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Summary of Contents for 6100E

Page 1: ...330255 Rev 02 6 01 Service Manual 6100E ...

Page 2: ...e tieing machine jacking machine storing machine pushing or towing and hardware information Chassis Tire wheel replacement brake adjustment and replacement steering adjustment and replacement Sweeping Hopper repair replacement brush repair replacement skirt seal repair replacement and sweeping troubleshooting Electrical Battery maintenance and replacement motor replacement electrical schematics an...

Page 3: ... BRAKING SYSTEM 1 6 TIRES 1 6 MACHINE DIMENSIONS 1 7 MAINTENANCE 1 8 MAINTENANCE CHART 1 8 PUSHING TOWING AND TRANSPORTING THE MACHINE 1 10 PUSHING OR TOWING THE MACHINE 1 10 TRANSPORTING THE MACHINE 1 10 MACHINE JACKING 1 13 STORING MACHINE 1 13 HARDWARE INFORMATION 1 14 STANDARD BOLT TORQUE CHART 1 14 METRIC BOLT TORQUE CHART 1 14 BOLT IDENTIFICATION 1 14 THREAD SEALANT AND LOCKING COMPOUNDS 1 1...

Page 4: ...GENERAL INFORMATION 1 2 6100E 330255 6 01 ...

Page 5: ...n reversing machine Do not carry riders on machine Always follow safety and traffic rules Report machine damage or faulty operation immediately 5 Before leaving or servicing machine Stop on level surface Set parking brake Turn off machine and remove key 6 When servicing machine Avoid moving parts Do not wear loose jackets shirts or sleeves when working on machine Block machine tires before jacking...

Page 6: ...he machine in the locations indicated If these or any labels become damaged or illegible install a new label in its place BATTERY CHARGING LABEL LOCATED IN BATTERY COMPARTMENT FOR SAFETY LABEL LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT FLYING DEBRIS LABEL LOCATED ABOVE HOPPER 352182 ...

Page 7: ...g path width 560 mm 22 in Sweeping path width with one side brush 762 mm 30 in Sweeping path width with two side brushes 965 mm 38 in Main sweeping brush pattern width 50 mm 2 in Hopper weight capacity 90 kg 200 lb Hopper volume capacity 85 L 3 cu ft Dust filter area 3 2 sq m 34 sq ft GVWR 2041 kg 1009 lb GENERAL MACHINE PERFORMANCE Item Measure Maximum forward speed 8 5 km h 5 5 mph Maximum rever...

Page 8: ... A Hz Phase VAC Charger 36 20 60 1 240 STEERING Type Power source Emergency steering Front wheel manual controlled Manual steering Manual BRAKING SYSTEM Type Operation Service brakes Mechanical disc brake 1 one front wheel rod actuated Parking brake Utilizes service brakes cable actuated TIRES Location Type Size Front 1 Solid 90 x 305 mm 3 5 in x12 in OD Rear 2 Solid 76 x 305 mm 3 in x 12 in OD ...

Page 9: ...GENERAL INFORMATION 1 7 6100E 330255 9 00 TOP VIEW SIDE VIEW 1520 mm 60 in 805 mm 32 in 1180 mm 46 in 352185 MACHINE DIMENSIONS ...

Page 10: ...ment 6 4 Main brush Check for damage or wear 1 5 Side brush es Check for damage or wear 1 2 Check brush pattern 1 2 7 Hopper dust filter Shake 1 3 Batteries Check and charge batteries 6 3 50 Hours 4 Main brush Rotate end for end 1 Check brush pattern 1 3 Batteries Check electrolyte level DW 6 3 14 Vacuum wand bag Option Check or change vacuum bag Vacuum wand fan s Option Check for damage or wear 2...

Page 11: ...eck for damage or wear 4 17 Steering castor pivot bearing Lubricate and check for wear SPL 1 200 Hours 11 Brake Check adjustment 1 13 Side brush es Check pivot adjustment 1 2 2 Vacuum fan belt Check tension and wear 1 3 Main brush belt Check for wear 1 16 Steering gear chain Lubricate EO 1 800 Hours 1 Electric motors Check carbon brushes 3 LUBRICANT FLUID DW Distilled water EO SAE 30 Engine oil SP...

Page 12: ... motor or damage may occur to the propelling system Only push or tow the machine for a very short distance and do not exceed 3 2 kp h 2 mph It is NOT intended to be pushed or towed for a long distance or at a high speed TRANSPORTING THE MACHINE 1 Position the front of the machine at the loading edge of the truck or trailer FOR SAFETY Use truck or trailer that will support the weight of the machine...

Page 13: ...er See PUSHING OR TOWING THE MACHINE section of this manual Make sure the machine is centered FOR SAFETY When loading machine onto truck or trailer use winch Do not drive the machine onto the truck or trailer unless the loading surface is horizontal AND is 380 mm 15 in or less from the ground 5 Position the machine onto the truck or trailer as far as possible If the machine starts to veer off the ...

Page 14: ...s 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 trailer FOR SAFETY When unloading machine off truck or trailer use winch Do not drive the machine off the truck ...

Page 15: ...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 The rear jacking locations are on the corners of the rear frame 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 j...

Page 16: ...280 291 380 313 407 424 552 1 00 in 500 650 678 881 757 984 1026 1334 NOTE Decrease torque by 20 when using a thread lubricant METRIC BOLT TORQUE CHART Thread Size Class 8 8 Torque ft lb _Nm Class 10 9 Torque ft lb Nm M4 2 3 3 4 M5 4 5 6 8 M6 7 9 10 14 M8 18 24 25 34 M10 32 43 47 64 M12 58 79 83 112 M14 94 127 133 180 M16 144 195 196 265 M20 260 352 336 455 M24 470 637 664 900 NOTE Decrease torque...

Page 17: ...FRONT TIRE AND WHEEL 2 17 TO REPLACE FRONT WHEEL DRIVE CHAIN 2 20 TO REPLACE FRONT WHEEL HUB BEARINGS 2 23 TO REMOVE GEARBOX ASSEMBLY 2 24 TO INSTALL GEARBOX ASSEMBLY 2 26 TO REPLACE DRIVE WHEEL COGGED BELT 2 28 TO REPLACE GEARBOX BEARINGS 2 31 TO ADJUST STEERING CHAIN 2 35 TO REPLACE STEERING CHAIN 2 37 TO REPLACE STEERING HOUSING BEARINGS 2 40 TO REPLACE STEERING U JOINT 2 46 TO REPLACE SMALL ST...

Page 18: ...CHASSIS 2 2 6100E 330255 9 00 ...

Page 19: ...CHASSIS 2 3 6100E 330255 9 00 INTRODUCTION This section includes information on the main chassis related components for example the seat steering brakes and tires ...

Page 20: ... and parking brake are each actuated with a foot pedal TO ADJUST SERVICE BRAKE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface place blocks in front and back of back wheels 1 If the service brake pedal has excessive movement before the brake is activated the service brake needs to be adjusted 2 Go under the front of the machine and locate the disc brake caliper assembly 3 Remo...

Page 21: ...nt of movement before the brakes are engaged If this is the case the adjustment is complete if not repeat the previous step NOTE If the lever does not reach the next hole loosen the two screws holding the small lever to the caliper The lever pin can now be moved up to the next hole Retighten the hardware TO ADJUST PARKING BRAKE The parking brake adjustment is made at the same time as the service b...

Page 22: ...top On Level Surface Set Parking Brake 1 Remove the front wheel assembly See TO REMOVE FRONT TIRE AND WHEEL instructions in this section 2 Remove the tension spring from the brake caliper lever and wheel housing 3 Remove the nuts from the shoulder screws holding the brake caliper to the wheel housing ...

Page 23: ...Note the orientation of the caliper assembly on the wheel housing 5 Remove the two shoulder screws from the caliper assembly 6 Pull the two brake pads out of the caliper assembly Note the orientation of the pads 7 Install the new pads into the caliper assembly in the same orientation ...

Page 24: ...es on the wheel housing Reinstall the two nyloc nuts and tighten to 18 24 Nm 15 20 ft lb Make sure the caliper free floats after the screws are tightened 10 Reinstall the tension spring onto the brake caliper lever and wheel housing 11 Reinstall the front tire and wheel assembly See TO INSTALL FRONT TIRE AND WHEEL instructions in this section 12 Operate the machine and check the brakes for proper ...

