Ventrac 2100C, Operator'S Manual

Page 1: ...Serial Number 2100C AP01001 AP01230 VENTRAC COM 2100C Revised 07 01 19 09 10146 Rev 03 Original Operator s Manual Operator s Manual ...

Page 2: ...er ____________________________________________________________________________ Dealer Address _____________________________________________________________________ _____________________________________________________________________ Dealer Phone Number _______________________________________________________________ Dealer Fax Number _______________________________________________________________...

Page 3: ...6 2100 Safety Procedures 16 Testing the Safety Interlock System 17 OPERATIONAL CONTROLS PAGE 18 Operational Control Locations 18 Cluster Gauge A 19 Headlight Switch B 19 Ignition Switch C 19 USB Receptacle D 19 Drive Control Handles E 19 Hydraulic Control Lever F 20 Parking Brake G 20 Choke Handle H 20 Throttle Lever I 20 Latch Handle Lock J 20 Attachment Latch Handle K 20 Auxiliary Hydraulic Quic...

Page 4: ...28 Checking Hydraulic Oil Level 29 Changing Hydraulic Oil Filters 30 Servicing Hydraulic Oil Cooler 31 Checking Engine Oil Level 31 Changing Engine Oil and Filter 32 Air Filter Service and Replacement 33 Filling the Fuel Tank 33 Changing the Fuel Filter 34 Cleaning Engine Compartment Engine 34 Servicing the Battery 34 Removing the Battery 35 Installing the Battery 35 Cleaning the Battery and Termi...

Page 5: ...OTING PAGE 47 Wiring Diagram Reference Key 47 Wiring Harness Diagram 48 Wiring Diagram Optional 30 0219 4 Pin Female Socket 30 0218 4 Pin Male Plug 50 Engine 51 Electrical 52 Hydraulic 52 Power Unit 53 SPECIFICATIONS PAGE 54 Engine 54 Electrical 54 Power Train 54 Controls Instrument Panel 54 Other Features 54 Dimensions 54 Fluid Capacities Specifications 55 Belt Chart 55 WARRANTY PAGE 56 SERVICE C...

Page 6: ... The manual should remain with the machine even if it is sold If this manual becomes damaged or unreadable it should be replaced immediately Con tact your local Ventrac dealer for a replacement When using a Ventrac attachment be sure to read and follow the safety and operating instructions of both the power unit and the attachment being used to ensure the safest operation possible The information ...

Page 7: ...roughout this manual Right Hand and Left Hand is determined as if facing forward from the operator station SIGNAL WORD DEFINITIONS Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is limited to the most extreme cases Indica...

Page 8: ...ty decals legible Remove all grease dirt and debris from safety decals and instructional labels If any decals are faded illegible or missing contact your dealer promptly for replacements When new components are installed be sure that current safety decals are affixed to the replacement components A C E D B C C F C C B F C ...

Page 9: ...s in 7 Do not carry passengers Stop the machine if someone enters the work area 8 Do not operate while under the influence of drugs or alcohol 9 WARNING Hydraulic fluid is under high pressure and can penetrate skin causing injury Keep hands face and body away from pinholes or nozzles that eject hydraulic fluid under high pressure 10 When towing or pushing the power unit the drive pumps must be dis...

Page 10: ...moking is prohibited 1 DANGER Battery acid is caustic and can cause chemical burns Keep by standers a safe distance from the battery 2 Wear eye protection such as goggles or a face shield when checking or servicing batteries 3 Wear appropriate protective gear such as rubber gloves and an apron when checking or servicing batteries 4 Do not expose batteries to arc sparks or open flames Do not use sm...

Page 11: ... parts Be sure guards and shields are in proper working condition and are secured in place Make all necessary adjustments before operating machine Some pictures in this manual may show shields or covers opened or removed in order to clearly illustrate any instructions Under no circumstance should the machine be operated without these devices in place Alterations or modifications to this machine ca...

Page 12: ... in a building without adequate ventilation Do not touch the engine or the muffler while the engine is running or immediately after stopping the engine These areas may be hot enough to cause a burn Do not change the engine governor settings or over speed the engine Operating engine at excessive speed may increase the hazard of personal injury To reduce the hazard of fire keep the battery compartme...

Page 13: ...und to improve stability While operating on slopes drive in an up and down direction when possible If turning is necessary while driving across slopes reduce speed and turn slowly in the downhill direction Assure a sufficient supply of fuel for continuous operation A minimum of one half tank of fuel is recommended Roadway Safety Operate with safety lights when operating on or near roadways Obey al...

