Tennant 6400E Service Manual Download

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ELECTRICAL

4-45

6400E MM434 (7--99)

MACHINE WILL NOT PROPEL

REPLACE THE

PROPEL MOTOR

CHECK PROPEL MOTOR TO

MAKE SURE ANY OF THE TERMINALS

ARE NOT SHORTED TO THE CASE

CONNECT A VOLTMETER TO B+ AND M--.

START THE MACHINE AND MEASURE

VOLTAGE WHILE MOVING THE PEDAL

FROM NEUTRAL TO FULL FORWARD. THE

VOLTMETER SHOULD READ FULL BATT

VOLTAGE WHEN THE PEDAL IS IN THE

NEUTRAL POSITION AND NEAR ZERO

WHEN THE PEDAL IS FULLY FORWARD.

MEASURE THE RESISTANCE BETWEEN

WIRES 32/PUR AND 31A/YEL AT TERMINALS

2 AND 3 OF THE PROPEL MOTOR CON-

TROLLER. WHEN THE PEDAL IS IN THE

NEUTRAL POSITION, THE READING

SHOULD BE BETWEEN 0--50 OHMS. THEN,

MEASURE THE RESISTANCE WITH THE

PEDAL POSITIONED FULL FORWARD. THE

READING SHOULD BE BETWEEN 4500--5500

OHMS. NEXT, MEASURE FOR RESISTANCE

WITH THE PEDAL PUSHED TO THE REAR.

THE VALUE SHOULD BE 1500--300 OHMS.

DOES M4 ENERGIZE WHEN THE

FOOT PEDAL IS MOVED FOR-

WARD AND M3 ENERGIZED WHEN

THE PEDAL IS MOVED REVERSE ?

FOLLOW THE PROCEDURE

FOR TROUBLESHOOTING

”MAIN POWER AND HY-

DRAULIC PUMP CONTAC-

TORS WILL NOT PULL IN”

DOES THE MAIN CONTACTOR

PULL IN AND STAY ENER-

GIZED AFTER STARTING

WITH THE KEY SWITCH ?

YES

IS THERE BATTERY VOLTAGE

TO GROUND ON BOTH SIDES

OF THE 80AMP FUSE FU2

WHEN M1 IS ENERGIZED ?

REPLACE FU2

YES

ARE THE CONNECTIONS AT THE

OPTIONAL SEAT SWITCH OR ITS

JUMPER PROVIDING A CONNECTION

BETWEEN 36K/BLU AND 36N/BLU ?

YES

REPLACE THE OPTIONAL

SEAT SWITCH OR JUMPER

IS TERMINAL 1 OF THE PROPEL

MOTOR CONTROLLER HAVE BAT-

TERY VOLTAGE TO ANY 13/BLK

WIRE WHEN M1 IS ENERGIZED ?

YES

RESET OR REPLACE

CB2 OR CHECK WIRING

CHECK SW4 AND SW5

IN THE FOOT PEDAL UNIT

BAD

REPLACE THE FOOT

PEDAL UNIT

YES

REPLACE THE FOOT

PEDAL UNIT

YES

CHECK THE POWER CONNECTIONS

TO THE M3 AND M4 CONTACTORS.

ALSO, INSPECT THE CONDITION OF

THE CONTACTS

REPLACE THE PROPEL

MOTOR CONTROLLER

YES

Summary of Contents for 6400E

Page 1: ...MM434 Rev 02 11 01 Service Manual 6400E ...

Page 2: ...is Tire wheel replacement brake adjustment and replacement seat removal and installation chassis lubrication and steering adjustment and replacement Sweeping Hopper repair replacement brush repair replacement skirt seal repair replacement and sweeping troubleshooting Electrical Battery maintenance and replacement instrument panel replacement and electrical troubleshooting Hydraulics Valve replacem...

Page 3: ... TOWING AND TRANSPORTING THE MACHINE 1 10 PUSHING OR TOWING THE MACHINE 1 10 TRANSPORTING THE MACHINE 1 10 MACHINE JACKING 1 12 STORING MACHINE 1 12 HARDWARE INFORMATION 1 13 STANDARD BOLT TORQUE CHART 1 13 METRIC BOLT TORQUE CHART 1 13 BOLT IDENTIFICATION 1 13 THREAD SEALANT AND LOCKING COMPOUNDS 1 13 HYDRAULIC FITTING INFORMATION 1 14 HYDRAULIC TAPERED PIPE FITTING NPT TORQUE CHART 1 14 HYDRAULI...

Page 4: ...GENERAL INFORMATION 1 2 6400E MM434 11 01 ...

Page 5: ...e if hopper is raised Make sure adequate clearance is available before raising hopper Do not carry riders on machine Always follow safety and traffic rules Report machine damage or faulty operation immediately 5 Before leaving or servicing machine Stop on level surface Set parking brake Turn off machine and remove key 6 When servicing machine Avoid moving parts Do not wear loose jackets shirts or ...

Page 6: ...d or illegible install a new label in its place BATTERY CHARGING LABEL LOCATED ON THE CONTROL BOX FOR SAFETY LABEL LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT HOPPER LIFT ARMS LABEL LOCATED ON BOTH LIFT ARMS HOPPER SUPPORT LABEL LOCATED ON BOTH LIFT ARMS AND THE HOPPER SUPPORT BAR FAN AND BELT LABEL LOCATED ON THE VACUUM FAN HOUSING AND BELT SHROUD 350158 ...

Page 7: ...Sweeping path width 915 mm 36 in Sweeping path width with side brush 1270 mm 50 in Main sweeping brush pattern width 50 to 75 mm 2 to 3 in Hopper weight capacity 315 kg 700 lb Hopper volume capacity 315 L 11 25 ft3 Dust filter area 6 9 m2 74 ft2 GVWR 2041 kg 4500 lb Ceiling height minimum dumping clearance 2340 mm 92 in GENERAL MACHINE PERFORMANCE Item Measure Maximum forward speed 8 km h 5 mph Ma...

Page 8: ...e STEERING Type Power source Emergency steering Rear wheel hydraulic cylinder and rotary valve controlled Hydraulic accessory pump Manual HYDRAULIC SYSTEM System Capacity Fluid Type Hydraulic reservoir 10 6 L 2 8 gal TENNANT part no 65870 Hydraulic total 12 1 L 3 2 gal p Propelling gearbox 2 6 L 2 7 qt SAE 90 Gear weight lubricant BRAKING SYSTEM Type Operation Service brakes Mechanical drum brakes...

Page 9: ...MATION 1 7 6400E MM434 11 01 TOP VIEW SIDE VIEW 930 mm 2085 mm 82 in 1230 mm 48 4 in 2260 mm 89 in 1135 mm 44 7 in 1135 mm 44 7 in 1395 mm 55 in 1435 mm 56 5 FRONT VIEW 2085 mm 82 in 350158 350165 MACHINE DIMENSIONS ...

Page 10: ...ervice Points Daily 8 Brush compartment skirts Check for damage wear and adjustment 5 15 Hopper lip skirts Check for damage wear and adjustment 3 11 Main brush Check for damage or wear 1 Check brush pattern 1 13 Side brush Check for damage or wear 1 Check brush pattern 1 12 Hopper dust filter Shake 1 50 Hours 11 Main brush Rotate end for end 1 3 Batteries Check electrolyte level DW 6 2 ...

Page 11: ...heck tension and wear 1 5 Main brush intermediate belt Check tension and wear 1 5 Main brush belt Check for wear 1 400 Hours 9 Front wheel bearings Check for seal damage 2 800 Hours 4 Hydraulic fluid reservoir Replace filler cap 1 y Replace suction strainer 1 Change hydraulic fluid HYDO 1 6 Hydraulic fluid filter Change filter element 1 Hydraulic hoses Check for wear and damage All 1 Propelling ge...

Page 12: ...iler FOR SAFETY Use truck or trailer that will support the weight of the machine NOTE Empty the hopper before transporting the machine 2 If the loading surface is not horizontal or is higher than 380 mm 15 in from the ground use a winch to load machine If the loading surface is horizontal AND is 380 mm 15 in or less from the ground the machine may be driven onto the truck or trailer 3 To winch the...

Page 13: ...in the wheel pockets at the front of the machine frame The rear tie down locations are the holes in the sides of the machine frame near the rear bumper 6 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 trai...

Page 14: ...e turn off machine and remove key The front jacking locations are on the flat bottom edge of the front of the machine frame next to the front tires The rear jacking location is the center of the rear bumper FOR SAFETY When servicing machine block machine tires before jacking up machine FOR SAFETY When servicing machine jack up machine at designated locations only Block machine up with jack stands ...

Page 15: ...291 380 313 407 424 552 1 00 in 500 650 678 881 757 984 1026 1334 NOTE Decrease torque by 20 when using a thread lubricant METRIC BOLT TORQUE CHART Thread Size Class 8 8 Torque ft lb _Nm Class 10 9 Torque ft lb Nm M4 2 3 3 4 M5 4 5 6 8 M6 7 9 10 14 M8 18 24 25 34 M10 32 43 47 64 M12 58 79 83 112 M14 94 127 133 180 M16 144 195 196 265 M20 260 352 336 455 M24 470 637 664 900 NOTE Decrease torque by ...