Page 25: ...es are free wheeling and have no braking capabilities TO REMOVE REAR TIRE ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Remove the debris hopper from the rear of the machine 2 Jack up the machine at the rear jack point Place a jack stand under the machine frame ...

Page 26: ... the large nyloc nut and washer holding the rear wheel axle to the machine Remove the nyloc nut and washer 4 Support the rear wheel and remove the axle shaft 5 Remove the rear tire assembly from the machine 6 Remove the three hex screws and nuts holding the wheel hub to the tire assembly ...

Page 27: ...CHASSIS 2 11 6100E 330255 9 00 7 Remove the hub assembly from the tire assembly ...

Page 28: ...hen through the wheel Install the nuts Center the hub on the wheel Tighten the nuts to 18 24 Nm 15 20 ft lb 2 Install the tire and hub assembly into the machine with the hub positioned on the inside of the machine frame 3 Hold the wheel in position and install the axle shaft from to outside of the machine frame Note the D shape of the frame mount hole and the D on the axle shaft Line these two up ...

Page 29: ...de of the machine frame and install the washer and nyloc nut Tighten to 37 48 Nm 26 34 ft lb 5 Spin the tire assembly to make sure it turns freely 6 Remove the jack stand and lower the machine to the floor 7 Operate the machine for proper operation ...

Page 30: ...controlled by a steering wheel which turns a chain that is connected to the front wheel housing The front wheel housing turns on a large bearing and rubber seal TO REMOVE FRONT TIRE AND WHEEL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface place blocks in front and back of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine...

Page 31: ...the drive sprocket Remove the master link from the drive chain Make sure to retain the four small O rings from behind the master link clip NOTE Try to keep the chain on the upper sprocket when removing the wheel 5 Remove the large nut and washer from the wheel axle 6 Support the front drive wheel Remove the axle from the front wheel 7 Let the front wheel drop down and out of the brake caliper Remo...

Page 32: ...the four screws holding the brake disc to the front hub assembly Make sure to retain the four steel sleeves Pull the brake disc off the hub 9 Remove the three wheel nuts holding the tire to the front hub Remove the tire assembly from the hub ...

Page 33: ...small amount of grease in the ID of the brake disc The hub of the brake disc is positioned toward the tire 3 Reinstall the four hex screws and steel sleeves Use red loctite 271 on the threads of the screws and tighten to 18 24 Nm 15 20 ft lb Tighten these screws in a criss cross pattern Make sure the disc floats on the hub 4 Position the front drive wheel assembly into the wheel housing The brake ...

Page 34: ...ft Line these two up and push the axle all the way into the mount hole 7 Install the washer and nyloc nut onto the axle shaft Tighten to 64 83 Nm 47 61 ft lb 8 Spread the drive chain and install around the large sprocket on the front wheel assembly Reinstall the master link Make sure the four small O rings are in place behind the master link clip 9 Push the motor gearbox up until the drive chain i...

Page 35: ... 6100E 330255 9 00 10 Reinstall the drive chain guard and tighten the two nuts to 18 24 Nm 15 20 ft lb 11 Remove the jack stands and lower the machine to the floor Operate the machine and check for proper operation ...

Page 36: ...ont and back of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Remove the two nuts holding the chain guard to the wheel support Remove the chain guard 3 Loosen the three nuts holding the drive motor gearbox to the wheel support Let the gearbox drop down so the drive chain has some slack ...

Page 37: ...lip 5 Pull the old chain off the drive motor sprocket and drive wheel sprocket Remove the old drive chain from the machine 6 Reinstall the new drive chain around the drive sprocket on the drive motor and front wheel assembly Reinstall the master link Make sure the four small O rings are in place behind the master link clip 7 Push the gearbox assembly up until the chain is tight 1 8 inch at mid poi...

Page 38: ...0255 9 00 8 Reinstall the drive chain guard and tighten the two nuts to 18 24 Nm 15 20 ft lb 9 Remove the jack stands and lower the machine to the floor Operate the machine and check the new drive chain for proper operation ...

Page 39: ...bly See TO REMOVE FRONT TIRE AND WHEEL instructions in this section 2 Use a long screw driver or punch to hammer the two bearings out of the front hub assembly Discard the old bearings 3 Use an arbor press to install the new bearings into the front hub Push the bearings down until they are seated flush against the housing 4 Reinstall the front wheel assembly See TO INSTALL FRONT TIRE AND WHEEL ins...

Page 40: ...t and back of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Remove the two nuts holding the chain guard to the wheel support Remove the chain guard 3 Loosen the three nuts holding the gearbox assembly to the wheel support Let the gearbox drop down so the drive chain has some slack ...

Page 41: ...to retain the four small O rings from behind the master link clip 5 Pull the chain off the drive motor sprocket and drive wheel sprocket Remove the drive chain from the machine 6 Disconnect the drive motor from the main electrical harness 7 Finish removing the three nuts and washers holding the gearbox assembly to the wheel support Remove the gearbox assembly from the machine ...

Page 42: ...rbox assembly onto the wheel support The three slots on the gearbox go over the three studs on the wheel support 2 Install the three washers and nuts onto the wheel housing studs Leave loose for now 3 Reinstall the drive chain around the drive sprocket on the drive motor and front wheel assembly Reinstall the master link Make sure the four small O rings are in place behind the master link clip ...

Page 43: ...Tighten nuts to 18 24 Nm 15 20 ft lb 5 Reinstall the drive chain guard and tighten the two nuts to 18 24 Nm 15 20 ft lb 6 Reconnect the drive motor to the main electrical harness 7 Remove the jack stands and lower the machine to the floor Operate the machine and check the gearbox assembly for proper operation ...

Page 44: ...ace blocks in front and back of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Disconnect the drive motor from the main electrical harness Turn the steering wheel all the way to the right 3 Remove the six hex screws holding the two black covers to the side of the gearbox ...

Page 45: ...ve to lightly pry the second cover off the locating pins 6 Loosen the two hex screws holding the electric drive motor to the back side of the gearbox assembly Let the motor slide toward the back of the machine The cogged belt will now be loose on the pulleys 7 Remove the old cogged belt from both drive pulleys Discard the old belt ...

Page 46: ...arbox Place one side of the pliers over the small pulley and the other side of the pliers on the front side of the gearbox Squeeze the pliers until the belt is tight 1 16 inch play at midpoint Tighten the two motor mount screws to 18 24 Nm 15 20 ft lb 11 Install the second belt cover onto the gearbox Install the remaining four hex screws and tighten to 18 24 Nm 15 20 ft lb Plug the drive motor int...

Page 47: ...s 1 Remove the gearbox assembly from the machine See TO REMOVE GEARBOX ASSEMBLY instructions in this section 2 Loosen the two set screws on the small sprocket on the gearbox assembly Remove and retain the small sprocket woodruff key and foam washer 3 Go to the other side of the gearbox assembly Remove the six hex screws holding the two black covers to the side of the gearbox ...

Page 48: ... drive motor to the back side of the gearbox assembly Let the motor slide toward the large sprocket The cogged belt will now be loose on the pulleys Remove the cogged belt from both drive pulleys 7 Pull the large pulley out of the gearbox You may have to lightly tap on the shaft to dislodge the inner bearing from the bottom case of the gearbox assembly Remove the three hex screws holding the hub t...

Page 49: ...ngs onto the pulley shaft in the same orientation as the old bearings Reinstall the hub and new bearings into the sprocket Tighten the three hex screws to 11 14 Nm 7 10 ft lb 10 Position the large belt pulley shaft and bearing assembly back into the bottom case of the gearbox assembly Make sure the inner bearing is seated properly in the lower case 11 Position the cogged belt onto the large and sm...

Page 50: ...er side of the pliers on the front side of the gearbox Squeeze the pliers until the belt is tight 1 16 inch play at midpoint Tighten the two motor mount screws to 18 24 Nm 15 20 ft lb 14 Install the second belt cover onto the gearbox Install the remaining four hex screws and tighten to 18 24 Nm 15 20 ft lb 15 Reinstall the gearbox assembly onto the wheel support assembly See TO INSTALL GEARBOX ASS...

Page 51: ...f the machine at the jack point Install jack stands under the machine frame 2 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws 3 Turn the steering wheel all the way to the left and then to the right Find the point in the rotation where the steering chain is the most tight ...

