 366: ... also stops the flow of LPG fuel when the engine is not operating The LPG is operated with engine vacuum The vaporizer section of the vaporizer regulator converts the liquid LPG fuel into a gaseous LPG fuel From the vaporizer section the gaseous LPG fuel is sent to the primary regulator section of the vaporizer regulator The primary regulator section reduces the pressure of the LPG fuel The second...

Page 367: ...ead sealant when reassembling Aging or high humidity does not affect this epoxy type sealant Be sure to follow application directions and apply proper torque when reconnecting fittings Never bypass safety components except to test If they are defective replace them before operating the machine Frosting does not occur before the engine reaches operating temperature Check after engine reaches operat...

Page 368: ... dirt paint or other debris in the valve openings The following specific checks must also be made Filler Valve Check the valve for proper functioning and the presence of the handwheel Valve must be closed except during filling Liquid Service Valves Check the valve for proper functioning and presence of the handwheel The valve must be closed except when in service Tank Service Valve Coupling Check ...

Page 369: ...sence of the relief valve elbow and the proper direction of the elbow If the rain cap is missing check for foreign matter and replace the rain cap Do not tamper with the relief valve setting Magnetic Liquid Level Gauge Check the operation against the maximum filling point as determined by weight ...

Page 370: ...d near combustible materials or high temperature sources such as ovens and furnaces since the heat may raise the pressure of the fuel to a point where the safety relief valves would function Store the tanks in a way that if the safety relief valves do function they will relieve vapor and not liquid Valves on empty tanks must be closed during storage and transportation Similar precautions should be...

Page 371: ... tank and inspect it for damage or leaks NOTE Make sure the LPG fuel tank matches the fuel system liquid tank with liquid system 10 Carefully put the LPG tank in the machine so that the tank centering pin enters the aligning hole in the tank collar NOTE If you cannot line up the centering pin make sure you have the correct LPG fuel tank and then adjust the pin locator in or out 11 Fasten the tank ...

Page 372: ...pletely disassemble the vaporizer regulator Clean all the parts in alcohol Inspect all the parts and replace where needed Carefully reassemble the vaporizer regulator with the seal repair kit Check for proper operation CARBURETOR If any malfunction is found completely disassemble the carburetor Clean all the parts in alcohol Inspect all the parts and replace where needed Carefully reassemble the c...

Page 373: ...ENG LIQUID COOLED 7 17 6400IC MM433 7 99 GOVERNOR The mechanical governor controls engine speed The governor is factory set and is not user serviceable ...

Page 374: ...rong type of fuel tank vapor withdrawal tank Replace vapor withdrawal tank with liquid withdrawal tank Plugged fuel filter Replace filter Kinked or restricted fuel line Straighten or replace fuel line Engine out of tune Tune up engine Restricted air filter Clean or replace air filter element Vaporizer regulator out of adjustment Adjust vaporizer regulator CYLINDER HEAD See Kubota engine service ma...

Page 375: ...ugs new or used should have the gaps checked and reset if necessary The proper spark plug gap is 1 mm 0 040 in TO REPLACE SPARK PLUGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set The Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Remove the spark plug wires from the three spark plugs NOTE Clean any dirt from the spark plug seat area before remov...

Page 376: ... SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Disconnect the battery cables from the battery 3 Cut any plastic wire ties holding the wire harness to the alternator bracket ...

Page 377: ...ket Remove and retain the heat shield 5 Push the alternator in toward the engine and remove the V belt 6 Disconnect the wires leading to the back of the alternator 7 Remove the hex screw and nyloc nut holding the bottom of the alternator to the lower mount bracket 8 The alternator can now be removed from the machine ...

Page 378: ...he pulley washer and hex nut on the new alternator Firmly tighten the nut with the impact 11 Install the new alternator back in the machine Align the bottom hole in the alternator with hole in lower mount bracket Reinstall the hex bolt ground cable and nyloc nut Leave it loose for now 12 Reconnect the wires to the back of alternator See the schematic in the ELECTRICAL section 13 Place the V belt b...

Page 379: ...ed mounting bracket Pull the alternator toward the operator compartment to tighten the belt See adjustment in ENGINE FAN BELT description Tighten the hex screw to 18 24 Nm 13 18 ft lb 15 Tighten the bottom hex screw to 18 24 Nm 15 20 ft lb 16 Reconnect the battery cables and start the engine Check the new alternator for proper operation ...