Page 16: ... ft lb 12 Nm 0 38 0 56 18 20 ft lb 27 Nm 0 50 0 75 16 30 ft lb 41 Nm 0 62 0 88 14 40 ft lb 54 Nm 0 75 1 12 12 70 ft lb 95 Nm 1 0 1 31 12 90 ft lb 122 Nm HYDRAULIC O RING FITTING TORQUE CHART Tube O D in Thread Size Minimum Torque Maximum Torque 0 25 0 44 20 6 ft lb 8 Nm 9 ft lb 12 Nm 0 38 0 56 18 13 ft lb 18 Nm 20 ft lb 27 Nm 10 ft lb 14 Nm 12 ft lb 16 Nm 0 50 0 75 16 20 ft lb 27 Nm 30 ft lb 41 Nm...

Page 17: ...ed Reset Thermo Sentryt Hopper door partially or completely closed Open hopper door Poor sweeping performance Brush bristles worn Replace brushes Main and side brushes not adjusted properly Adjust main and side brushes Debris caught in main brush drive mechanism Remove debris from drive mechanism Main brush drive failure Contact Tennant service personnel Side brush drive failure Contact Tennant se...

Page 18: ...GENERAL INFORMATION 1 16 6400E MM434 7 99 ...

Page 19: ...AIN 2 6 FRONT TIRES AND WHEELS 2 7 TO REPLACE FRONT WHEEL BEARINGS 2 7 BRAKES AND TIRES 2 10 SERVICE BRAKES 2 10 TO REPLACE BRAKE SHOES 2 10 PARKING BRAKE 2 13 TO ADJUST BRAKES 2 14 PROPELLING GEARBOX 2 16 REAR WHEEL SUPPORT 2 16 STEERING LINK 2 16 TO REMOVE PROPELLING GEARBOX 2 17 TO INSTALL PROPELLING GEARBOX 2 20 HURTH GEARBOX REPAIR MANUAL 2 23 ...

Page 20: ...CHASSIS 2 2 6400E MM434 7 99 ...

Page 21: ...CHASSIS 2 3 6400E MM434 7 99 INTRODUCTION This section includes information on the main chassis related components for example the seat steering brakes and tires ...

Page 22: ...he front of the right hand seat bracket TO REPLACE OPERATOR SEAT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Tilt the seat shroud back against the support cable 2 Remove the four hex nuts holding the seat brackets to the seat shroud 3 Remove the seat assembly from the seat shroud ...

Page 23: ...ientation of the brackets 5 Install the two seat brackets on the bottom of the new seat 6 Position the new seat and brackets on the seat shroud Line up the holes and install the hardware Tighten the hex screws to 18 5 24Nm 15 20 ft lb 7 Close the seat shroud and adjust the seat to a comfortable position ...

Page 24: ... grasp the lock lever 2 Move the lock lever to the left until the seat moves freely 3 Slide the seat forward or backward to a comfortable position Release the lock lever 4 The seat is now locked in the chosen position STATIC DRAG CHAIN The static drag chain prevents build up of static electricity in the machine The chain is attached near the rear of the brush compartment skirts The chain should be...

Page 25: ...SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Disengage the parking brake if activated 2 Jack up one front corner of the machine Place jack stands under machine frame FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands ...

Page 26: ... wheel off the axle 6 Press the old bearings out Press the new bearings in the wheel in the same orientation 7 Slide the wheel back on the axle 8 Slide the flat washer and nut on the shaft 9 Tighten the nut with a hand wrench until the wheel binds then back the nut off to nearest cotter pin hole 10 Insert a new cotter pin through nut and hole ...

Page 27: ...CHASSIS 2 9 6400E MM434 7 99 11 After making sure the wheel spins freely carefully reinstall the hub cap 12 Remove the jackstands and lower the machine 13 Repeat the procedure on the other wheel ...

Page 28: ... should not travel more than 2 inches to fully engage the brakes TO REPLACE BRAKE SHOES FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Disengage the parking brake if activated 2 Jack up one front corner of the machine Place jack stands under machine frame FOR SAFETY Block machine tires before jacking machine up Jack machine ...

Page 29: ...d flat washer 5 Slide the wheel off the axle 6 Remove the one large C shaped tension spring holding the old brake shoes together Remove the old brake shoes 7 Replace the old brake shoes with new brake shoes 8 Reinstall the one large C shaped brake tension spring on the new brake shoes 9 Slide the wheel back on the axle ...

Page 30: ... with a hand wrench until the wheel binds then back the nut off to nearest cotter pin hole 12 Insert a new cotter pin through nut and hole 13 After making sure the wheel spins freely carefully reinstall the hub cap 14 Remove the jackstands and lower the machine 15 Repeat the procedure on the other wheel ...

Page 31: ...when the machine rolls after setting the parking brake and after every 200 hours of operation The parking brake may be tightened by adjusting the brake rod clevis on the ends of the brake cross shaft See TO ADJUST BRAKES instructions Adjust the parking brake so it will hold the Machine on a smooth 8 degree incline The brake pedal should not travel more than 2 inches to fully engage the brakes ...

Page 32: ...achine And Remove Key 1 Raise the hopper and engage the support bar 2 Disengage the parking brake if activated FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 3 Remove the cotter pin and the clevis pin holding the brake rod clevis to the brake assembly lever ...

Page 33: ...tment and pedal travel The pedal should move no more than 1 before engaging the brakes 6 Reinstall the cotter pin and the clevis pin in the brake rod clevis and the brake assembly lever 7 Repeat the procedure on both sides 8 Drive the machine and operate the brakes Check for equal engagement of the brakes on both wheels ...

Page 34: ...s while rotating the gearbox from stop to stop Fill the second grease fitting while rotating the gearbox back to the original position The bearing cavity is full when grease comes out of the top seal Lubricate with Lubriplate EMB grease Tennant part number 01433 1 after every 200 hours of machine operation or after steam cleaning the gearbox area FOR SAFETY When servicing machine block machine tir...

Page 35: ...ve Key 1 Raise the rear of the machine and place jack stands under the machine frame FOR SAFETY When servicing machine jack up machine at designated locations only Block machine up with jack stands 2 Remove the rear tire and wheel assembly 3 Remove the drain plug from the bottom of the gear box to drain the gear lube Reinstall the plug after all the lube has been drained ...

Page 36: ...teries 6 Mark the location of the drive motor in relation to the gearbox Lift the drive motor up and out of the gearbox Place the motor out of the way for now 7 Mark the location of the steering cylinder mount ring in relation to the gearbox Remove the seven hex screws holding the steering cylinder mount ring to the top of the propelling gearbox ...

Page 37: ...is removed The propelling gearbox is top heavy and tippy during the removal operation 9 Mark the location of the gearbox in relation to the machine frame 10 Remove the six hex screws holding the propelling gearbox to the machine frame 11 Drop the gearbox down and out of the machine NOTE Make sure to support the top of the propelling gear box when removing it from the machine to keep it from tippin...

Page 38: ...ns only Block machine up with jack stands 2 Position the gearbox under the rear of the machine The gearbox must be stood straight up and jacked into position NOTE Place a jack under the gearbox and use it to lift the gearbox into place 3 Line up the threaded mount holes in the top of the gearbox with the mount holes in the machine frame Reinstall the six hex screws using 242 blue loctite and tight...

Page 39: ...ing cylinder mount ring is installed on top of the gearbox in the same orientation as it was removed 6 Position the drive motor in the top of the gearbox Line up the three mount holes in the motor with the holes in the gear box NOTE Make sure the drive motor is installed in the same orientation on the gearbox as it was removed 7 Go under the rear of the machine in back and reinstall the three hex ...

Page 40: ...stall the rear tire and wheel assembly Tighten the wheel nuts to 122 150 Nm 90 110 ft lb 9 Remove the jack stands and lower the machine 10 Reconnect the batteries Start the machine and operate the propel circuit Check for proper operation ...

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Page 63: ... TO REPLACE SIDE BRUSH 3 42 TO ADJUST SIDE BRUSH PATTERN 3 45 TO ADJUST SIDE BRUSH TILT PATTERN 3 46 SIDE BRUSH GUARD 3 48 TO ROTATE OR REPLACE SIDE BRUSH GUARD 3 48 SIDE BRUSH PIVOT 3 49 Page SKIRTS AND SEALS 3 50 HOPPER LIP SKIRTS 3 50 TO REPLACE HOPPER LIP SKIRTS 3 50 BRUSH DOOR SKIRTS 3 52 TO REPLACE AND ADJUST RIGHT HAND BRUSH DOOR SKIRT 3 52 TO REPLACE AND ADJUST LEFT HAND BRUSH DOOR SKIRT 3...

Page 64: ...SWEEPING 3 2 6400E MM434 7 99 ...

Page 65: ...34 7 99 INTRODUCTION The side brush sweeps debris into the path of the main brush The main brush sweeps debris from the floor into the hopper The vacuum system pulls dust and air through the hopper and the hopper dust filter ...

Page 66: ...o regular maintenance If hopper components are repaired or replaced some components may need to be readjusted for best performance The hopper may need to be removed from the machine for some repair or service work TO REMOVE HOPPER 1 Start the machine and raise the hopper Engage the support bar 2 Remove the hopper level adjustment bolt nut and washers 3 Cut the plastic ties holding the hopper harne...

Page 67: ... Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 6 Disconnect the hydraulic hoses leading to the side brush motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 7 Disconnect the side brush lift cable at the hydraulic motor 8 Remove the four hex screws holding the hopper bumper to the sides of the hopper ...