Page 14: ...nents while the engine is running or imme diately after stopping the engine These areas may be hot enough to cause a burn Allow the engine to cool before storing and do not store near an open flame Do not change the engine governor settings or over speed the engine Operating engine at excessive speed may increase the hazard of personal injury Springs may contain stored energy Use caution when dise...

Page 15: ... tubes are in good condition Repair any leaks and replace any damaged or deteriorated hoses or tubes before starting the machine Hydraulic leaks can occur under high pressure Hydraulic leaks require special care and attention Use a piece of cardboard and a magnifying glass to locate sus pected hydraulic leaks Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic...

Page 16: ...Resource Code Section 4442 to use or operate this engine on forest covered brush covered or grass covered lane unless the exhaust system is equipped with a spark arrestor maintained in effective working order If your power unit is not equipped with a spark arrestor contact your authorized Ventrac dealer for purchase of a spark arrestor Operating servicing and maintaining off road equipment can exp...

Page 17: ... the parking brake place the drive control handles in neutral or out of neutral and stand on the operator platform or step off the platform The engine should continue running or stop running as described for each test Tests 10 13 test the PTO function For each test turn the key to the RUN position do not start the engine As listed for each test place the PTO switch in the ON or OFF position and st...

Page 18: ...t Switch C Ignition Switch D USB Receptacle E Drive Control Handles F Hydraulic Control Lever G Parking Brake H Choke Handle I Throttle Lever J Latch Handle Lock K Attachment Latch Handle L Auxiliary Hydraulic Quick Couplers M Circuit Breaker Battery Disconnect N Fuel Shut off Valve Optional Operational Controls AA Rear Work Light Switch BB Power Take Off PTO Switch CC Front 12V Switch Momentary O...

Page 19: ...or Stop Position 1 2 3 all 12 volt power going through the key switch is off 2 On or Run Position engine run position 12 volt power is sent to accessories 3 Start Position when the key is turned to the start position the starter will engage USB Receptacle D The USB receptacle has two USB charging ports with a sealed cover Drive Control Handles E The drive control handles are used to control both t...

Page 20: ...ngine Push the choke handle in for operation Throttle Lever I Moving the throttle lever forward toward the 2 1 fast position 1 increases the engine Revolu tions Per Minute RPM Moving the throttle lever backward toward the slow position 2 decreases the engine RPM Latch Handle Lock J The latch handle lock prevents the accidental release of the attachment latch handle To release the attachment latch ...

Page 21: ...cket provides electrical power to attach ments that are equipped with electrical controls e g broom rotation actuator 1 Momentary On 2 Momentary On 2 1 The switch controls the electrical power to the front 4 pin socket Pressing the top 1 or bottom 2 portion of the momentary on off momentary on switch turns on electrical power to the 4 pin socket Releasing the switch turns off electrical power Brin...

Page 22: ... system for operator safety The safety interlock system requires the parking brake to be engaged in order for the engine to start 1 Turn the fuel shut off valve to the On position 2 Set the battery disconnect switch to the On position 3 Pull the choke handle out to the choke on or start position Choke may not be required if the engine is already warm 4 Move the throttle lever to half throttle posi...

Page 23: ...position to make a complete stop If in the case of an emergency the power unit cannot be stopped with the drive control levers pull back on the parking brake handle to engage the parking brake CAUTION If the parking brake is engaged while the power unit is moving the engine will shut off and the power unit will come to an abrupt stop Shutting Off the Engine 1 Park the power unit on a level surface...

Page 24: ...ng brake and shut off the power unit engine 6 Rotate the attachment latch handle forward to the latched position Make sure the latch tabs B are engaged in the lower latch plate and the latch handle lock C is engaged to prevent accidental disengagement of the latch handle 7 B C Place the attachment belt onto the PTO drive pulley on the power unit Ensure the belt is prop erly seated in each pulley 8...

Page 25: ...o lower the attachment Push the lever forward until the float detent engages and holds the lever in place to operate in float Front Auxiliary Couplers CAUTION Dirt and other debris in the hydraulic system can cause damage to the system Wipe the mating parts of the couplers clean before coupling If the attachment requires auxiliary hydraulics couple the attachment hoses with the front auxiliary cou...