Page 380: ...ARTER 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 2 Disconnect the battery cables from the battery 3 Disconnect the wires leading to the back of the starter ...

Page 381: ...and remove it from the machine 6 Install the new starter in the machine Align the two holes in the starter with the holes in the bellhousing Reinstall the two hex screws Tighten to 18 24 Nm 15 20 ft lb 7 Reconnect the wires to the back of the starter See the schematic in the ELECTRICAL section 8 Reconnect the battery cables and check the starter for proper operation ...

Page 382: ...SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Disconnect the battery cables from the battery 3 Remove the large hose leading from the vacuum fan to the shut off assembly ...

Page 383: ...ssembly from the machine 5 Drain the engine oil and remove the engine oil filter NOTE Oil filter must be removed in order to access the right rear motor mount bolt 6 Disconnect the fuel line at the connection between the hose and steel line on a gas machine On an LPG machine disconnect the line leading from the tank to the fuel lockoff vaporizer 7 Drain the coolant from the radiator ...

Page 384: ... assembly Let the filter drop down Do not disconnect the hydraulic hoses 10 Remove the hex screw holding the radiator mount strap to the lower right corner of the radiator assembly 11 Remove the two hex screws holding the radiator assembly to the machine frame 12 Remove the radiator assembly from the machine 13 Remove the hex screws holding the exhaust pipe to the engine manifold ...

Page 385: ...f the way for engine removal 15 Disconnect the engine ground strap from the machine frame 16 Using an overhead hoist hook a chain through the two pick up points on the top of the engine Put a slight amount of tension on the chain 17 Remove the two hex screws and nyloc nuts holding the rear motor mounts to the rubber isolators on the frame brackets ...

Page 386: ...ving the engine 19 Remove the two hex screws holding the front motor mount plate to the bottom of the bellhousing 20 Disconnect the throttle cable and choke cable from the engine 21 Pull the engine back until the hydraulic pump assembly is free of the bellhousing 22 The engine can now be carefully lifted out NOTE Make sure the engine is clear of any wires or hoses before you lift it out of the fra...

Page 387: ...hoses wire harness exhaust pipe and propel pump are pulled back out of the way when lowering engine assembly into place 2 Slide the engine toward the front of the machine until the propel pump is positioned back in the bellhousing Start the two hex screws only Use a small amount of blue loctite 242 on the threads NOTE Make sure the splines on pump line up with splines in coupler when installing pu...

Page 388: ... rear frame bracket may need to be loosened up in order to install both motor mount hex screws 5 Go back and tighten the propel pump hardware to 37 48 Nm 26 34 ft lb 6 Tighten the hex screws holding the front motor mount plate to the bellhousing Tighten to 13 18 Nm 10 13 ft lb 7 Tighten the hex screws holding the rear rubber isolators to the frame mount brackets Hand tighten tight 8 Remove the hoi...

Page 389: ...Reinstall the hex screws and hand tighten tight 11 Install a new engine oil filter and fill the engine with the proper grade of oil On the Gas LPG engine use 3 3 L 3 5 qt 10W 30 SAE SG SH with a new filter 12 Reconnect the wire harness to the engine components alternator starter oil switch temperature sender ect See schematic in the ELECTRICAL section of this manual ...

Page 390: ...er of the radiator assembly Tighten to 18 24 Nm 15 20 ft lb Go back and tighten the two hex screws on the bottom of the mount bracket Tighten to 37 48 Nm 26 34 ft lb 15 Reinstall the radiator hoses to engine and fill the radiator with coolant 16 Position the hydraulic oil filter on the bottom of the radiator mount bracket and reinstall the four hex screws On the standard filter tighten to 11 13 Nm...

Page 391: ...porizer 19 Reconnect the throttle cable and choke cable 20 Reinstall the air cleaner mount bracket and air cleaner assembly to the bottom of the frame lintel Tighten to 18 24 Nm 15 20 ft lb 21 Reinstall the large hose to the vacuum fan and shut off assembly 22 Reconnect the battery cables to the battery ...

Page 392: ... rear of the machine FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 24 Start the engine and check for any leaks and proper operation Reinstall the front rubber firewall ...