Page 68: ... hopper 10 Remove the bumper and side brush assembly from the machine 11 Remove the two hex screws and nyloc nuts holding the pivot bearings to each side of the hopper lift arm 12 The hopper can now be pulled away from the machine 13 Disconnect and plug the hydraulic hoses leading to the hopper dump door cylinder 14 The hopper can now be removed from the machine ...

Page 69: ...careful not to pinch hydraulic hoses or electrical wires during this procedure 2 Reconnect the hydraulic hoses to the dump door cylinder See the schematic in the HYDRAULICS section of this manual for proper hose connections NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 3 Line up the holes in the hopper pivot bearing flanges with the holes in the hopper lift arms Inst...

Page 70: ...stall the seven hex screws and tighten to 18 24 Nm 15 20 ft lb 6 Reconnect the hydraulic hoses to the side brush motor See the schematic in the HYDRAULICS section of this manual for proper hose connections 7 Reconnect the side brush lift cable at the side brush assembly 8 Reconnect the hopper harness to the main harness 9 See the schematic in the ELECTRICAL section of this manual for proper harnes...

Page 71: ...400E MM434 7 99 10 Reinstall the lip height adjustment bolt on the back of the hopper 11 Start the machine and check for proper operation of hopper vacuum fan dump door side brush rotation and side brush up and down ...

Page 72: ...nt adjust the length of the adjustment bolt on the back of the hopper TO ADJUST HOPPER BUMPER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Loosen the four hex screws and nyloc nuts holding the hopper bumper to the sides of the hopper 2 Loosen the three hex screws holding the hopper bumper to the front of the hopper 3 Adjus...

Page 73: ...ns TO REMOVE HOPPER LIFT ARM 1 Park the machine on a smooth level surface 2 Stop the machine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Remove the debris hopper See TO REMOVE HOPPER FROM MACHINE instructions 4 Remove the cotter pins from the upper hopper lift cylinder pin ...

Page 74: ...e the hex hardware holding the hopper pivot pins to the frame towers 7 Raise up slightly on the lift arm to take pressure off the pins Remove the pins and washers and remove the lift arm from the machine 8 If the large self aligning bearing needs to be changed remove retaining rings and press the old bearing out of the lift arm ...

Page 75: ...he machine aligning the upper bearings in the lift arm with the holes in the towers of the machine NOTE Make sure the side brush lift cable is looped over the plastic pulley on the right hand lift arm pin 4 Install the lift arm pins in the bearings from the inside of the machine Make sure to reinstall the spacer washers that were removed when the pins were removed 5 Align the hole in lift arm pin ...

Page 76: ... 6 Align the small fiberglide bearing in the lift arm cylinder lug with the hole in the clevis on the hopper lift cylinder Reinstall the cylinder pin and cotter pins 7 Reinstall the hopper assembly See TO INSTALL HOPPER instructions ...

Page 77: ... DUMP DOOR 1 Make sure the hopper is emptied of all debris Engage the parking brake 2 Raise the hopper and engage the prop rod WARNING Raised Hopper May Fall Engage Hopper Support Bar 3 Open the dump door Shut off the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Disconnect the rod end of dump door cylinder from the...

Page 78: ...ack off the hopper 6 Remove the five hex screws holding the seal on the front of the dump door to the back of the hopper 7 Use a razer knife to remove the RTV from the two dump door pivot bolts on each side of the hopper Remove the two hex screws 8 Drop the dump door down and out of the hopper ...

Page 79: ... Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Position the dump door in the hopper Line up the pivot holes in the dump door with the mount holes in each side of the hopper 4 Install the two hex screws and nuts Hand tighten tight 5 Put a small amount of RTV around the two hex screws 6 Reinstall the seal on the front of the dump door Hand tighten the...

Page 80: ...nt bracket on the center of the dump door 8 Reconnect the two tension springs to the mount bracket 9 Start the machine and open and close hopper door a few times Check for proper operation NOTE Make sure the seals on the dump door are adjusted so they contact the inside wall of the hopper ...

Page 81: ...the Filter shaker position D TAPPING Tap the filter gently on a flat surface with the dirty side down Do not damage the edges of the filter element and seals or the filter will not seat properly in the filter frame D AIR Blow air through the dust filter opposite the direction of the arrows This may be done with the dust filter in the machine Always wear eye protection when using compressed air FOR...

Page 82: ...open the hopper cover Support the hopper with the hopper cover prop rod 3 Lift the dust filter element out of the hopper insert 4 Clean or discard the dust filter as required 5 Clean and inspect the filter sealing surfaces Make sure the foam element centering strips attached to the hopper and intact Put the cleaned or new dust filter in the hopper insert with the arrows pointing up 6 Lower the hop...

Page 83: ...h in the lowered position Adjust the main brush pattern by turning the main brush down pressure knob and moving the brush stop Rotate the main brush end for end after every 50 hours of operation for maximum brush life and best sweeping performance Replace the main brush when the remaining bristles measure 25 mm 1 in in length TO REPLACE MAIN BRUSH 1 Stop the machine and set the parking brake FOR S...

Page 84: ...ment 6 Put the new or rotated end for end main brush on the floor next to the access door 7 Slide the main brush onto the drive plug Rotate the brush until it engages the drive plug and push it all the way onto the plug 8 Slide the main brush idler plate plug in the main brush 9 Reinstall the attachment bolt 10 Close the right side main brush access door Check the main brush pattern ...

Page 85: ...n the main brush over the chalked area 3 Lower and start the main brush for 15 to 20 seconds while keeping a foot on the brakes to keep the machine from moving This will lower the rotating main brush NOTE If chalk or other material is not available allow the brushes to spin on the floor for two minutes A polish mark will remain on the floor 4 Raise and stop the main brush 5 Drive the machine off t...

Page 86: ...TE To decrease the width of the main brush pattern loosen the main brush pattern adjustment handle and slide backward in the slot NOTE If the main brush pattern is tapered more than 15 mm 0 5 in on one end than the other adjust taper 1 Loosen the brush shaft bearing bracket mounting bolts A Move the brush shaft bearing bracket up or down in the slots B Re check the main brush pattern and readjust ...

Page 87: ...ndary belt uses a spring idler for tension WARNING Moving belt and fan Keep away TO REPLACE MAIN BRUSH PRIMARY BELT 1 Park the machine on a smooth level surface 2 Stop the machine and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the seat shroud 4 Remove the belt guard ...

Page 88: ... the idler plate back to remove tension on the primary belt Remove the primary belt from the pump sheave groove 6 Open the LH brush door 7 Remove the tension spring from the lower idler plate 8 Remove the hex screw holding the lower idler plate to the brush shaft 9 Remove the lower idler plate from the machine ...

Page 89: ...e machine 12 Position the new belt on the lower sheave 13 Route the new belt up toward the hydraulic pump sheave 14 Reinstall the lower idler plate on the brush shaft Tighten the hex screw to 18 24 Nm 15 20 ft lb 15 Position the new belt on the hydraulic pump sheave 16 Reinstall the tension spring on the lower idler plate ...

Page 90: ...he upper idler plate forward to tension to primary belt The correct tension is when the belt deflects 8 mm 0 3 in from a force of 2 3 kg 5 lb at belt midpoint Tighten the hex screws to 37 48 Nm 26 34 ft lb 18 Reinstall the belt guard 19 Start the machine and check the main brush for proper operation ...

Page 91: ...e FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the seat shroud 4 Remove the belt guard 5 Loosen the hex screws holding the upper idler plate to the machine frame Pull the idler plate back to remove tension on the primary belt Remove the primary belt from the pump sheave groove ...

Page 92: ...LH brush door 7 Remove the tension spring from the lower idler plate 8 Remove the hex screw holding the lower idler plate to the brush shaft 9 Remove the lower idler plate from the machine 10 Remove the primary belt from the lower sheave groove ...

Page 93: ...acket 12 Remove the secondary belt from the brush sheave and idler shaft sheave Remove the belt 13 Position the new belt on the brush sheave and idler shaft sheave 14 Reinstall the hopper up brush lift cable bracket to the brush arm Tighten the two hex screws to 37 48 Nm 26 34 ft lb 15 Position the primary belt on the lower idler shaft sheave ...

Page 94: ... tension spring on the lower idler plate 18 Push the upper idler plate forward to tension to primary belt The correct tension is when the belt deflects 8 mm 0 3 in from a force of 2 3 kg 5 lb at belt midpoint Tighten the hex screw to 18 24 Nm 15 20 ft lb 19 Reinstall the belt guard 20 Start the machine and check the main brush for proper operation ...

Page 95: ...mp the debris hopper 1 Raise the hopper and engage the prop rod FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Open the left hand brush door 3 Check to see if the V belt leading to the main brush drive pulley is disengaged If the V belt is loose the cable is adjusted properly If the V belt is tight the cable needs to be adju...

Page 96: ...ds showing above the cable clevis 5 Loosen the jam nut that is against the cable clevis 6 Remove the clevis pin holding the cable clevis to the lift bracket 7 Turn the cable clevis clockwise a few turns 8 Reconnect the lift cable to the bracket Check to see if the V belt is now disengaged loose NOTE Repeat steps 5 thru 7 if necessary ...