Page 26: ...ory Certain attachments or accessories require a 12 volt auxiliary outlet Plug the attachment s 12 volt power cord into the 4 pin outlet The actions of the front 12 volt outlet are controlled by a momentary on off on switch on the right dash panel Towing Or Pushing the Power Unit 1 Attention Avoid damage to your power unit Before tow ing read and understand the information below Severe damage will...

Page 27: ...nnect any hoses and wire harnesses that route through the grommets in the top and right side of the engine covers and pull the hoses harnesses out of the engine covers 6 Remove the three bolts B that fasten the top of the left and right covers to each other and to the tower frame cover B 7 Remove the three bolts C that fasten the left side cover to the airflow divider plate 8 C D Remove the two bo...

Page 28: ...vider plate to the left side cover using a 1 4 x 3 4 bolt C washer and flange nut and a 1 4 x 3 4 socket head cap screw D and washer Do not tighten 8 Install a 1 4 x 3 4 bolt E and washer in the hole where the left and right covers meet 9 Loosely fasten the left and right covers to the front tower cover in the upper corners using two 1 4 x 3 4 bolts F and washers Do not tighten 10 F F G Fasten the...

Page 29: ...treated with a corrosion preventative CAUTION If the engine has been running it must be allowed to cool in order to prevent damage to the block and exhaust manifold Do not direct high pressure water at the engine muffler hydraulic oil cooler or any electrical components Allow the power unit and all components to cool before washing Refer to the specific service section for proper cleaning techniqu...

Page 30: ...Accessory mount shield frame 2 1 4 3 7 5 5 Right door 6 Right engine cover 7 Front access panel engine 8 PTO drive cover 9 PTO belt cover under muffler 6 8 9 Lubrication Locations Lubrication is required at the following locations Refer to the maintenance schedule for service inter vals and amount of grease Refer to Specifications section for grease type Lift Cylinder Lower End Hitch Pivots Operat...

Page 31: ...he hydraulic oil level Park the power unit on a level surface 2 Fully raise the front hitch 3 Engage the parking brake and shut off the engine 4 Remove the key from the ignition switch and allow time for the hydraulic system to cool 5 Remove the operator cushion from the rear pan els of the power unit 6 Remove the dipstick A A from the hydraulic oil tank and wipe with a clean cloth 7 Set the dipst...

Page 32: ...moval drain the filters into the drain pan 13 B Ensure filter mounting surfaces are clean 14 Apply a thin film of clean oil to the gasket of the new large filter and screw the filter onto the filter head until the gasket makes contact with the mounting surface Tighten the filter an additional 3 4 of a turn may require using a strap type filter wrench 15 Apply a thin film of clean oil to the gasket...

Page 33: ...level between the FULL and ADD marks Do not add oil with the engine running Park the power unit on a level surface 2 Engage the parking brake and shut off the engine 3 Remove the key from the ignition switch and allow the engine and oil to cool 4 Open the left door 5 Remove the oil dipstick A from the engine and wipe with a clean cloth 6 A Insert the dipstick back into the engine without threading...

Page 34: ...he oil is warm 8 Remove the oil filter C located on the side of the engine Turn the filter counterclockwise to remove 9 C Wipe the filter mounting surface with a clean cloth 10 Apply a thin film of clean oil to the gasket of the new oil filter 11 Install the new filter turning it clockwise until the gasket makes contact with the mounting surface Tighten the filter 1 2 to 3 4 of a turn more by hand...

Page 35: ... 9 Place the foam element onto the paper filter ele ment and reinstall the air filter cover Filling the Fuel Tank 1 DANGER Fuel is flammable and or explosive Follow all safety instructions in the Fuel Safety section of this manual and in the engine owner s manual WARNING Long term exposure to fuel vapors can cause serious injury or illness Avoid prolonged breathing of fuel vapors If fuel is spille...

Page 36: ...for leaks 13 Close the right door Cleaning Engine Compartment Engine Inspect or clean the engine compartment and engine daily to reduce the risk of engine overheating 1 Park the power unit on a level surface 2 Engage the parking brake and shut off the engine 3 Remove the key from the ignition switch and allow the engine to cool 4 Open the left and right doors 5 Remove accumulated dust or debris fr...

Page 37: ... the cell 7 Rinse the battery with clean water and dry 8 Clean the battery posts and battery cable termi nals with a wire brush 9 Reinstall the battery in the power unit 10 Place the covers back over the battery terminals 11 Close the right door Charging the Battery DANGER Batteries produce explosive gases Charge the battery in a well ventilated space where the gases produced by charging can dissi...