Page 393: ...ILTER ELEMENT 8 6 FUEL SYSTEM DIESEL 8 9 FUEL FILTERS 8 9 TO REPLACE THE FUEL FILTER CARTRIDGE 8 9 FUEL LINES 8 10 PRIMING FUEL SYSTEM 8 10 TO PRIME FUEL SYSTEM 8 10 GOVERNOR 8 11 CYLINDER HEAD 8 11 VALVE TAPPET CLEARANCE 8 11 CRANKCASE VENTILATION SYSTEM 8 11 TO REPLACE ALTERNATOR 8 12 TO REPLACE STARTER 8 16 TO REMOVE ENGINE 8 18 TO INSTALL ENGINE 8 23 DIESEL ENGINE SERVICE MANUAL KUBOTA D905B E...

Page 394: ...ENGINE DIESEL 8 2 6400IC MM433 7 99 ...

Page 395: ...ENGINE DIESEL 8 3 6400IC MM433 7 99 INTRODUCTION This section includes repair information on the engine and related systems such as fuel electrical and engine removal ...

Page 396: ...of operation Tighten the clamps if they are loose Replace the hoses and clamps if the hoses are cracked harden or swollen Check the radiator core exterior and hydraulic cooler fins for debris every 100 hours of operation Blow or rinse all dust which may have collected on the radiator in through the grille and radiator fins opposite the direction of normal air flow The grille and hydraulic cooler o...

Page 397: ...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 AIR FILTER INDICATOR OPTIONAL 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 replac...

Page 398: ...LEMENT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set The Parking Brake Turn Off Machine And Remove Key 1 Start the engine and raise the debris hopper Engage the support bar 2 Unscrew the clamp ring on the filter 3 Remove the dust cap ...

Page 399: ...nterior of the air cleaner housing with a camp cloth Clean the element housing sealing surfaces 8 Using an air hose direct dry clean air maximum 205 kPa 30 psi up and down pleats on the inside of the filter Do not rap tap or pound dust out of the element FOR SAFETY When Servicing Machine Wear Eye And Ear Protection When Using Pressurized Air Or Water ...

Page 400: ...o replace the element after cleaning it three times 10 Install the new or cleaned filter element so the fins on the element are at the intake end of the air cleaner Be careful not to damage the fins Make sure the element is seating evenly Tighten the element wing nut 11 Install the dust cap with the arrows pointing up Tighten the clamp ring to hold it in place Check all intake hose connections for...

Page 401: ...proper times Excess fuel is returned to the fuel tank through an overflow pipe FUEL FILTERS The large fuel filter cartridge filters impurities from the fuel It is located low on the left side of the machine below the radiator mount The smaller in line fuel filter is located ahead of the fuel pump It filters out impurities that could damage the fuel pump TO REPLACE THE FUEL FILTER CARTRIDGE FOR SAF...

Page 402: ...om entering the lines Dirt in the lines can cause fuel injection pump malfunction PRIMING FUEL SYSTEM Priming the fuel system removes pockets of air in the fuel lines and fuel components Air in the fuel system will prevent smooth engine operation Prime the fuel system after running out of fuel changing fuel filter element or repairing a fuel system component TO PRIME FUEL SYSTEM FOR SAFETY Before ...

Page 403: ...d is not user serviceable CYLINDER HEAD VALVE TAPPET CLEARANCE The valve tappet clearance must be checked and adjusted if necessary every 400 hours of operation See Kubota Diesel Engine Workshop Manual for 78 4 mm Stroke Series CRANKCASE VENTILATION SYSTEM See Kubota Diesel Engine Workshop Manual for 78 4 mm Stroke Series ...

Page 404: ...AFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Disconnect the battery cables from the battery 3 Cut any plastic wire ties holding the wire harness to the alternator bracket ...

Page 405: ...t Remove and retain the heat shield 5 Push the alternator in toward the engine and remove the V belt 6 Disconnect the wires leading to the back of the alternator 7 Remove the hex screw and nyloc nut holding the bottom of the alternator to the lower mount bracket 8 The alternator can now be removed from the machine ...

Page 406: ... pulley washer and hex nut on the new alternator Firmly tighten the nut with the impact 11 Install the new alternator back in the machine Align the bottom hole in the alternator with hole in lower mount bracket Reinstall the hex bolt ground cable and nyloc nut Leave it loose for now 12 Reconnect the wires to the back of alternator See the schematic in the ELECTRICAL section 13 Place the V belt bac...

Page 407: ... mounting bracket Pull the alternator toward the operator compartment to tighten the belt See adjustment in ENGINE FAN BELT description Tighten the hex screw to 18 24 Nm 13 18 ft lb 15 Tighten the bottom hex screw to 18 24 Nm 15 20 ft lb 16 Reconnect the battery cables and start the engine Check the new alternator for proper operation ...