Page 97: ... running place the main brush lift lever in the raised position NOTE Check to make sure the main brush stops turning If the brush stops no adjustment is necessary If the brush continues to turn go to the next step FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Shut off the machine and lower the main brush 3 Open the left han...

Page 98: ...ustment bolt Turn the bolt counter clockwise a few turns to lengthen it Tighten the jam nut 6 Start the machine and raise the main brush Check the brush for rotation NOTE If the main brush stops turning in the raised position the adjustment procedure is complete If the main brush still turns after the lift lever is placed in the raised position repeat steps 5 and 6 ...

Page 99: ... On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Remove the main brush idler arm from the machine 2 Remove the plastic cap from the idler plug 3 Clean the area around where the cap was mounted in the idler plug 4 Remove the M12 flat screw nyloc hex nut and washer holding the idler plug to the idler arm ...

Page 100: ...Place a new bearing the old seal plate and the retainer on the idler 8 Reinstall the four hex screws that hold the bearing seal plate and retainer in place Leave screws loose for now 9 Install the idler shaft in the new bearing Tighten the four hex screws to 8 10 Nm 6 8 ft lb 10 Position the idler plug on the idler arm shaft Reinstall the long flat screw Tighten to 68 81 Nm 50 60 ft lb ...

Page 101: ...9 6400E MM434 7 99 11 Put a small amount of RTV on the lip of the plastic cap and install in the end of the idler plug 12 Reinstall the idler arm on the machine 13 Operate the machine and check for proper operation ...

Page 102: ...et Parking Brake Turn Off Machine And Remove Key 1 Remove the main brush idler arm and brush from the right side of the machine 2 Remove the main brush motor arm assembly from the left side of the machine 3 Remove the large hex screw and nyloc nut holding the brush arm to the pivot bearings 4 Let the brush arm drop down and out of the way ...

Page 103: ...arings on the mount brackets Make sure to have the lock collars pointing to the outside of the machine 8 Reinstall the two bolts holding each of the two brush shaft bearings and retainers to the bearing brackets Tighten to 18 24 Nm 15 20 ft lb 9 Reinstall the main brush motor plate and idler plate 10 Check main brush pattern for taper and width Adjust as necessary See TO CHECK AND ADJUST MAIN BRUS...

Page 104: ...er counter clockwise to increase the brush contact with the sweeping surface and clockwise to decrease the brush contact with the sweeping surface The side brush should be replaced when it no longer sweeps effectively for your application A guideline length is when the remaining bristles measure 50 mm 2 in in length You may change the side brush sooner if you are sweeping light litter or wear the ...

Page 105: ...e pin Remove the pin 5 Slide the side brush off the side brush motor shaft NOTE Remove the drive hub and put it on the new brush if one is not installed 6 Slide the new side brush on the side brush motor shaft 7 Reinstall the side brush retaining pin through the side brush hub and shaft 8 Secure the pin by clipping the pin keeper over the end of the pin ...

Page 106: ...SWEEPING 3 44 6400E MM434 7 99 9 Disengage the hopper support bar and lower the hopper 10 Adjust the side brush pattern with the side brush down pressure lever ...

Page 107: ...Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Lower the side brush 2 Turn the side brush lever clockwise to decrease side brush pattern Turn the side brush lever counter clockwise to increase side brush pattern NOTE One half of the bristles should normally contact the floor 3 Raise the side brush ...

Page 108: ...ervicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Lower the side brush 2 Raise the hopper slightly and shut off the machine 3 Loosen the two hex screws on the back of the hopper bumper near the side brush assembly 4 Tilt the side brush in either direction ...

Page 109: ...SWEEPING 3 47 6400E MM434 7 99 5 Tighten the hardware firmly 6 Lower the hopper 7 Start the machine and turn on the side brush Check the side brush pattern 8 Raise the side brush ...

Page 110: ...lace the brush guard after all four sides have been used TO ROTATE OR REPLACE SIDE BRUSH GUARD FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Remove the side brush 2 Remove the four bolts holding the side brush guard to the side brush motor 3 Rotate or replace the side brush guard 4 Reinstall the four bolts in the side brush...

Page 111: ...ould be checked for excessive movement after every 200 hours of operation Torque the front and rear compression springs to reduce excessive movement The side brush tilt is adjusted with the side brush cable Turn the clevis on the cable to get the desired side brush pattern ...

Page 112: ...the hopper lip skirts for wear or damage daily Replace the hopper lip skirts when they no longer touch the floor TO REPLACE HOPPER LIP SKIRTS 1 Dump the machine debris hopper 2 Set the machine parking brake 3 Raise the hopper engage the hopper support bar Shut off the machine WARNING Raised Hopper May Fall Engage Hopper Support Bar FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surfa...

Page 113: ...trip hopper lip and the back up strip Discard the hopper lip 6 Thread the retaining strip mounting bolts through the retaining strip the new hopper lip and the back up strip 7 Tighten the mounting hardware to 8 14 Nm 6 10 ft lb 8 Start the machine and lower the hopper ...

Page 114: ...r otherwise Check the skirts for wear or damage and adjustment daily NOTE The brush door skirts have slotted holes to allow for a ground clearance adjustment The door must be closed for proper adjustment TO REPLACE AND ADJUST RIGHT HAND BRUSH DOOR SKIRT 1 Park the machine on a smooth level surface 2 Stop the machine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine S...

Page 115: ...ead the skirt retaining bolts through the brush door the door skirt and in the skirt retaining strip NOTE The brush door skirts have slotted holes to allow for a ground clearance adjustment The door must be closed for proper adjustment 9 Slide the brush door skirt up or down so it will clear the floor by 3 5 mm 0 12 to 0 25 in Hand tighten the hex screws firmly 10 Operate the machine and check the...

Page 116: ...ace 2 Stop the machine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the left hand brush door 4 Remove the four hex screws holding the skirt mount plate to the machine 5 Remove the brush skirt retaining bolts ...

Page 117: ...rt retaining strip NOTE The brush skirts have slotted holes to allow for a ground clearance adjustment The skirt plate must be mounted on the machine for proper adjustment 10 Reinstall the skirt mount plate on the machine Tighten the hex screws to 18 24 Nm 15 20 ft lb 11 Slide the brush door skirt up or down so it will clear the floor by 3 5 mm 0 12 to 0 25 in Hand tighten the hex screws firmly 12...

Page 118: ...ar or damage every 100 hours of operation REAR SKIRT AND DEFLECTOR BLADE The rear skirt and the deflector blade are located on the bottom rear of the main brush compartment The rear skirt should clear the floor up to 5 mm 0 25 in in dusty conditions and touch the floor otherwise The deflector blade is spring loaded Check the skirt and blade for wear or damage and adjustment daily NOTE Rear tire pr...

Page 119: ...on a smooth level surface 2 Stop the machine and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the main brush doors 4 Remove the main brush 5 Remove the retaining strip and floor skirt Discard the old skirt ...

Page 120: ... and the retaining strip toward the rear wheel 8 Slide the rear floor skirt up or down so that the skirt clears the floor up to a maximum of 5 mm 0 25 in 9 Tighten the rear floor skirt mounting bolts to 8 14 Nm 6 10 ft lb 10 Remove the brush contact blade retaining strip and the brush contact blade Discard the old blade up to 5 mm up to 0 25 in ...

Page 121: ...d the mounting bolts through the mounting bracket the brush contact blade and the retaining strip 13 Tighten the brush contact blade mounting bolts to 8 14 Nm 6 10 ft lb 14 Reinstall the main brush 15 Close the main brush doors 16 Operate the machine and check for proper operation ...

Page 122: ... hardware to 4 5 Nm 3 4 ft lb Inspect the seals for wear or damage every 100 hours of operation HOPPER TOP SEAL The hopper dust seal is located under the front of the machine frame in the area of the machine that is contacted when the hopper is in the down position Check the seal for wear or damage every 100 hours of operation You can reach the seal by lifting the hopper and engaging the prop arm ...

Page 123: ...Engage Hopper Support Bar FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Remove the skirt retainer and skirt from each side of the machine Remove the plastic hardware by prying under the head 5 Position the new skirt and existing retainer on the front of the machine frame Secure with plastic push in hardware 6 Repeat on the ...

Page 124: ...AN SEAL The hopper vacuum fan seal is mounted on the front the vacuum fan inlet assembly Check the seal for wear or damage every 100 hours of operation You can reach the seal by removing the hopper insert HOPPER DUMP DOOR SEALS The hopper door seals are located on the hopper door They seal the hopper when the hopper door is closed Tighten hardware to 3 4 Nm 2 5 3 5 ft lb Check the seals for wear o...

Page 125: ...ngage hopper support bar WARNING Raised Hopper May Fall Engage Hopper Support Bar FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Remove the six hex screws holding the dump door seal retainer and sponge cord to dump door Discard the old seal 5 Remove the three hex screws holding each side seal to the dump door Discard the old...

Page 126: ...en to 3 3 4 4 Nm 30 39 In lb 7 Align the holes in the new side seal with holes on the edge of the dump door and retainer Reinstall the three hex screws Tighten to 3 3 4 4 Nm 30 39 In lb Make sure the seals are lined up with edge of hopper when tightening 8 Start machine and lower hopper 9 Operate the machine and check the dump door for proper operation ...