Page 52: ... forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 5 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering chain for proper operation ...

Page 53: ...k of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots ...

Page 54: ...ering chain Remove the master link and steering chain 6 Position the new steering chain around both the large steering sprocket and small sprocket Install a new master link in the new chain 7 Turn the steering wheel all the way to the left and then to the right Find the point in the rotation where the steering chain is the most tight ...

Page 55: ... forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 9 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering chain for proper operation ...

Page 56: ...e Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the steering U joint Loosen the two set screws on the top of the steering U joint ...

Page 57: ...oint 5 Remove the two hex screws holding the steering bearing housing to the machine frame Push the bearing housing back in the slots 6 Go under the machine and locate the small steering chain sprocket 7 Locate the master link on the steering chain Remove the master link and steering chain from the small steering sprocket ...

Page 58: ...and retain the U joint and square key 10 Loosen the set screw holding the small steering sprocket to the bottom of the short steering shaft Remove and retain small sprocket and woodruff key 11 Use an arbor press to press the short steering shaft and two bearings out of the housing Discard the bearings Retain the short shaft Note the orientation of the shaft in the housing ...

Page 59: ...13 Use the arbor press to install the short steering shaft into the new bearings 14 Reinstall the small steering sprocket and woodruff key on the bottom of the steering housing Tighten the set screws tight 15 Reinstall the U joint and square key on the top of the steering housing Tighten the set screws tight ...

Page 60: ...ng shaft and steering wheel into the top of the steering U joint Tighten the set screws tight 18 Go under the machine and reinstall the steering chain around the small steering sprocket Reinstall the master link 19 Turn the steering wheel all the way to the left and then to the right Find the point in the rotation where the steering chain is the most tight ...

Page 61: ... forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 21 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering chain for proper operation ...

Page 62: ...Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Go to the operators compartment and locate the steering U joint Loosen the two set screws on the top of the steering U joint 3 Pull the steering wheel and long steering shaft up and out of the top of the steering U joint ...

Page 63: ...iscard the U joint and square key 5 Install the new U joint and square key on the top of the steering housing Tighten the set screws tight 6 Position the long steering shaft and steering wheel into the top of the steering U joint Tighten the set screws tight 7 Operate the machine and check the steering U joint for proper operation ...

Page 64: ... the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain ...

Page 65: ...teering chain 6 Loosen the set screw holding the small steering sprocket to the bottom of the short steering shaft Remove and discard the small sprocket Retain the woodruff key 7 Install the new small sprocket and woodruff key onto the steering shaft The teeth of the new sprocket face down Position the sprocket in the same location as the old one Tighten the two set screws tight ...

Page 66: ... to the right Find the point in the rotation where the steering chain is the most tight 10 Push the bearing housing forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 11 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering for proper operation ...

Page 67: ...tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain ...

Page 68: ...ONT TIRE AND WHEEL instructions in this section 6 Go under the machine and locate the short brake rod coming through the center of the wheel support bearing assembly Disconnect the clevis end of the short brake cable where it attaches to the brake lever 7 Remove the four hex screws holding the wheel support and large sprocket to the pivot bearing assembly Drop the wheel support and large sprocket ...

Page 69: ...g pin on the wheel support is inserted in the locating pin hole in the new sprocket 10 Position the wheel support and sprocket assembly into the machine Line up the mount holes in the wheel support and sprocket with the threaded holes in the bottom of the pivot bearing assembly Reinstall the four screws and tighten to 64 83 Nm 47 61 ft lb 11 Reconnect the short brake rod to the brake lever ...

Page 70: ... Turn the steering wheel all the way to the left and then to the right Find the point in the rotation where the steering chain is the most tight 15 Push the bearing housing forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 16 Remove the jack stands and lower the machine to the floor Operate the machine and check the stee...

Page 71: ... of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain ...

Page 72: ...e machine 5 Disconnect the drive motor from the main harness 6 Go to the operators compartment and locate the clevis pin holding the brake pedal assembly to the floor plate Remove the clevis pin and tension spring from the brake pedal 7 Pull the brake pedal up and disconnect the clevis end of the short brake rod where it attaches to the brake pedal assembly ...

Page 73: ...ive assembly in the machine Lower the drive assembly down and out of the machine 9 Remove the small thread roller screw holding the castle nut to the pivot shaft Remove the castle nut and flat washer 10 Pull the cone bearing out of the swivel plate 11 Pull the swivel plate off the swivel plate weldment Make sure to retain the rubber seal ring ...

Page 74: ...sher Install the second thrust washer on top of the needle bearing 15 Reinstall the swivel plate onto the swivel plate weldment Make sure the rubber seal ring is in place on the swivel plate before installing 16 Reinstall the cone bearing in the swivel plate Grease the bearing if needed 17 Reinstall the large flat washer and castle nut Tighten to 37 48 Nm 26 34 ft lb Reinstall the small thread rol...

Page 75: ...e Reinstall the four button head screws and tighten to 64 83 Nm 47 61 ft lb Make sure the drive motor is facing the front of the machine 20 Reinstall the steering chain onto both steering sprockets Reinstall the master link 21 Go back to the operators compartment Push the steering housing forward in the slots This will remove any slack in the steering chain Tighten the two hex screws to 37 48 Nm 2...

Page 76: ...rive motor to the main harness 23 Reconnect the short brake rod to the brake pedal 24 Reinstall the brake pedal and clevis pin 25 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering for proper operation ...

Page 77: ...rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain ...

Page 78: ...e machine 5 Disconnect the drive motor from the main harness 6 Go to the operators compartment and locate the clevis pin holding the brake pedal assembly to the floor plate Remove the clevis pin and tension spring from the brake pedal 7 Pull the brake pedal up and disconnect the clevis end of the short brake rod where it attaches to the brake pedal assembly ...

Page 79: ...ve the small thread roller screw holding the castle nut to the pivot shaft Remove the castle nut and flat washer 10 Pull the cone bearing out of the swivel plate 11 Grease the new cone bearing Reinstall the cone bearing into the swivel plate 12 Reinstall the large flat washer and castle nut Tighten to 37 48 Nm 26 34 ft lb Reinstall the small thread roller into the cross hole Back off the castle nu...

Page 80: ...e Reinstall the four button head screws and tighten to 64 83 Nm 47 61 ft lb Make sure the drive motor is facing the front of the machine 15 Reinstall the steering chain onto both steering sprockets Reinstall the master link 16 Go back to the operators compartment Push the steering housing forward in the slots This will remove any slack in the steering chain Tighten the two hex screws to 37 48 Nm 2...

Page 81: ...rive motor to the main harness 18 Reconnect the short brake rod to the brake pedal 19 Reinstall the brake pedal and clevis pin 20 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering for proper operation ...

Page 82: ...CHASSIS 2 66 6100E 330255 9 00 ...

Page 83: ...EARINGS 3 21 TO REPLACE MAIN BRUSH DRIVE BELT IDLER PULLEY 3 26 SIDE BRUSH 3 29 TO REPLACE SIDE BRUSH 3 30 SIDE BRUSH GUARD 3 32 SIDE BRUSH PIVOT 3 32 TO REPLACE SIDE BRUSH LIFT CABLE 3 33 SKIRTS AND SEALS 3 35 REAR SKIRT 3 35 SIDE SKIRTS 3 36 TO ADJUST SIDE SKIRTS 3 36 LARGE DEBRIS TRAP SKIRT 3 38 TO ADJUST FRONT FLAP SKIRT 3 38 HOPPER SEALS 3 39 TO ADJUST RECIRCULATING SKIRT CAM 3 40 VACUUM FAN ...

Page 84: ... section includes information on the sweeping operation of the model 6100E 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 85: ...achine under the battery compartment The hopper rolls in and out of position and rests in grooves that hold the hopper in place The hopper is held in operating position with a retaining clip NOTE Check that the hopper retaining clip is securely in place each time before operating machine ...

Page 86: ...icing Machine Stop On Level Surface Set Parking Brake 1 Go to the back of the machine 2 Grasp the hopper retainer clip Turn the retainer clip out of the way of the hopper lip 3 Grasp the hopper handle Pull up slightly then pull out on the hopper 4 Remove the hopper from the machine ...