Page 38: ... booster battery s positive terminal 2 7 Connect the negative booster cable to the booster battery s negative terminal 3 8 Connect the other end of the negative booster cable to the disabled power unit s ground stud 4 9 Start the disabled power unit and remove the booster cables in reverse order of installation negative booster cable first Replacing Fuses 1 Park the power unit on a level surface 2...

Page 39: ...rive pulley for easier inspection The PTO drive belt B can be B inspected at the front hitch Typical wear on a drive belt may result in the conditions shown in the diagram If any of these conditions occur the drive belt will require replacement Pump Drive Belt Replacement 1 Park the power unit on a level surface 2 Engage the parking brake and shut off the engine 3 Remove the key from the ignition ...

Page 40: ...wn around the clutch body then pull forward and up between the clutch torque bracket and the power unit frame 9 Remove the belt from the front idler pulleys 10 Install the new belt by sliding one end of the belt down through the main frame in front of the clutch torque bracket Pull the end back underneath the bracket and install onto the clutch pulley 11 Route the belt forward to the idler pulleys...

Page 41: ...A Use the next set of holes in the grip plate to position the grip plate closer to the tire and reinstall onto the brake bar Torque the bolts to 210 in lbs 24 Nm Repeat on opposite side of power unit 8 Engage the parking brake and remove the wheel chocks Parking Brake Switch Adjustment An improperly adjusted parking brake switch can prevent the engine from cranking If the parking brake is engaged ...

Page 42: ...e 10 After adjustment is complete torque the platform switch bracket hardware to 100 in lbs 11 Nm 11 Engage the parking brake turn the ignition key to the Off position and remove the wheel chocks Drive Control Handle Adjustment Drive tracking and top forward speed A are controlled by the pump stop bolt A on both pumps The drive control handles should be adjusted to have a 1 16 1 5 mm gap between t...

Page 43: ...tral arm forward or backward to center the riser tip under the bearing When the neutral arm is positioned correctly torque the nut to 31 ft lbs 42 Nm 8 After both neutral arms have been adjusted inspect and adjust the neutral switches Neutral Switch Adjustment 1 Park the power unit on a level surface 2 Engage the parking brake and shut off the engine 3 Remove the key from the ignition switch 4 Rem...

Page 44: ...ther long term storage 4 months or longer or short term storage less than 4 months Long Term Storage 4 Months or Longer 1 Change the engine oil to prevent damage that can be caused by acidic build up in used motor oil 2 Drain all fuel out of the fuel tank start the power unit and allow to run until the engine stops to ensure all fuel is out of fuel lines carburetor passages etc 3 Turn the key to t...

Page 45: ...information and complete servicing information Silicon Based Spray Lubricant Check Front Hitch Pivot Bolts Torque to 150 ft lbs 203 Nm Ventrac recommends servicing more frequently at 1 2 the standard service interval Check Tire Pressure Check Wheel Lug Nuts Torque to 85 ft lbs 115 Nm Inspect for Loose Missing or Worn Components Inspect Battery Electrical Connections and Lights Inspect Belts Fuel L...

Page 46: ...aper Air Filter Service Engine Remove air cleaner cover Inspect and Clean Clean Engine Compartment Engine and Engine Rotating Screen Inspect Operator Interlock System Check Hydraulic Oil Level Change Hydraulic Filters Replace Fuel Filter Drain Water Sediment from Fuel Tank Hydraulic System Change Hydraulic Oil Parking Brake Parking Brake Inspection Adjustment Inspection Inspect Safety Decals Elect...

Page 47: ...SERVICE Service 47 Ventrac Maintenance Log Model Number ___________________ Serial Number Date Hours Description of Repairs Service Initials ...

Page 48: ...SERVICE Service 48 Ventrac Maintenance Log Date Hours Description of Repairs Service Initials ...

Page 49: ...owever some components such as lights may be wired where black may be positive Components breakout should be covered in High temp Loom rating 500v All other wire colors are as shown Black Ground Lt Blue Safety Circuit Brown Engine Run Kill Gray 12v Aux Horn power Green Start Speed Directional Lt Green 12 Aux Pink Alarm Purple PTO Red Keyed Power White Power Direct to Battery Yellow Light Wire Colo...