Page 127: ...lling air from the main brush area through the hopper to the dust filters TO REMOVE VACUUM FAN ASSEMBLY 1 Park the machine on a smooth level surface 2 Stop the machine and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the seat shroud 4 Remove the vacuum hose connected to the vacuum fan assembly ...

Page 128: ...wn on the vacuum fan assembly and remove the V belt from the vacuum fan sheave 7 Remove the tension spring from the frame bracket 8 Remove the two hex screws holding the vacuum fan assembly to the frame mount bracket 9 Remove the vacuum fan assembly from the machine ...

Page 129: ... brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the seat shroud 4 Position the vacuum fan assembly in the machine 5 Align the holes in vacuum fan mount bracket with the bracket on the machine Reinstall the two hex screws and nuts Tighten to 37 48 Nm 27 35 ft lb ...

Page 130: ...et 7 Push down on the vacuum fan assembly Reinstall the V belt on the vacuum fan sheave 8 Reinstall the belt guard Tighten the hardware to 18 24 Nm 15 20 ft lb 9 Reconnect the hose to the vacuum fan housing 10 Start the machine and operate the vacuum fan Check for proper operation ...

Page 131: ...ects 5 mm 0 19 in from a force of 1 4 kg 3 0 lb WARNING Moving belt and fan Keep away TO REPLACE VACUUM FAN BELT 1 Park the machine on a smooth level surface 2 Stop the machine and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the seat shroud 4 Remove the vacuum fan belt guard ...

Page 132: ...om the main electric motor sheave Remove the V belt from the machine 7 Place the new V belt over the main electric motor sheave 8 Push down on the vacuum fan assembly and place the new V belt over the sheave on the vacuum fan Allow the tension spring to pull the vacuum fan assembly back up and tension the V belt 9 Reinstall the belt guard 10 Start the machine and check the vacuum fan for proper op...

Page 133: ...ake Turn Off Machine And Remove Key 3 Remove the vacuum fan assembly from the machine See TO REMOVE VACUUM FAN ASSEMBLY instructions in this section 4 Remove the nine thread cutting screws holding the fan housing to the fan assembly Remove the housing 5 Hold the impeller from turning and remove the hex nut from the end of the fan impeller shaft Pull the impeller straight off the shaft NOTE Make su...

Page 134: ... are in place on the impeller shaft 7 Reinstall the hex nut on the end of the impeller shaft 8 Hold the new impeller from turning and firmly tighten the flex lock nut 9 Reinstall the fan housing on the fan assembly 10 Reinstall the nine thread cutting screws in the fan housing Hand tighten 11 Reinstall the vacuum fan assembly in the machine See TO INSTALL VACUUM FAN ASSEMBLY instructions in this s...

Page 135: ...g Brake Turn Off Machine And Remove Key 3 Remove the vacuum fan assembly from the machine See TO REMOVE VACUUM FAN ASSEMBLY instructions in this section 4 Remove the nine thread cutting screws holding the fan housing to the fan assembly Remove the housing 5 Hold the impeller from turning and remove the hex nut from the end of the fan impeller shaft Pull the impeller straight off the shaft NOTE Mak...

Page 136: ...e four hex screws holding the bearing assembly to the fan mount bracket and fan assembly back plate Remove the bearing assembly 8 Use a small press to remove the impeller shaft and two bearings from the bearing housing NOTE Make sure to note the orientation of the bearings and impeller shaft in relation to the bearing housing 9 Press two new bearings in the bearing housing ...

Page 137: ...te on the fan mount plate Tighten the four M6 hex screws and nyloc nuts to 7 6 9 9 Nm 5 6 ft lb 12 Reinstall the spacer key and impeller on the shaft NOTE Place a small amount of grease on the impeller shaft to ease installation 13 Reinstall the fan impeller housing using the nine thread cutting screws Tighten to 223 290 Ncm 20 25 in lb ...

Page 138: ...he other side and reinstall the square key and sheave Push the sheave all the way on and hand tighten the two set screws tight 15 Reinstall the vacuum fan assembly in the machine See TO INSTALL VACUUM FAN ASSEMBLY instructions in this section ...

Page 139: ... Turn Off Machine And Remove Key 1 Use a static 40lbs or 3lbs to tension the V belt The correct tension is when the belt at midpoint deflects 5 mm 0 19 in from a force of 1 4 kg 3 0 lb 2 Tighten or loosen the hex nut on the eye bolt that attaches the tension spring to the vacuum fan assembly This will raise or lower the vacuum fan belt tension ...

Page 140: ...pen the hopper door Thermo Sentryt tripped Reset Thermo Sentryt Poor sweeping performance Brush bristles worn Replace brushes Main and side brushes not adjusted properly Adjust main and side brushes Debris caught in main brush drive mechanism Free drive mechanism of debris Main brush drive failure Contact TENNANT service personnel Side brush drive failure Contact TENNANT service personnel Hopper f...

Page 141: ...7 TO REPLACE FILTER SHAKER MOTOR 4 20 DIRECTIONAL PEDAL 4 23 TO REPLACE DIRECTIONAL CONTROLLER 4 23 REAR DRIVE MOTOR 4 27 TO REPLACE REAR DRIVE MOTOR 4 27 MAIN ACCESSORIES MOTOR 4 31 TO REPLACE MAIN ACCESSORIES MOTOR 4 31 ELECTRICAL SCHEMATIC 4 36 WIRE HARNESS GROUP 4 38 CONTROL PANEL CABLE GROUP 4 39 CONTROL PANEL WIRE GROUP 4 40 WIRE HARNESS GROUP 4 41 TROUBLESHOOTING 4 43 6400E ELECTRICAL SCHEM...

Page 142: ...ELECTRICAL 4 2 6400E MM434 7 99 ...

Page 143: ...ELECTRICAL 4 3 6400E MM434 7 99 INTRODUCTION The machines electrical system consists of the batteries instrument panel drive motor actuators switches relays and circuit breakers ...

Page 144: ...on of baking soda and water Brush the solution sparingly over the battery tops terminals and cable clamps Do not allow any baking soda solution to enter the batteries Use a wire brush to clean the terminal posts and the cable connectors After cleaning apply a coating of clear battery post protectant to the terminals and the cable connectors Keep the tops of the batteries clean and dry Keep all met...

Page 145: ...nd acid are not thoroughly mixed the readings may not be accurate Check the hydrometer readings against the following chart to determine the remaining battery charge level SPECIFIC GRAVITY at 25_ C 77_ F Charge Level 315A hr Battery 340A hr Battery 440A hr Battery 100 1 290 1 300 1 315 20 1 250 1 155 1 155 0 1 140 1 120 1 115 NOTE If the readings are taken when the battery electrolyte is any tempe...

Page 146: ...on level surface set parking brake turn off machine and remove key 3 Open the seat support 4 Check the electrolyte level in all the battery cells 5 If the level is low add just enough distilled water to cover the battery plates DO NOT OVERFILL The batteries can overflow during charging due to expansion NOTE Make sure the battery caps are in place while charging FOR SAFETY When maintaining or servi...

Page 147: ...he battery The charger can not charge the battery when this happens 8 The Tennant charger will start automatically When the batteries are fully charged the Tennant charger will automatically turn off NOTE Use a charger with the proper rating for the batteries to prevent damage to the batteries or reduce the battery life NOTE If the charger needs to be disconnected from the machine before the batte...

Page 148: ...arge indicator shows the charge level of the batteries It displays the charge level when the machine is operating When the batteries are fully charged the indicator on the far right is lit As the batteries discharge the indicator will move along the display to the left Recharge the batteries when the indicator flashes NOTE The reading on the battery discharge indicator is not accurate when the mac...

Page 149: ...o Sentryt stops the vacuum fan and cuts off the air flow TO REPLACE THERMO SENTRYt FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the hopper cover and engage prop rod 2 Locate the Thermo Sentryton the back of the filter shaker motor bracket Unplug the two wires leading to the Thermo Sentryt ...

Page 150: ...4 7 99 3 Remove the hex screws holding the Thermo Sentryt to the bracket Remove from the hopper 4 Install the new Thermo Sentryt on the bracket Reinstall the hardware and tighten 5 Reconnect the wires and close the hopper cover ...

Page 151: ...op On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Cut the plastic wire tie holding the Thermo Sentryt solenoid wire to the machine Disconnect the Thermo Sentryt solenoid wire harness from hopper harness 3 Remove the pin connecting the rod of the Thermo Sentryt solenoid to the lever ...

Page 152: ...t holding Thermo Sentryt solenoid to the bracket Remove the Thermo Sentryt solenoid from the machine 5 Mount the new Thermo Sentryt solenoid on the bracket with existing hardware 6 Reconnect the wires to the Thermo Sentryt solenoid 7 Close the seat support ...

Page 153: ... meter fuel gauge horn button circuit breakers and indicator light panel TO REPLACE INDICATOR LIGHT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the hopper and engage the support bar 2 Open the seat support and disconnect the battery ...

Page 154: ...unt plate back away from the instrument panel 5 Unplug the two wires leading to the light that needs to be changed 6 Squeeze the sides of the light and push the light out of the mount plate 7 Install the new light in the mount plate Snap in place 8 Reconnect the wires to the new light See schematic in this section 9 Position the mount plate back on the instrument panel Reinstall the two nyloc nuts...

Page 155: ...ELECTRICAL 4 15 6400E MM434 7 99 10 Reconnect the battery cables 11 Close the seat support 12 Start the machine and lower the hopper Check the indicator lights for proper operation ...