Page 87: ...fore Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Position the hopper into the back of the machine 2 Push the hopper in until it is flush with the back of the machine frame 3 Rotate the retainer clip down to lock the hopper in the machine ...

Page 88: ...switch to the Filter shaker position D TAPPING Remove the filter and 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 protecti...

Page 89: ...ER DUST FILTER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Remove the debris hopper from the machine 2 Un latch the two filter pivot latches at the rear of the machine 3 Let the hooper filter pivot down ...

Page 90: ...res 5 Remove the filter from the filter tray 6 Pull back on the tension spring located on the shaker assembly Cut the plastic ties holding the shaker to the filter 7 Remove the filter shaker assembly from the filter 8 Install the filter shaker assembly onto the new filter Make sure the pin on the shaker assembly is inserted in the hole in the filter shaker comb ...

Page 91: ...erly the edge of the shaker should be between the filter and the filter seal 10 Reinstall the filter assembly into the filter tray 11 Reconnect the wires to the filter shaker 12 Pivot the filter tray up and re latch the latches 13 Reinstall the debris hopper and lock the retainer bracket ...

Page 92: ...n brush in the lowered position 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 FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Stop the machine set the parking brake and turn the mach...

Page 93: ... idler arm assembly 4 Grasp the main brush pull it off the brush drive plug and out of the main brush compartment 5 Put the new or rotated end for end main brush on the floor next to the access door 6 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 ...

Page 94: ...00 7 Check that the recirculation skirt is tucked in behind the frame 8 Slide the main brush idler arm plug onto the main brush 9 Secure the idler arm on the bolts Hand tighten the mounting knobs 10 Close the main brush access door ...

Page 95: ... and main brush and position the main brush over the chalked area 3 Start and lower the main brush for 15 to 20 seconds while keeping a foot on the brakes to keep the machine from moving 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 the main brush 5 Drive the machine off the test area ...

Page 96: ...stem have been replaced If the main brush pattern is tapered more than 15 mm 0 5 in on one end than the other adjust the taper as follows 1 Loosen the brush shaft bearing bracket mounting bolt and the idler arm securing head 2 Allow the brush to operate and float into position for approximately 30 seconds 3 Tighten the adjustment bolt and idler arm securing knob 4 Check the main brush pattern and ...

Page 97: ...RNING Moving belt and fan Keep away TO REPLACE MAIN BRUSH DRIVE BELT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Remove the four screws holding the right hand brush door to the machine frame Remove the right hand side brush door 2 Locate the main brush drive belt idler pulley between the small motor drive pulley and the larger brush pulley ...

Page 98: ...back in the slot 5 Remove the main brush drive belt from the two remaining pulleys Remove and discard the old drive belt 6 Position the new main brush drive belt onto the motor and brush drive pulleys 7 Move the idler pulley forward in the slot until the belt is tight Tighten the hex nut to 18 24 Nm 15 20 ft lb ...

Page 99: ...SWEEPING 3 17 6100E 330255 9 00 8 Reinstall the right hand side brush door 9 Operate the machine and check the main brush for proper operation ...

Page 100: ...aving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the left hand side brush door 2 Remove the main brush idler mount plate See TO REPLACE MAIN BRUSH instructions in this sections 3 Remove the hex screw nut and washer holding the idler plug assembly to the brush lift plate ...

Page 101: ...x screws holding the bearing retainer to the idler plug Remove the retainer 6 Remove and discard the idler ball bearing from the idler plug 7 Position the new ball bearing into the idler plug 8 Reinstall the bearing retainer plate on the idler plug Reinstall the four screws and tighten to 8 10 Nm 6 7 ft lb ...

Page 102: ...late Reinstall the hex screw washer and nyloc nut Tighten to 37 48 Nm 26 34 ft lb 10 Reinstall the main brush idler mount plate See TO REPLACE MAIN BRUSH instructions in this sections 11 Close the left hand side brush door 12 Operate the machine and check the main brush for proper operation ...

Page 103: ...Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack points Install jack stands under the machine frame 2 Open the left hand side brush door 3 Remove the main brush idler mount plate and main brush See TO REPLACE MAIN BRUSH instructions in this sections 4 Remove the right hand brush door ...

Page 104: ...e nut from the center of this pulley NOTE THIS IS A LEFT HAND THREAD NUT 7 Remove the main brush V belt pulley larger one from the main brush shaft Make sure to retain the washer from behind the pulley 8 Hold the main brush drive plug from turning Remove the large nut from the center of the drive plug NOTE THIS IS A LEFT HAND THREAD NUT 9 Remove the main brush idler plug assembly from the main bru...

Page 105: ...rd the bearing 14 Use an arbor press to remove the bearing from the main brush shaft Discard the bearing 15 Install one new bearing onto the main brush shaft 16 Install one new bearing into the outer side of the main brush housing 17 Install the new bearing and main brush shaft assembly into the main brush housing Install one of the nuts onto the outside of the main brush shaft Use a hammer to lig...

Page 106: ...nstall the left hand nut Tighten to 52 67 Nm 39 51 ft lb 20 Reinstall the main brush drive belt See TO REPLACE MAIN BRUSH DRIVE BELT instructions in this section 21 Reinstall the main brush See TO REPLACE MAIN BRUSH instructions in this sections 22 Reinstall the right hand brush door and close the left hand brush door ...

Page 107: ...SWEEPING 3 25 6100E 330255 9 00 23 Remove the jack stands and lower the machine 24 Operate the machine and check the main brush for proper operation ...

Page 108: ...e Stop On Level Surface Set Parking Brake 1 Remove the four screws holding the right hand brush door to the machine frame Remove the right hand side brush door 2 Locate the main brush drive belt idler pulley between the small jackshaft pulley and the larger brush pulley 3 Loosen the hex nut in the center of the idler pulley ...

Page 109: ...back in the slot 5 Remove the main brush drive belt from the two remaining pulleys 6 Remove the hex nut in the center of the idler pulley Remove and discard the pulley 7 Install the new idler pulley onto the hex bolt Reinstall the hex nut Leave loose for now ...

Page 110: ...e two drive pulleys and on top of the idler pulley 9 Push down on the idler pulley until the belt is tight Tighten the pulley nut to 18 24 Nm 15 20 ft lb 10 Reinstall the right hand side brush door 11 Operate the machine and check the main brush for proper operation ...

Page 111: ...s in motion Adjust the side brush pattern by loosening the hex screw located above the side brush cable pulley in the front of the operators compartment Move the pulley mount bracket up or down to achieve the proper side brush pattern Retighten the hex screw The side brush should be replaced when it no longer sweeps effectively for your application A guideline length is when the remaining bristles...

Page 112: ...f FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Remove the side brush retaining pin from the side brush drive shaft by pulling the pin keeper off over the end of the pin 3 Slide the side brush off the side brush drive shaft 4 Slide the new side brush onto the side brush drive shaft ...

Page 113: ...ure the pin by clipping the pin keeper over the end of the pin 7 Adjust the side brush pattern by loosening the hex screw located above the side brush cable pulley in the front of the operators compartment 8 Move the pulley mount bracket up or down to achieve the proper side brush pattern Retighten the hex screw ...

Page 114: ...er every 200 hours of operation Replace the brush guard after it begins to show serious wear SIDE BRUSH PIVOT The side brush pivot should be checked for excessive movement after every 200 hours of operation Torque the front and rear compression springs to reduce excessive movement ...

Page 115: ...e 2 Go under the front of the machine near the side brush Locate the side brush lift cable clevis under the brush pivot hex nut Remove the nut only Pull the side brush lift cable off the hex screw 3 Go to the operators compartment Remove the three cable pulleys sleeves and cable clips from the side brush lift assembly Note the orientation of the cable clips for proper re assembly ...

Page 116: ... cable from the machine 5 Route the new side brush lift cable in the machine 6 Reinstall the three cable pulleys sleeves and cable clips Make sure the cable clips are in the correct orientation Tighten the hardware to 18 24 Nm 15 20 ft lb 7 Connect the new side brush lift cable to the side brush pivot screw Hand tighten the hex nut Cable should pivot on the hardware 8 Raise the side brush ...

Page 117: ...ompartment The vertical skirt should clear the floor up to 2 mm 0 09 in The recirculation skirt requires no adjustment Check the skirts for wear or damage and adjustment daily NOTE The recirculation skirt must be folded in between the brush and the machine frame before the brush door is mounted on for the machine to work properly ...