Page 50: ...31 A 032 A 037 A 038 A 040 A 041 A 053 A 006 A 001 A 002 A 003 A 004 A 016 A 017 A 018 A 023 A 026 A 027 A 100 A 006 A 023 A 025 A 026 A 027 A 028 A 021 A 024 A 020 A 005 A 036 A 037 A 020 A 021 A 034 A 035 A 020 A 088 A 046 A 059 A 050 C 051 A 052 A 050 A 061 A 063 A 064 A 065 A 138 A 062 A 061 A 062 A 063 A 064 A 065 A 066 A 065 A 067 A 068 A 071 A 072 A 075 A 080 A 076 A 073 A 068 A 054 A 077 A...

Page 51: ...87 A 090 A 094 A 092 A 093 A 089 A 001 A 095 A 097 A 098 A 101 A 106 A 107 A 108 B A A 037 A 025 A 045 A 056 A 057 A 104 A 092 A 096 A B A 051 A 110 A 111 A 112 A 113 A 043 A 110 A 111 A 112 A 114 A 110 A 111 A 112 A 113 C 115 A 090 A 114 A 090 A 101 A 113 B 089 B 090 C 122 C 123 C 124 C 125 D 058 D 127 D 128 D 128 D 129 D 131 D 130 D 131 D 130 E 117 E 132 E 133 E 134 E 135 E 137 E 136 E 138 Charg...

Page 52: ...ack Positive Negative Momentary Switched Reversing 4 White Positive Negative Momentary Switched Reversing 30 0219 4 pin female socket is used in the 70 6006 12 Volt Front Kit 30 0218 4 pin plug is used on attachments to connect to the 30 0219 socket on the power unit 30 0219 4 Pin Female Socket 1 1 2 2 3 3 4 4 Front View of Socket Without Cover Rear View of Socket 30 0218 4 Pin Male Plug 1 2 3 4 4...

Page 53: ...l OR wrong seasonal fuel mixture Insufficient fuel level Faulty spark plugs Moisture in spark plug pockets Incorrect choke setting Faulty fuel pump Incorrect valve clearance Valve seat failure Engine low on power Plugged or partially plugged air filters Plugged or partially plugged fuel filters Dirty or faulty carburetor Low cylinder compression Engine overheats Debris in engine compartment Oil li...

Page 54: ...lutch Hydraulic Symptom Possible Cause Front attachment does not lift Hydraulic oil level is low Excessive load on front lift Plugged hydraulic oil suction filter Faulty hydraulic cylinder Pump charge pressure is low Hardware missing on lift cylinder Hardware missing on hydraulic control lever links Excessive noise in hydraulic system Hydraulic oil level is low Plugged hydraulic oil suction filter...

Page 55: ...e is open Pump drive belt failure Faulty hydraulic pump or motor Engine stalls when the drive control handles are moved forward or backward out of neutral Parking brake is engaged Defective or out of adjustment parking brake switch Defective or out of adjustment operator presence switch Engine stalls when the parking brake is disengaged while operator is on platform Defective or out of adjustment ...

Page 56: ...c Hydraulic Oil Filtration 10 Micron 25 Micron Controls Instrument Panel Throttle Control Cable Directional Control Right Left Drive Control Handles Gauges Hour Meter Fuel Parking Emergency Brake Tire Brake Bar Optional PTO Power Take Off Electric w brake Other Features Tires 18 x 8 5 10 46 x 22 26 Headlight LED Flood 1200 Lumen Attachment System Quick Attach Hitch Dimensions Wheelbase 28 inches 7...

Page 57: ...ter Fuel System Unleaded Gasoline Max 10 Ethanol 3 3 gallons 12 5 liters Grease Lithium Complex NLGI 2 Refer to Maintenance Chart use API Classification SJ or higher For optimal engine life and performance use Ventrac Full Synthetic Engine Oil Part 15 0037 1 Attention Engine Oil Recommendation ENGINE OIL SAE 10W 30 Premium Full Synthetic Belt Chart Location Belt Size Ventrac Part Number Pump Drive...

Page 58: ...o claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Ventrac equipment Proof of purchase may be required by the dealer to substantiate any warranty claim Only warranty work performed and submitted by an Authorized Ventrac Dealer may be eligible for warranty credit This warranty extends only to Ventrac commercial equipment operated under normal ...

Page 59: ... forth herein V P I shall not be liable for cost of removal or installation nor shall V P I be responsible for any direct indirect special or consequential damages of any nature In no event shall V P I be liable for any sum in excess of the price received for the goods for which liability is claimed There are no representations or warranties which have been authorized to the buyer of the Ventrac c...