Page 156: ...op current flow until the problem is corrected The circuit breakers are located in the operator compartment This chart lists the circuit breakers and the electrical components they protect Circuit Breaker Rating Circuit Protected CB 1 15 A Thermo Sentryt CB 2 15 A Instrument panel seat switch CB 3 15 A Operating lights CB 4 15 A Horn FUSES Fuses are one time protection devices designed to stop the...

Page 157: ... Turn Off Machine And Remove Key 1 Raise the hopper and engage the support bar 2 Open the seat support and disconnect the battery 3 Locate the circuit breakers below the indicator light panel 4 Use the electrical schematic in this section to locate the circuit breaker that needs to be replaced 5 Disconnect the wires leading to the faulty circuit breaker ...

Page 158: ...t off 7 Remove the old circuit breaker and discard 8 Position the new circuit breaker in the hole in the panel Install the metal lock ring NOTE The circuit breaker will only fit in the hole in one direction 9 Plug the main harness wires into the new circuit breaker See the schematic in this section 10 Reconnect the battery cables ...

Page 159: ...ELECTRICAL 4 19 6400E MM434 7 99 11 Close the seat support 12 Start the machine and lower the hopper Check the new circuit breaker for proper operation ...

Page 160: ...Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the hopper cover and engage the prop rod 2 Locate the filter shaker motor on the top side of the filter shaker assembly 3 Unplug the filter shaker motor from the hopper harness ...

Page 161: ...o hex screws holding the shaker motor bracket to the motor assembly Remove the motor from the assembly 6 Loosen the two set screws on the eccentric weight Pull the weight off the motor shaft 7 Install the eccentric weight on the new shaker motor Position the weight flush with the guard plate 8 Install the new shaker motor on the assembly mount plate Tighten the two hex screws to 18 24 Nm 15 20 ft ...

Page 162: ... shaker motor support bracket Make sure the sleeves are in place on the two hex screws tighten to 18 24 Nm 15 20 ft lb 10 Plug the shaker motor into the hopper harness 11 Test the shaker motor for proper operation 12 Disengage the hopper cover prop rod and lower the cover ...

Page 163: ...ress the faster the machine travels The machine will coast for a short distance before changing direction when the directional pedal is reversed Use the brake pedal to stop the machine TO REPLACE DIRECTIONAL CONTROLLER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support and disconnect the batteries 2 Remove ...

Page 164: ...rectional pedal 5 Remove the cotter pin and clevis pin holding the directional pedal to the directional assembly Remove the pedal from the machine 6 Remove the two hex screws holding the directional controller to the two mount brackets Remove the directional controller from the machine NOTE Mark the orientation of the arm to the controller for proper re assembly ...

Page 165: ... Install the arm and balljoint assembly on the shaft of the new controller in the same orientation as it was removed Hand tighten the two set screws firmly 9 Position the new controller on the left hand mount bracket Reinstall the two hex screws and nuts Tighten to 8 10 Nm 5 6 ft lb 10 Position the pedal clevis pin and cotter pin back on the mount brackets ...

Page 166: ...d balljoint so it lines up with the hole in the accelerator arm Reinstall the nut on the balljoint and tighten to 8 10 Nm 5 6 ft lb 12 Feed the controller wire harness back down under the floor plate and reconnect to the main harness 13 Reconnect the batteries and operate the machine Check the controller for proper operation ...

Page 167: ...nspected after every 800 hours of machine operation TO REPLACE REAR DRIVE MOTOR FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the rear of the machine and place jack stands under the machine frame FOR SAFETY When servicing machine jack up machine at designated locations only Block machine up with jack stands 2 Remove t...

Page 168: ...or to the gearbox 4 Open the seat support and disconnect the batteries 5 Remove the four power cables leading to the rear drive motor 6 Mark the location of the drive motor in relation to the gearbox Lift the drive motor up and out of the gearbox Remove the drive motor from the machine ...

Page 169: ... Make sure the key is installed on the tapered shaft Tighten the hex nut to 14 18 Nm 10 13 ft lb 10 Position the new motor on the propelling gearbox in the same orientation as the old one Line up the holes in the motor with the holes in the propelling gearbox 11 Reinstall the three hex screws and tighten to 18 24 Nm 15 20 ft lb 12 Reinstall the rear tire and wheel assembly Tighten the wheel nuts t...

Page 170: ...13 Reconnect the four power cables to the drive motor See Power Cable drawing in this section 14 Reconnect the batteries and close the seat support 15 Lower the machine to the floor and operate the propelling Check for proper operation ...

Page 171: ...acuum fan hydraulic pump and the main sweep brush The carbon brushes on the accessories motor should be inspected after every 800 hours of machine operation TO REPLACE MAIN ACCESSORIES MOTOR FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support and disconnect the batteries 2 Remove the hose leading to the vacu...

Page 172: ...sioning spring 5 Remove the two hex screws holding the vacuum fan mount bracket to the machine frame Remove the vacuum fan assembly from the machine 6 Loosen the two hex screws in the adjustment slots on the motor mount pivot Let the pivot drop down and remove the V belt from the motor sheave 7 Disconnect the two electrical cables leading to the accessories motor ...

Page 173: ... not tighten the set screws at this time NOTE Make sure the key is installed on the shaft of the new motor before installing sheave 10 Install the new motor assembly on the mount pivot Reinstall the four hex screws and slide the motor towards the hopper until the motor base contacts the stops on the bracket Tighten the four hex screws to 18 24 Nm 15 20 ft lb 11 Use a straight edge to line up the s...

Page 174: ...nect the two electric cables to the new motor See electrical diagram in this section 14 Reinstall the vacuum fan assembly in the machine Line up the two mount holes in the vacuum fan assembly with the mount holes in the machine frame Reinstall the two hex screws Leave loose for now 15 Use a straight edge to line up the sheave on the vacuum fan assembly with the sheave on the accessories motor Tigh...

Page 175: ... fan sheave and large diameter accessories motor sheave Let up on the vacuum fan Check vacuum fan belt tension See TO TENSION VACUUM FAN BELT in the sweeping section 18 Reinstall the hose on the vacuum fan assembly 19 Reconnect the batteries Start the machine and check the new motor for proper operation ...

Page 176: ...ELECTRICAL 4 36 6400E MM434 11 01 ELECTRICAL SCHEMATIC 1 2 3 4 ...

Page 177: ...ELECTRICAL 4 37 6400E MM434 11 01 ELECTRICAL SCHEMATIC 1 2 3 4 ...

Page 178: ... 6400E MM434 11 01 WIRE HARNESS GROUP WIRE ASSY MAIN HARNESS 340 OR 425 AMP HOUR HEAVY DUTY BATTERIES 18 VOLTS OPTION 340 OR 425 AMP HOUR HEAVY DUTY BATTERIES 18 VOLTS OPTION ELECTRONIC CONTROL PANEL SEE DETAIL G 1 5 ...

Page 179: ...ELECTRICAL 4 39 6400E MM434 11 01 CONTROL PANEL CABLE GROUP ...

Page 180: ...ELECTRICAL 4 40 6400E MM434 11 01 CONTROL PANEL WIRE GROUP ...

Page 181: ...FROM THE REAR CIRCUIT BREAKERS CB 1 15 AMP HOPPER TEMP VAC FAN CB 2 15 AMP SHAKER MOTOR HOPPER DOOR HOPPER POSITION CLOGGED HYD PLUGGED DUST FILTER SIDE BRUSH PROPEL MOTOR B D I CB 3 15 AMP LIGHTS CB 4 15 AMP HORN 57A PUR 57 PUR 36F BLU 52 BRN 36E BLU 36E BLU 36C BLU 36C BLU 36A BLU 25 GRN 36J BLU 36H BLU 1A RED 7D GRY 7C GRY TAILLIGHT VOLTAGE DROPPING RESISTOR 12 BRN 7D GRY 5A PUR 5 PUR 13G BLK 1...

Page 182: ...ELECTRICAL 4 42 6400E MM434 11 01 WIRE HARNESS GROUP ...

Page 183: ...6400E MM434 7 99 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 184: ...IONAL SEAT SWITCH SW8 36M BLU 36N BLU PROPEL MOTOR CONTROLLER 160 AMP MAXIMUM CURRENT LIMIT ACCELERATOR B 31B YEL R2 POTENTOIMETER HAS A RANGE OF 5K OHMS RESISTANCE IN EACH DIRECTION F D 36L BLU 36K BLU REVERSE FORWARD SW5 SW6 36B BLU 36D BLU 34 ORA 35 GRN E C REVERSE FORWARD M3 M4 13U BLK 13T BLK 35A GRN 36G BLU 7D GRY 36A BLU 77 BRN BDI HOUR METER BATTERY DISCHARGE INDICATOR 13C BLK 13A BLK 4 2 ...

Page 185: ...BE 1500 300 OHMS DOES M4 ENERGIZE WHEN THE FOOT PEDAL IS MOVED FOR WARD AND M3 ENERGIZED WHEN THE PEDAL IS MOVED REVERSE FOLLOW THE PROCEDURE FOR TROUBLESHOOTING MAIN POWER AND HY DRAULIC PUMP CONTAC TORS WILL NOT PULL IN DOES THE MAIN CONTACTOR PULL IN AND STAY ENER GIZED AFTER STARTING WITH THE KEY SWITCH NO YES IS THERE BATTERY VOLTAGE TO GROUND ON BOTH SIDES OF THE 80AMP FUSE FU2 WHEN M1 IS EN...