Page 118: ...ides of the main brush compartment The skirts should clear the floor up to 5 mm Check the skirts for wear or damage daily TO ADJUST SIDE SKIRTS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the LH brush door 2 Remove the RH brush door ...

Page 119: ...en the hardware holding the side skirts to the frame 4 Place a flat washer under the bottom edge of the skirts Make sure the skirt is touching the washer Tighten the hardware to 560Ncm 5 Close the LH brush door 6 Reinstall the RH brush door ...

Page 120: ...d be adjusted so it touches the floor and is curled back toward the main brush curl back should be 3 4 inch 1 4 inch Sweeping performance will be adversely affected if this skirt does not contact the floor Check the skirt for wear or damage after every 100 hours of operation TO ADJUST FRONT FLAP SKIRT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 The fron...

Page 121: ...he hopper rests on the seals when the hopper is setting in proper sweeping position Check the seals for wear or damage after every 100 hours of operation The upper hopper seal is located above the hopper on the bottom of the filter weldment Check the seal for wear or damage after every 100 hours of operation ...

Page 122: ...LATING SKIRT CAM FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Pull the brush lift handle forward 2 Lift the recirculation cam until it hits the frame 3 Slowly lower the brush lift handle to the down position ...

Page 123: ...SWEEPING 3 41 6100E 330255 9 00 4 If the cam follows the lever do NOT adjust 5 If the lever does not lower Loosen the hardware and move the lever NOTE The lever must not move to the front of the cam ...

Page 124: ...ant Accesst filter The vacuum fan is driven off the engine jack shaft VACUUM FAN BELT Check the vacuum fan belt tension and wear after every 200 hours of operation The correct tension is when the belt deflects 8 38 mm 0 33 in from a force of 42 kg 90 to 95 lb at belt midpoint WARNING Moving belt and fan Keep away ...

Page 125: ...m fan drive belt remove the right hand side panel Start by lifting up on the panel pop the brush lift slot over the black knob then move the panel backward and off the machine 2 Remove the four screws holding the right hand brush door to the machine frame Remove the right hand side brush door 3 Loosen the four hex screws holding the vacuum fan housing to the machine frame ...

Page 126: ...in the slots to loosen the vacuum fan V belt 5 Remove the two hex screws holding the cover over the V belt pulley Remove the cover 6 Remove the vacuum fan V belt from both pulleys Remove the old V belt from the machine 7 Install the new vacuum fan V belt over both pulleys ...

Page 127: ... is when the belt deflects 8 38 mm 0 33 in from a force of 42 kg 90 to 95 lb at belt midpoint Tighten the screws hand tight 9 Reinstall the V belt cover Tighten the two screws hand tight 10 Reinstall the right hand side brush door 11 Reinstall the right hand machine cover 12 Operate the machine Check the vacuum fan for proper operation ...

Page 128: ...side panel Start by lifting up on the panel pop the brush lift slot over the black knob then move the panel backward and off the machine 2 Loosen the four hex screws holding the vacuum fan housing to the machine frame 3 Pull the vacuum fan assembly toward the back of the machine to tighten the V belt The correct tension is when the belt deflects 8 38 mm 0 33 in from a force of 42 kg 90 to 95 lb at...

Page 129: ...SWEEPING 3 47 6100E 330255 9 00 4 Tighten the four mounts screws hand tight 5 Reinstall the right hand machine cover 6 Operate the machine Check the vacuum fan for proper operation ...

Page 130: ...access the vacuum fan drive belt remove the right hand side panel Start by lifting up on the panel pop the brush lift slot over the black knob then move the panel backward and off the machine 2 Loosen the four hex screws holding the vacuum fan housing to the machine frame 3 Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V belt ...

Page 131: ...5 Remove the vacuum fan V belt from the vacuum fan sheave 6 Remove the four hex nuts holding the vacuum fan assembly to the machine Remove the assembly from the machine Make sure to retain the two steel sleeves from the bottom two hex screws 7 Place the assembly on a work bench with the vacuum fan inlet plate facing up ...

Page 132: ...g Make sure to retain the five steel sleeves 9 Remove the nyloc nut holding the vacuum fan impeller to the fan shaft Pull the impeller off the shaft Make sure to retain the square key 10 Install the new vacuum fan impeller onto the fan shaft Make sure to reinstall the square key on the fan shaft 11 Reinstall the nyloc nut onto the fan shaft Tighten to 11 14 Nm 7 10 ft lb ...

Page 133: ...bly onto the right side off the machine Reinstall the four hex screws and nuts Make sure to install the two steel sleeves on the bottom two hex screws Leave the hardware loose for now 14 Install the vacuum fan V belt over the vacuum fan sheave 15 Pull the vacuum fan assembly toward the back of the machine to tighten the V belt The correct tension is when the belt deflects 8 38 mm 0 33 in from a fo...

Page 134: ...SWEEPING 3 52 6100E 330255 9 00 17 Reinstall the V belt cover Tighten the two screws hand tight 18 Reinstall the right hand machine cover 19 Operate the machine Check the vacuum fan for proper operation ...

Page 135: ... 1 To access the vacuum fan assembly remove the right hand side panel Start by lifting up on the panel pop the brush lift slot over the black knob then move the panel backward and off the machine 2 Loosen the four hex screws holding the vacuum fan housing to the machine frame 3 Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V belt ...

Page 136: ...5 Remove the vacuum fan V belt from the vacuum fan sheave 6 Remove the four hex nuts holding the vacuum fan assembly to the machine Remove the assembly from the machine Make sure to retain the two steel sleeves from the bottom two hex screws 7 Place the assembly on a work bench with the vacuum fan inlet plate facing up ...

Page 137: ...re to retain the five steel sleeves 9 Remove the nyloc nut holding the vacuum fan impeller to the fan shaft Pull the impeller off the shaft Make sure to retain the square key 10 Loosen the two set screws holding the V belt pulley to the fan shaft Remove the pulley 11 Remove the four hex screws holding the vacuum fan bearing assembly to the bearing plate Remove the bearing assembly ...

Page 138: ...housing with the thin flange The long end of fan shaft is on the side of the housing with the wide flange NOTE Make sure the bearings are pressed down tight The fan will be noisy if there is any play in the bearings The retaining rings must be tight to the housing 14 Reinstall the bearing housing onto the bearing housing plate The long end of the shaft is on the side with the sound foam Reinstall ...

Page 139: ... the vacuum fan impeller onto the fan shaft Make sure to reinstall the square key on the fan shaft 17 Reinstall the nyloc nut onto the fan shaft Tighten to 11 14 Nm 7 10 ft lb 18 Reinstall the vacuum fan inlet plate onto the bearing housing plate Reinstall the five steel sleeves hex screws and nuts Center the hole in the plate over the impeller fins Tighten the hardware to 18 24 Nm 15 20 ft lb ...

Page 140: ...x screws Leave the hardware loose for now 20 Install the vacuum fan V belt over the vacuum fan sheave 21 Pull the vacuum fan assembly toward the back of the machine to tighten the V belt The correct tension is when the belt deflects 8 38 mm 0 33 in from a force of 42 kg 90 to 95 lb at belt midpoint 22 Tighten the four mounts screws hand tight 23 Reinstall the V belt cover Tighten the two screws ha...

Page 141: ...SWEEPING 3 59 6100E 330255 9 00 24 Reinstall the right hand machine cover 25 Operate the machine Check the vacuum fan for proper operation ...

Page 142: ...nel Side brush drive failure Contact Tennant service personnel Hopper full Empty hopper Hopper lip skirts worn or damaged Replace lip skirts Wrong sweeping brush Contact Tennant representative for recommendations Large debris trap damaged Repair or replace large debris trap No machine power Power kill switch on Turn kill switch clockwise until it pops up Turn machine off and on Low battery power C...

Page 143: ...CIRCUIT BREAKERS 4 27 TO REPLACE ELECTRICAL PANEL CIRCUIT BREAKER 4 28 FUSES 4 31 TO REPLACE ELECTRICAL PANEL 40 AMP FUSE 4 31 DIRECTIONAL PEDAL 4 34 TO REMOVE DIRECTIONAL PEDAL ASSEMBLY 4 34 TO INSTALL DIRECTIONAL PEDAL ASSEMBLY 4 36 TO REPLACE DIRECTIONAL PEDAL POTENTIOMETER 4 38 TO SET POTENTIOMETER NEUTRAL 4 41 ELECTRIC MOTORS 4 44 TO REPLACE FRONT DRIVE WHEEL MOTOR 4 44 TO REPLACE MAIN BRUSH ...