Page 408: ...TER 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 2 Disconnect the battery cables from the battery 3 Disconnect the wires leading to the back of the starter ...

Page 409: ...d remove it from the machine 6 Install the new starter in the machine Align the two holes in the starter with the holes in the bellhousing Reinstall the two hex screws Tighten to 18 24 Nm 15 20 ft lb 7 Reconnect the wires to the back of the starter See the schematic in the ELECTRICAL section 8 Reconnect the battery cables and check the starter for proper operation ...

Page 410: ...FETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Disconnect the battery cables from the battery 3 Remove the large hose leading from the vacuum fan to the shut off assembly ...

Page 411: ...ine lintel Remove the air cleaner assembly from the machine 5 Drain the engine oil and remove the engine oil filter NOTE Oil filter must be removed in order to access the right rear motor mount bolt 6 Disconnect the fuel line at the injector pump Remove the fuel line were it goes through the radiator mount 7 Drain the coolant from the radiator ...

Page 412: ...ssembly Let the filter drop down Do not disconnect the hydraulic hoses 10 Remove the hex screw holding the radiator mount strap to the lower right corner of the radiator assembly 11 Remove the two hex screws holding the radiator assembly to the machine frame 12 Remove the radiator assembly from the machine 13 Remove the hex screws holding the exhaust pipe to the engine manifold ...

Page 413: ...t of the way for engine removal 15 Disconnect the engine ground strap from the machine frame 16 Using an overhead hoist hook a chain through the two pick up points on the top of the engine Put a slight amount of tension on the chain 17 Remove the two hex screws and nyloc nuts holding the rear motor mounts to the rubber isolators on the frame brackets ...

Page 414: ...n removing the engine 19 Remove the two hex screws holding the front motor mount plate to the bottom of the bellhousing 20 Disconnect the throttle cable from the engine 21 Pull the engine back until the hydraulic pump assembly is free of the bellhousing 22 The engine can now be carefully lifted out NOTE Make sure the engine is clear of any wires or hoses before you lift it out of the frame ...

Page 415: ...ses wire harness exhaust pipe and propel pump are pulled back out of the way when lowering engine assembly into place 2 Slide the engine toward the front of the machine until the propel pump is positioned back in the bellhousing Start the two hex screws only Use a small amount of blue loctite 242 on the threads NOTE Make sure the splines on pump line up with splines in coupler when installing pump...

Page 416: ...ear frame bracket may need to be loosened up in order to install both motor mount hex screws 5 Go back and tighten the propel pump hardware to 37 48 Nm 26 34 ft lb 6 Tighten the hex screws holding the front motor mount plate to the bellhousing Tighten to 13 18 Nm 10 13 ft lb 7 Tighten the hex screws holding the rear rubber isolators to the frame mount brackets Hand tighten tight 8 Remove the hoist...

Page 417: ... 10 Reinstall the exhaust pipe onto the engine manifold Reinstall the hex screws and hand tighten tight 11 Reconnect the fuel line to the injector pump 12 Install a new engine oil filter and fill the engine with the proper grade of oil On the Diesel engine use 5 1 L 5 4 qt 10W 30 SAE CC CD with a new filter ...

Page 418: ...s Leave loose for now 15 Reinstall the hex screw holding the radiator brace to the bottom right corner of the radiator assembly Tighten to 18 24 Nm 15 20 ft lb Go back and tighten the two hex screws on the bottom of the mount bracket Tighten to 37 48 Nm 26 34 ft lb 16 Reinstall the radiator hoses to engine and fill the radiator with coolant 17 Position the hydraulic oil filter on the bottom of the...

Page 419: ...ttle cable 19 Reinstall the air cleaner mount bracket and air cleaner assembly to the bottom of the frame lintel Tighten to 18 24 Nm 15 20 ft lb 20 Reinstall the large hose to the vacuum fan and shut off assembly 21 Reconnect the battery cables to the battery ...

Page 420: ...jacking machine up Jack machine up at designated locations only Block machine up with jack stands 23 Start the engine and check for any leaks and proper operation See TO BLEED FUEL SYSTEM instructions if needed 24 Start the engine and check for any leaks and proper operation Reinstall the front rubber firewall ...

Page 421: ...ave 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 ...

Page 422: ...GE 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 ...

Page 423: ...ave 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 ...

Page 424: ...GE 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 ...

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