Page 186: ...IONAL SEAT SWITCH SW8 36M BLU 36N BLU PROPEL MOTOR CONTROLLER 160 AMP MAXIMUM CURRENT LIMIT ACCELERATOR B 31B YEL R2 POTENTOIMETER HAS A RANGE OF 5K OHMS RESISTANCE IN EACH DIRECTION F D 36L BLU 36K BLU REVERSE FORWARD SW5 SW6 36B BLU 36D BLU 34 ORA 35 GRN E C REVERSE FORWARD M3 M4 13U BLK 13T BLK 35A GRN 36G BLU 7D GRY 36A BLU 77 BRN BDI HOUR METER BATTERY DISCHARGE INDICATOR 13C BLK 13A BLK 4 2 ...

Page 187: ...RY VOLTAGE BETWEEN 1 RED AT M1 AND ANY 13 BLK WIRE CHECK FOR BATTERY VOLTAGE BETWEEN 7 GRY AND ANY 13 BLK YES NO RESET OR REPLACE CB1 NO REPLACE DIODE D3 YES HOLD THE KEY SWITCH IN THE START POSITION AND MEASURE FOR BATTERY VOLTAGE BETWEEN 3 GRN AND ANY 13 BLK WIRE YES NO REPLACE THE KEY SWITCH CHECK FOR BATTERY VOLTAGE BETWEEN 27 YEL AND ANY 13 BLK WIRE WHEN THE KEY SWITCH IS HELD IN THE START PO...

Page 188: ...ELECTRICAL 4 48 6400E MM434 7 99 ...

Page 189: ...29 HYDRAULIC SOLENOID VALVE 5 32 TO REPLACE SOLENOID VALVE 5 32 TO REPLACE SIDE BRUSH MOTOR 5 35 HYDRAULIC SCHEMATIC ELECTRIC 5 38 HYDRAULIC HOSE GROUP ELECTRIC 5 39 TROUBLESHOOTING 5 40 SIDE BRUSH ON CIRCUIT 5 41 SIDE BRUSH DOES NOT TURN ON 5 42 SIDE BRUSH DOES NOT TURN OFF 5 43 STEERING CIRCUIT RIGHT TURN 5 44 STEERING CIRCUIT LEFT TURN 5 45 POWER STEERING IS NOT NORMAL 5 46 HOPPER DOOR CIRCUIT ...

Page 190: ...HYDRAULICS 5 2 6400E MM434 7 99 ...

Page 191: ...HYDRAULICS 5 3 6400E MM434 7 99 INTRODUCTION The hydraulic system consists of the propel pump accessory pump control valve drive motors and vacuum fan motor ...

Page 192: ...et with a film of hydraulic fluid before putting the cap back on the reservoir ATTENTION Do not overfill the hydraulic fluid reservoir or operate the machine with a low level of hydraulic fluid in the reservoir Damage to the machine hydraulic system may result Drain and refill the hydraulic fluid reservoir with new hydraulic fluid after every 800 hours of operation The hydraulic fluid filter is lo...

Page 193: ...premature failure of hydraulic components ATTENTION Hydraulic components depend on system hydraulic fluid for internal lubrication Malfunctions accelerated wear and damage will result if dirt or other contaminants enter the hydraulic system HYDRAULIC HOSES Check the hydraulic hoses after every 800 hours of operation for wear or damage Fluid escaping at high pressure from a very small hole can be a...

Page 194: ...ill the hydraulic fluid reservoir Do not overfill 4 Check the hydraulic fluid level in the reservoir with the fluid level dipstick 5 Add hydraulic fluid until the level in the reservoir is between the ADD and the FULL range Do not overfill NOTE Do not overfill the hydraulic fluid reservoir Hydraulic fluid expands as it reaches its normal operating temperature Always allow for expansion when fillin...

Page 195: ...top On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support and disconnect the batteries 2 Remove the pump vacuum fan belt guard 3 Push down on the vacuum fan assembly to release tension on the belt Remove the V belt from the large diameter sheave on the accessories motor ...

Page 196: ...V belt leading down to the main brush 5 Remove the main brush V belt from the small diameter sheave on the hydraulic pump 6 Loosen the two hex screws in the adjustment slots on the accessories motor mount pivot Let the pivot drop down and remove the V belt from the large diameter sheave on the hydraulic pump 7 Remove the four allen screws from the sheave on the hydraulic pump Remove the sheave ...

Page 197: ...he hydraulic pump to the machine frame Remove the pump from the machine 10 Remove the hydraulic fittings from the old pump and install in the new pump in the same orientation 11 Loosen the two set screw holding the pump sheave hub to the pump shaft Remove the pump hub and install it on the new pump in the same orientation Hand tighten the set screws tight NOTE Make sure the key is installed on the...

Page 198: ...equirements when opening hydraulic lines 14 Reinstall the sheave on the hydraulic pump hub Tighten the four allen screws to 11 14 Nm 7 10 ft lb 15 Reinstall the V belt leading from the small diameter accessories motor sheave to the large diameter sheave on the hydraulic pump Pull up on the motor mount pivot until the V belt is tight The proper tension is when the belt deflects 4mm 15in from a forc...

Page 199: ...l diameter sheave on the hydraulic pump 18 Use a 1 2 in square drive breaker bar or ratchet wrench to move the upper idler plate forward to tension to primary belt The correct tension is when the belt deflects 8 mm 0 3 in from a force of 2 3 kg 5 lb at belt midpoint Tighten the hex screws to 37 48 Nm 26 34 ft lb 19 Reinstall the pump vacuum fan belt guard 20 Start the machine and check the new hyd...

Page 200: ... 5 5 lb WARNING Moving belt and fan Keep away TO REPLACE HYDRAULIC PUMP BELT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support and disconnect the batteries Remove the pump vacuum fan belt guard 2 Push down on the vacuum fan assembly to release tension on the belt Remove the V belt from the large diameter s...

Page 201: ...stment slots on the accessories motor mount pivot Let the pivot drop down far enough to remove the V belt from the large diameter sheave on the hydraulic pump Remove the old hydraulic pump V belt from the machine 6 Install the new hydraulic pump belt on the small diameter accessories motor sheave and over to the large diameter sheave on the hydraulic pump Pull up on the motor mount pivot until the...

Page 202: ...e small diameter sheave on the hydraulic pump 9 Push the main brush idler in far enough to put tension on the V belt leading down to the main brush The correct tension is when the belt deflects 8 mm 0 3 in from a force of 2 3 kg 5 lb at belt midpoint Tighten the hex screws to 37 48 Nm 26 34 ft lb 10 Reinstall the pump vacuum fan belt guard 11 Start the machine and check the new hydraulic pump V be...

Page 203: ...forth a few times FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Disconnect and cap the two hydraulic hoses leading to the hopper lift cylinder NOTE Always observe hydraulic cleanliness requirements when opening hydraulic lines 5 Remove the inside cotter pin from the upper clevis pin on the upper end of the hopper lift cylin...

Page 204: ...emove the hopper lift cylinder from the machine 8 Remove the fittings from the old cylinder and install in the new cylinder in the same orientation 9 Position the new cylinder in the machine with the rod end pointing to the front of the machine 10 Align the bottom of the lift cylinder with the hole in the frame mount lug Reinstall the clevis pin and cotter pin ...

Page 205: ...ylinder with the hole in the lift arm cylinder mount lug Reinstall the clevis pin and cotter pin 12 Reconnect the hydraulic hoses to the new cylinder See schematic in this section 13 Start the machine and operate the hopper Check for any leaks and proper operation ...

Page 206: ...3 Set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Disconnect and plug the two hoses leading to the hopper dump door cylinder 5 Remove the cotter pin and clevis pin from the top of the dump door cylinder were it attaches to the center rear of the debris hopper ...

Page 207: ...oor cylinder were it attaches to the center of the dump door 7 Remove the old cylinder from the hopper 8 Remove the fittings from the old cylinder and install in the new cylinder in the same orientation 9 Position the new cylinder in the machine with the rod end pointing to the center of the dump door ...

Page 208: ... dump door cylinder 11 Reinstall the clevis pin and cotter pin in the upper end of the dump door cylinder 12 Reconnect the hydraulic hoses to the dump door cylinder See the schematic in this section 13 Start the machine and open and close the hopper dump door Check for any leaks and proper operation ...

Page 209: ...ING CYLINDER 1 Raise the hopper and engage the support bar FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Open the seat support 3 Turn the steering wheel all the way to the left ...

Page 210: ...t of the machine frame 5 Remove the cotter pin castle nut spacer and hex screw holding the steering drag link to the rear drive gear box 6 Disconnect and cap the two hydraulic hoses leading to the steering cylinder NOTE Always observe hydraulic cleanliness requirements when opening hydraulic lines 7 Remove the steering cylinder from the machine ...

Page 211: ...he old cylinder and install in the new cylinder in the same orientation Tighten the jam nut 10 Loosen the jam nut on the rod end of the steering cylinder and remove the drag link Install the drag link on the new cylinder in the same orientation Tighten the jam nut 11 Position the new steering cylinder assembly in the machine with the drag link pointing toward the rear of the machine ...