Page 144: ...ELECTRICAL 4 2 6100E 330255 9 00 ...

Page 145: ...ELECTRICAL 4 3 6100E 330255 9 00 INTRODUCTION The 6100E electrical system consists of the batteries instrument panel drive motor switches relays and circuit breakers ...

Page 146: ... strong solution of baking soda and water Brush the solution sparingly over the battery tops terminals and cable clamps Do not allow any baking soda solution to enter the batteries Use a wire brush to clean the terminal posts and the cable connectors After cleaning apply a coating of clear battery post protectant to the terminals and the cable connectors Keep the tops of the batteries clean and dr...

Page 147: ...rmine the remaining battery charge level Spec Gravity at 27 C 80 F Charge Level 220 AH Battery 100 1 265 75 1 223 50 1 185 25 1 148 Discharged 1 110 NOTE If the readings are taken when the battery electrolyte is any temperature other than shown the reading must be temperature corrected Add or subtract to the specific gravity reading 0 004 4 points for each 6_ C 10_ F above or below 25_C 77_ F TO C...

Page 148: ...rging FOR SAFETY When maintaining or servicing machine avoid contact with battery acid 6 Unplug the battery connector from the machine connector 7 Plug the connector from the batteries into the battery charger connector WARNING Batteries emit hydrogen gas Explosion or fire can result Keep sparks and open flame away Keep covers open when charging NOTE Plug the charger connector into connector that ...

Page 149: ...o the batteries or reduce the battery life NOTE If the charger needs to be disconnected from the machine before the batteries are fully charged and the charger has not automatically shut off turn off the charger before disconnecting it 9 After the charger has turned off unplug the charger connector from the battery connector on the machine 10 Reconnect the battery connector to the machine connecto...

Page 150: ...ACE BATTERIES FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries 3 Remove the five small battery cables from the batteries ...

Page 151: ... nearest the rear of the machine first by lifting with the lifting loop at each end of the battery 6 Pull the three batteries nearest the front of the machine toward the rear of the battery tray Remove these batteries next 7 Install the front three batteries first Push these batteries toward the front of the machine ...

Page 152: ...255 9 00 8 Install the rear three batteries next 9 Reinstall the five small battery cables onto the new batteries 10 Reinstall the connector assembly onto the batteries 11 Reconnect the battery connect to the machine connector ...

Page 153: ...ELECTRICAL 4 11 6100E 330255 9 00 12 Disengage the prop rod and lower the seat support 13 Start the machine and check the new batteries for proper operation ...

Page 154: ...l 6100E contains the switches gauges and instruments needed to run the machine functions TO ACCESS INSTRUMENT PANEL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries ...

Page 155: ...d lower the seat support 4 Tie the side brush in the up position 5 Remove the four hex screws and two pan screws holding the instrument panel to the front shroud 6 Pull the instrument panel back away from the front shroud for better access to the circuit breakers ...

Page 156: ... Position the instrument panel back onto the front shroud Reinstall the hardware and hand tighten tight 8 Remove the tie holding the side brush in the up position 9 Open the seat support and engage the prop rod 10 Reconnect the batteries ...

Page 157: ...ELECTRICAL 4 15 6100E 330255 9 00 11 Disengage the prop rod and lower the seat support 12 Start the machine and check for proper operation ...

Page 158: ...RUMENT PANEL CIRCUIT BREAKER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries 3 Disengage the prop rod and lower the seat support ...

Page 159: ...up position 5 Remove the four hex screws and two pan screws holding the instrument panel to the front shroud 6 Pull the instrument panel back away from the front shroud for better access to the circuit breakers 7 Locate the circuit breaker that needs to be changed ...

Page 160: ...ut of the hole Retain the clear rubber boot and discard the circuit breaker 11 Position the new circuit breaker into the mount hole NOTE The mount hole has a D shape to match the shape of the circuit breaker 12 Install the metal retainer ring onto the back of the new circuit breaker Push the retainer all the way down the circuit breaker 13 Install the rubber boot onto the out side of the new circu...

Page 161: ... new circuit breaker See schematic in the ELECTRICAL section 15 Position the instrument panel back onto the front shroud Reinstall the hardware and hand tighten tight 16 Remove the tie holding the side brush in the up position 17 Open the seat support and engage the prop rod ...

Page 162: ...ELECTRICAL 4 20 6100E 330255 9 00 18 Reconnect the batteries 19 Disengage the prop rod and lower the seat support 20 Start the machine and check for proper operation ...

Page 163: ...ar corner of the machine The electrical panel contains the propel controller relays contactors circuit breakers and fuse TO ACCESS ELECTRICAL PANEL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries ...

Page 164: ... 330255 9 00 3 Remove the left side machine panel by lifting up and back on the panel 4 Make any repairs to the electrical components located on the electrical panel 5 Reinstall the left side panel 6 Reconnect the batteries ...

Page 165: ...ELECTRICAL 4 23 6100E 330255 9 00 7 Disengage the prop rod and lower the seat support 8 Start the machine and check for proper operation ...

Page 166: ...CONTROLLER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries 3 Remove the left side machine panel by lifting up and back on the panel ...

Page 167: ...s and nuts holding the controller to the electrical panel Remove the controller from the machine 6 Install the new controller onto the electrical panel in the same orientation as the old one Reinstall the hardware and hand tighten Do not over tighten 7 Reconnect the wires to the new controller See schematic in this section ...

Page 168: ...ELECTRICAL 4 26 6100E 330255 9 00 8 Reinstall the left side panel 9 Reconnect the batteries 10 Disengage the prop rod and lower the seat support 11 Start the machine and check for proper operation ...

Page 169: ...ker to trip is still there the circuit breaker will continue to stop current flow until the problem is corrected Circuit breakers 1 through 6 are located above the foot pedals Numbers 7 through 10 are located back under the left side panel The chart lists the circuit breakers and the electrical components they protect Circuit Breaker Rating Circuit Protected CB 1 5 A Main Power CB 2 5 A Main Power...

Page 170: ...EL CIRCUIT BREAKER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries 3 Remove the left side machine panel by lifting up and back on the panel ...

Page 171: ...5 Remove the two pan screws holding the circuit breaker to the panel Pull the circuit breaker out of the mount hole 6 Mark and disconnect the wires leading to the bottom of the circuit breaker 7 Connect the electrical wires to the new circuit breaker See schematic in the ELECTRICAL section ...

Page 172: ...circuit breaker into the mount hole Reinstall the two pan screws and hand tighten tight 9 Reinstall the machine side panel 10 Reconnect the batteries 11 Disengage the prop rod and lower the seat support 12 Start the machine and check for proper operation ...

Page 173: ...oad Never substitute higher value fuses than specified The fuse is located in the control box Fuse Rating Circuit Protected FU 1 40 A Main TO REPLACE ELECTRICAL PANEL 40 AMP FUSE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries ...

Page 174: ...nel 5 Loosen the two hex screws holding the fuse to the insulator stand offs 6 Pivot one end of the fuse up and off the hex screw then slip the other end of the fuse from under the other hex screw Remove and discard the fuse 7 Install the new fuse under the two hex screws Hand tighten the hex screws tight 8 Reinstall the machine side panel ...

Page 175: ...ELECTRICAL 4 33 6100E 330255 9 00 9 Reconnect the batteries 10 Disengage the prop rod and lower the seat support 11 Start the machine and check for proper operation ...

Page 176: ...eed of the machine with the pressure of your foot on the pedal the harder you press the faster the machine travels Use the brake pedal to stop the machine TO REMOVE DIRECTIONAL PEDAL ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries ...

Page 177: ...rectional pedal 5 Disconnect the directional pedal connector from the main harness Remove any plastic ties holding the directional pedal harness to the main harness 6 Go the the operators compartment and locate the directional pedal assembly Remove the four thread rolling screws holding the directional pedal to the floor plate 7 Remove the pedal assembly from the machine ...

Page 178: ... Parking Brake 1 Position the directional pedal assembly in the machines operators compartment 2 Feed the pedal harness down through the access hole in the floor plate 3 Line up the mount holes in the pedal assembly plate with the mount holes in the machines floor plate 4 Reinstall the four thread rolling screws and tighten to 8 10 Nm 6 7 ft lb ...

Page 179: ...ect the directional pedal connector to the main harness Reinstall any plastic ties that were holding the directional pedal harness to the main harness 7 Reconnect the batteries 8 Disengage the prop rod and lower the seat support 9 Start the machine and check for proper operation Set the pedal neutral if needed See TO SET POTENTIOMETER NEUTRAL instructions in this section ...

Page 180: ...ace Set Parking Brake 1 Remove the directional pedal assembly from the machine See TO REMOVE DIRECTIONAL PEDAL ASSEMBLY instructions in this section 2 Loosen the hex screw and nut holding the accelerator lever to the potentiometer Remove the accelerator lever from the potentiometer shaft 3 Remove the thin hex nut from the potentiometer shaft ...

Page 181: ...eutral position reinstall the accelerator lever onto the shaft of the potentiometer Hand tighten the hex screw and nut 7 Check the length of the threaded rod ball joint assembly Measure the distance between the ball joint centers The dimension should be approximately 4 inches If an adjustment needs to be made loosen the upper jam nut and turn the rod Re tighten the jam nut 8 Reinstall the directio...

Page 182: ...TRICAL 4 40 6100E 330255 9 00 9 Check the new potentiometer for neutral See TO SET POTENTIOMETER NEUTRAL instructions in this section 10 Operate the machine Check the new potentiometer for proper operation ...

Page 183: ...5 9 00 TO SET POTENTIOMETER NEUTRAL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries 3 Lower the side brush ...

Page 184: ...onal pedal connector from the main harness Remove any plastic ties holding the directional pedal harness to the main harness 6 Use a multimeter set to the OHMS setting Check the red B and white A of the connector with the meter 7 The meter reading should be 2500 OHMS 50 OHMS 8 Loosen the upper jam nut on the threaded rod Turn the rod to achieve the proper OHM reading Tighten the jam nut ...

Page 185: ...ELECTRICAL 4 43 6100E 330255 9 00 9 Reconnect the batteries 10 Disengage the prop rod and lower the seat support 11 Operate the machine Check the machine for proper neutral operation ...

Page 186: ... inspected after every 800 hours of machine operation TO REPLACE FRONT DRIVE WHEEL MOTOR FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Open the seat support and engage the prop rod ...

Page 187: ...n guard 5 Loosen the three nuts holding the gearbox assembly to the wheel support Let the gearbox drop down so the drive chain has some slack 6 Turn the front tire until the master link is visible at the bottom of the drive sprocket Remove the master link from the drive chain Make sure to retain the four small O rings from behind the master link clip ...

Page 188: ...rive chain from the machine 8 Disconnect the drive motor from the main electrical harness 9 Finish removing the three nuts and washers holding the gearbox assembly to the wheel support Remove the gearbox assembly from the machine 10 Remove the four hex screws holding the smaller black cover to the side of the gearbox ...

Page 189: ...y Slide the motor and remove the cogged belt from the sprocket 13 Remove the two hex screws from the drive motor Remove the motor from the gearbox Make sure to note the orientation of the drive motor electric wires in relation to the gearbox 14 Loosen the set screws holding the small timing sprocket to the drive motor Slide the sprocket off the shaft Make sure to retain the square key ...

Page 190: ...t on the new motor Locate the small sprocket flush with the end on the motor shaft 18 Position the cogged belt onto the small sprocket 19 Use a large channel lock pliers to pull the drive motor to the front of the gearbox Place one side of the pliers over the small pulley and the other side of the pliers on the front side of the gearbox Squeeze the pliers until the belt is tight 1 16 inch play at ...

Page 191: ... the wheel support The three slots on the gearbox go over the three studs on the wheel support 22 Install the three washers and nuts onto the wheel housing studs Leave loose for now 23 Reinstall the drive chain around the drive sprocket on the drive motor and front wheel assembly Reinstall the master link Make sure the four small O rings are in place behind the master link clip ...

Page 192: ... Tighten nuts to 18 24 Nm 15 20 ft lb 25 Reinstall the drive chain guard and tighten the two nuts to 18 24 Nm 15 20 ft lb 26 Reconnect the drive motor to the main electrical harness 27 Remove the jack stands and lower the machine to the floor Operate the machine and check the gearbox assembly for proper operation ...

Page 193: ...ELECTRICAL 4 51 6100E 330255 9 00 28 Reconnect the batteries 29 Disengage the prop rod and lower the seat support 30 Operate the machine Check the machine for proper operation ...

Page 194: ...R FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Lower the main brush lever 3 Open the seat support and engage the prop rod ...

Page 195: ...e the four screws holding the right hand brush door to the machine frame Remove the right hand side brush door 6 Locate the main brush drive belt idler pulley between the small motor drive pulley and the larger brush pulley 7 Loosen the hex nut in the center of the idler pulley ...

Page 196: ...lt from the two remaining pulleys Remove the main brush drive belt 10 Loosen the two set screws holding the small V belt pulley to the main brush motor shaft Pull the pulley off the shaft Retain the square key 11 Remove the two hex screws holding the brush arm lift link to the front of the brush arm weldment ...

Page 197: ...cess holes 13 Go under the front of the machine and locate the main brush motor behind the front drive assembly Disconnect the main brush motor from the main harness 14 Remove the main brush motor from the machine Note the orientation of the motor and electrical wires 15 Install the new main brush motor into the machine Make sure to orientate the motor so the wires are pointed to the front of the ...

Page 198: ...e four flat head screws Tighten to 11 14 Nm 7 10 ft lb You may have to rotate the brush arm weldment to line up the access holes 18 Wire tie the motor wires to the motor housing 19 Reinstall the small main brush V belt pulley onto the new main brush motor shaft Line up the small V belt pulley with the larger V belt pulley Make sure the square key is installed on the shaft Hand tighten the two set ...

Page 199: ...ldment Reinstall the two hex screws and tighten to 18 24 Nm 15 20 ft lb 21 Position the main brush drive belt onto the motor and brush drive pulleys 22 Move the idler pulley forward in the slot until the belt is tight Tighten the hex nut to 18 24 Nm 15 20 ft lb 23 Reinstall the right hand side brush door ...

Page 200: ...0255 9 00 24 Reconnect the batteries 25 Disengage the prop rod and lower the seat support 26 Remove the jack stands and lower the machine to the floor Operate the machine and check the new main brush motor for proper operation ...

Page 201: ...g Or Servicing Machine Stop On Level Surface Set Parking Brake 1 The main brush motor must be removed before the vacuum fan motor can be removed See TO REPLACE MAIN BRUSH MOTOR instructions in this section 2 Open the seat support and engage the prop rod 3 Disconnect the machine batteries ...

Page 202: ... slot over the black knob then move the panel backward and off the machine 5 Remove the four screws holding the right hand brush door to the machine frame Remove the right hand side brush door 6 Loosen the four hex screws holding the vacuum fan housing to the machine frame 7 Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V belt ...

Page 203: ...pulley off the shaft Retain the square key 10 Remove the four hex screws holding the vacuum fan motor to the mount bracket 11 Go under the front of the machine and locate the vacuum fan motor behind the front drive assembly Disconnect the vacuum fan motor from the main harness 12 Remove the vacuum fan motor from the machine Note the orientation of the motor and electrical wires ...

Page 204: ... to the main harness 15 Line up the mount holes in the new motor with the mount holes in the motor mount bracket Reinstall the four hex screws Tighten to 11 14 Nm 7 10 ft lb 16 Reinstall the vacuum fan V belt pulley onto the new vacuum fan motor shaft Line up the V belt pulley with the V belt pulley up at the impeller Make sure the square key is installed on the shaft Hand tighten the two set scre...

Page 205: ...he machine to tighten the V belt The correct tension is when the belt deflects 8 38 mm 0 33 in from a force of 42 kg 90 to 95 lb at belt midpoint Tighten the screws hand tight 18 Reinstall the right hand side brush door 19 Reinstall the right hand machine cover 20 Reconnect the batteries ...

Page 206: ...4 64 6100E 330255 9 00 21 Disengage the prop rod and lower the seat support 22 Remove the jack stands and lower the machine to the floor Operate the machine and check the new vacuum fan motor for proper operation ...

Page 207: ...r Servicing Machine Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Lower the side brush 3 Remove the side brush from the motor assembly See TO REPLACE SIDE BRUSH instructions in the SWEEPING section ...

Page 208: ...n wire harness 5 Remove the four hex screws holding the side brush motor to the motor mount bracket 6 Drop the motor out of the mount bracket and past the brush guard 7 Position the new side brush motor onto the motor mount bracket The motor is positioned to the rear of the machine ...

Page 209: ...Reinstall the four hex screws and tighten to 8 10 Nm 6 7 ft lb 9 Reconnect the side brush motor to the main harness 10 Wire tie the motor wires to the motor housing 11 Reinstall the side brush See TO REPLACE SIDE BRUSH instructions in the SWEEPING section 12 Operate the machine Check the side brush for proper operation ...

Page 210: ...ELECTRICAL 4 68 6100E 330255 6 01 ELECTRICAL SCHEMATIC 1 2 3 ...

Page 211: ...ELECTRICAL 4 69 6100E 330255 6 01 ELECTRICAL SCHEMATIC 1 2 3 ...

Page 212: ...ELECTRICAL 4 70 6100E 330255 6 01 WIRE HARNESS ...

Page 213: ...ELECTRICAL 4 71 6100E 330255 6 01 WIRE HARNESS ...

Page 214: ...ELECTRICAL 4 72 6100E 330255 6 01 WIRE HARNESS ...

Page 215: ...6100E 330255 9 00 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 216: ...N 6 BLU AT M1 RELAY MACHINE IS PASSING THE POWER UP TESTING CHECK FOR VOLTAGE ON 25 GRY AT KEYSWITCH AND 5A GRN AT RELAY M1 B VOLTAGE CHECK FOR VOLTAGE ON 27C GRN AT M1 RELAY CYCLE AND HOLD THE KEYSWITCH IN THE START POSITION 25 GRY D 2 8A BLU CB 2 5 GRN 5A GRN FUSE 1 OR THE BATTERY CONNECTION TO FUSE 1 ARE OPEN 0 VOLTS THE KEYSWITCH BETWEEN PINS 50 AND 15 IN THE START POSITION WIRES 26 ORA 27A GR...

Page 217: ...GRN AND 13L BLK AT THE MOTOR CONTROLLER 0 VOLTS WIRES 5B GRN OR 13L BLK ARE OPEN B VOLTAGE DISCONNECT P1 CONNECTOR AND RECONNECT IT SO THAT ONLY 34 BLU IS HOOKED UP TO P1 6 NOTE P1 6 MUST HAVE B VOLTAGE FOR THE NEXT TEST VERIFY THE THROTTLE VOLTAGES P1 1 0 VDC P1 2 2 5 VDC P1 3 5 VDC ALL VOLTAGES 3 VDC VOLTAGES INCORRECT REPLACE THE MOTOR CONTROLLER VOLTAGES MEET SPEC RECONNECT THE P1 CONNECTOR PR...

Page 218: ...GREATER THAN 25 VDC REPLACE THE MOTOR CONTROLLER RECONNECT WIRES 35 YEL AND 36 ORA CHECK THE VOLTAGE ACROSS WIRES 35 YEL AND 36 ORA AT THE DISCON NECTED PROPEL MOTOR CONNECTOR WITH THE THROTTLE IN THE FULL FOR WARD POSITION 0 VDC WIRES 35 YEL 36 ORA OR THE MOTOR CONNECTOR TERMINALS ARE OPEN GREATER THAN 25 VDC THE PROPEL MOTOR OR ASSOCIATED WIRES AND CONNECTOR ARE OPEN REPLACE THE MOTOR NOTE THE R...

Page 219: ...EL OR ADAPTOR HARNESS BETWEEN THE THROTTLE AND MOTOR CONTROLLER ARE OPEN OR THE POTENTIOMETER THROTTLE IS DISCONNECTED OR BAD POTENTIOMETER TESTING POTENTIOMETER THROTTLE IS NOT CENTERED PROPERLY READJUST LINKAGE AT FOOT PEDAL NOTE THE MACHINE WILL NOT PROPEL UNTIL A NEUTRAL SIGNAL IS SENSED AT THE THROTTLE CONTINUED ON NEXT PAGE THROTTLE SIGNAL VOLTAGES ARE WITHIN SPEC NORMAL OPERATION 1 With thr...

Page 220: ...GREATER THAN 25 VDC REPLACE THE MOTOR CONTROLLER RECONNECT WIRES 35 YEL AND 36 ORA CHECK THE VOLTAGE ACROSS WIRES 35 YEL AND 36 ORA AT THE DISCON NECTED PROPEL MOTOR CONNECTOR WITH THE THROTTLE IN THE FULL FOR WARD POSITION 0 VDC WIRES 35 YEL 36 ORA OR THE MOTOR CONNECTOR TERMINALS ARE OPEN GREATER THAN 25 VDC THE PROPEL MOTOR OR ASSOCIATED WIRES AND CONNECTOR ARE OPEN REPLACE THE MOTOR NOTE THE R...

Page 221: ... THERMAL SENTRY SWITCH S 4 OR THE VAC BRUSH ROCKER SWITCH BETWEEN 16 GRY AND 17A BLU ARE OPEN CHECK FOR VOLTAGE BETWEEN 17A BLU AND 13AA BLK AT RELAY M2 WIRE 13AA BLK IS OPEN FROM RELAY M2 AND MACHINE GROUND B VOLTAGE CHECK FOR VOLTAGE ON 2A ORA AT RELAY M2 VAC FAN MAIN BRUSH STILL ON 0 VOLTS REPLACE RELAY M2 B VOLTAGE CHECK FOR VOLTAGE ON 3 GRY AT CB 8 0 VOLTS WIRE 2A ORA OR CB 8 IS OPEN B VOLTAG...

Page 222: ... BRN OR THE SIDE BRUSH SWITCH S 6 ARE OPEN CHECK FOR VOLTAGE BETWEEN 12A BRN AND 13Z BLK AT RELAY M3 WIRE 13Z BLK IS OPEN FROM RELAY M3 AND MACHINE GROUND B VOLTAGE CHECK FOR VOLTAGE ON 9 GRN AT RELAY M3 0 VOLTS 2 ORA 9 GRN OR CB 7 IS OPEN B VOLTAGE CHECK FOR VOLTAGE ON 11B PUR AT M3 RELAY 0 VOLTS REPLACE M3 RELAY B VOLTAGE DISCONNECT SIDE BRUSH MOTOR AND CHECK VOLTAGE ACROSS 11A PUR AND 13B BLK A...

Page 223: ...A BLU CB 3 THERMAL SENTRY SWITCH S 4 OR THE VAC BRUSH ROCKER SWITCH BETWEEN 16 GRY AND 17A BLU ARE OPEN CHECK FOR VOLTAGE BETWEEN 17A BLU AND 13AA BLK AT RELAY M2 WIRE 13AA BLK IS OPEN FROM RELAY M2 AND MACHINE GROUND B VOLTAGE CHECK FOR VOLTAGE ON 2B ORA AT RELAY M2 VAC FAN MAIN BRUSH STILL ON 0 VOLTS REPLACE RELAY M2 B VOLTAGE CHECK FOR VOLTAGE ON 14 PUR AT CB 9 0 VOLTS WIRE 2B ORA OR CB 9 IS OP...

Page 224: ...BETWEEN 18 GRN PIN 3 AND 13AB BLK PIN 1 AT SHAKER MODULE 0 VOLTS B VOLTAGE WIRE 13AB BLK IS OPEN FROM SHAKER MODULE PIN 3 AND MACHINE GROUND CHECK FOR VOLTAGE ON 10D YEL AT THE SHAKER SOLENOID SV 1 0 VOLTS B VOLTAGE WIRE 10D YEL IS OPEN DISCONNECT THE SHAKER SOLENOID SV 1 AND MEASURE THE RESISTANCE OF THE COIL sHOULD BE 6 2 OHMS WITHIN SPEC NOT WITHIN SPEC REPLACE SHAKER SOLENOID AND RE TEST RECON...

Page 225: ...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 226: ...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 227: ...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 228: ...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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