Page 212: ...h the steering cylinder drag link Tighten very firmly then line up the hole in the hex screw with the castle nut Install the cotter pin 14 Reconnect the hydraulic hoses to the steering cylinder See schematic in this section NOTE Always observe hydraulic cleanliness requirements when opening hydraulic lines 15 Start machine and turn steering wheel in both directions Observe the steering cylinder fo...

Page 213: ...bar FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Turn off the machine and engage the parking brake Open the seat support 3 Disconnect the battery 4 Remove the rubber cap in the center of the steering wheel Remove the large nut ...

Page 214: ...haft 6 Tilt the steering wheel to the lowest position 7 Remove and plug the five hydraulic hoses on the steering control motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 8 Remove the hex screws holding the hydraulic steering valve to the steering column 9 The hydraulic steering valve can now be removed from machine ...

Page 215: ...e new hydraulic steering valve in the machine Position the ports in the same orientation as the old valve Reinstall the hex screws and tighten to 31 40 Nm 27 35 ft lb 12 Reconnect the hydraulic hoses to hydraulic steering valve See the schematic in this section 13 Reinstall the steering wheel on the steering column Tighten the wheel nut to 18 24 Nm 15 20 ft lb ...

Page 216: ...HYDRAULICS 5 28 6400E MM434 7 99 14 Reinstall the rubber steering wheel cover 15 Reconnect the battery cables and start the machine Turn the steering wheel and check for any leaks and proper operation ...

Page 217: ...will only turn on when the handles are in the down position TO REPLACE CONTROL VALVE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the seat support 2 Remove the two valve handle boots 3 Mark disconnect and plug the hydraulic hoses leading to the control valve NOTE Observe hydraulic cleanliness requirements when opening...

Page 218: ...x screws and nyloc nuts holding the control valve to the valve mount bracket Remove the valve from the machine 6 Remove the fittings from the old valve and install in the new valve in the same orientation 7 Remove the valve handles and C pins from the old valve and install on the new valve in the same orientation OUT IN BYD B D ...

Page 219: ... in the machine center panel Reinstall the two M6 hex screws and nyloc nuts Tighten to 11 14 Nm 7 10 ft lb 9 Reconnect the hydraulic hoses See schematic in this section 10 Reconnect the tension spring to the left handle 12 Reinstall the valve handle boots 13 Start the machine and check the control valve for proper operation OUT IN BYD B D ...

Page 220: ... side brush or main brush handles are placed in the down position The solenoid valve also contains a relief valve to protect the hydraulic system from damage TO REPLACE SOLENOID VALVE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Raise the hopper and engage the support bar 2 Open the seat support 3 Disconnect the battery ...

Page 221: ...l coils from the main harness 6 Go in front of the machine and down under the brush wrap Locate the two hex screws holding the solenoid valve to the machine frame Remove the valve from the machine 7 Remove the fittings from the old solenoid valve and install in the new valve in the same orientation T3 M1 M2 T2 P T1 T4 T3 M1 M2 T2 P T1 T4 ...

Page 222: ... in the valve Reinstall the two hex screws and tighten to 18 24 Nm 15 20 ft lb 9 Reconnect the hydraulic hoses See schematic in this section 10 Reconnect the two electrical coils to the main harness 11 Reconnect the battery 12 Start the machine and check the new valve for any leaks and proper operation T3 M1 M2 T2 P T1 T4 ...

Page 223: ...cing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Remove the side brush retaining pin from the side brush drive shaft by pulling the pin keeper over the end of the pin 5 Remove the side brush from the side brush motor 6 Remove and plug the hydraulic hoses leading to the side brush motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic line...

Page 224: ...hine 8 Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation 9 Install the new side brush motor and the side brush guard on the mount bracket Tighten the four hex screws to 27 35 ft lb 10 Reconnect the hydraulic hoses to the side brush motor See schematic in this section 11 Reinstall the side brush on the side brush motor ...

Page 225: ... brush retaining pin through the side brush hub and shaft 13 Secure the pin by clipping the pin keeper over the end of the pin 14 Disengage the hopper support bar and lower the hopper 15 Adjust the side brush pattern with the side brush down pressure lever ...

Page 226: ...HYDRAULICS 5 38 6400E MM434 11 01 HYDRAULIC SCHEMATIC ELECTRIC ...

Page 227: ...HOSE GROUP ELECTRIC P B A T R P L T BYD C D B A IN OUT IN OUT HYDRAULIC RESERVOIR STEERING CYLINDER STEERING VALVE HOPPER LIFT CYLINDER MAIN CONTROL VALVE HYDRAULIC PUMP SOLENOID CONTROL VALVE HYDRAULIC FILTER DUMP DOOR CYLINDER SIDE BRUSH MOTOR ...

Page 228: ... MM434 7 99 TROUBLESHOOTING The troubleshooting charts that follow are organized so they lead you through the hydraulic circuits They include flow charts and instructions for you as to where to insert your test instruments ...

Page 229: ...M434 7 99 PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F SIDE BRUSH STRAINER 3 1 GPM TOTAL 1 3 GPM UNLOAD 1 3 T A B SV 1 RV 2 1300 PSI CK1 1000 RPM RV 1 800 PSI GPM x 225 PSI 90 RPM SIDE BRUSH ON CIRCUIT ...

Page 230: ...UMBING OK SV1 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV1 STEM CARTRIDGE YES NO PUMP OUTLET FLOW PRESSURE OK SIDE BRUSH DOES NOT TURN ON YES NO MOTOR INLET FLOW OK NO YES REPAIR OR REPLACE PLUMBING NO YES REPAIR OR REPLACE PUMP YES RV1 RELIEF CARTRIDGE OK NO REPAIR OR REPLACE RV RELIEF CARTRIDGE NO ...

Page 231: ...S 5 43 6400E MM434 7 99 SV1 STEM MAGNETIZED CHECK ELECTRICAL SYSTEM SV1 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV1 STEM CARTRIDGE YES NO SIDE BRUSH DOES NOT TURN OFF NO REPLACE SV1 STEM CARTRIDGE SEALS YES ...

Page 232: ...ESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F R L STEERING CIRCUIT RIGHT TURN FILTER RV4 25 PSI PUMP STRAINER x P T RV3 550 PSI STRG CYL 3 1 GPM 1000 RPM 50 PSI STATIONARY 175 PSI TURNING CONCRETE 550 PSI HELD AT STOP ...

Page 233: ...ESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F R L STEERING CIRCUIT LEFT TURN FILTER RV4 25 PSI PUMP STRAINER x P T RV3 550 PSI STRG CYL 3 1 GPM 1000 RPM 50 PSI STATIONARY 175 PSI TURNING CONCRETE 550 PSI HELD AT STOP ...

Page 234: ...PLACE PLUMBING PUMP OUTLET FLOW PRESSURE OK REPAIR OR REPLACE PUMP YES NO POWER STEERING IS NOT NORMAL NO STEER CYLINDER ROD ENDS SEALS OK REPAIR OR REPLACE STEER CYLINDER OR ROD ENDS NO YES STEERING INLET PRESSURE OK REPAIR OR REPLACE STEERING CONTROL NO YES ...

Page 235: ...99 PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F HOPPER DOOR CIRCUIT CLOSED PUMP STRAINER RV2 IN SIDE BRUSH CIRCUIT 1300 PSI 3 1 GPM 1000 RPM 1300 PSI DOOR HELD CLOSED C D A B DOOR LIFT CLOSE LIFT IN OUT BYD x ...

Page 236: ...HIFTING OK REPAIR OR REPLACE MANUAL CONTROL VALVE PLUMBING OK REPAIR OR REPLACE PLUMBING YES NO HOPPER DOOR DOES NOT OPEN NO DOOR CYLINDER CLEVIS PINS SEALS OK REPLACE DOOR CYLINDER OR CLEVIS PINS NO YES PUMP OUTLET FLOW PRESSURE OK REPAIR OR REPLACE PUMP NO YES ...

Page 237: ...K REPAIR OR REPLACE MANUAL CONTROL VALVE PLUMBING OK REPAIR OR REPLACE PLUMBING YES NO NO DOOR CYLINDER CLEVIS PINS SEALS OK REPLACE DOOR CYLINDER OR CLEVIS PINS NO YES PUMP OUTLET FLOW PRESSURE OK REPAIR OR REPLACE PUMP NO YES RV1 RELIEF PRESSURE OK REPAIR OR REPLACE RELIEF VALVE CARTRIDGE YES NO ...

Page 238: ...PPER DOOR DOES NOT STAY CLOSED MANUAL CONTROL VALVE SPOOL SHIFTING OK REPAIR OR REPLACE MANUAL CONTROL VALVE PLUMBING OK REPAIR OR REPLACE PLUMBING YES NO NO DOOR CYLINDER CLEVIS PINS SEALS OK REPLACE DOOR CYLINDER OR CLEVIS PINS NO YES ...

Page 239: ...34 7 99 PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F HOPPER LIFT CIRCUIT PUMP STRAINER 3 1 GPM 1000 RPM 1300 PSI HOPPER UP FULL C D A B DOOR LIFT CLOSE LIFT IN OUT BYD RV2 IN SIDE BRUSH CIRCUIT 1300 PSI x ...

Page 240: ... CONTROL VALVE CYLINDER ORIFICE PLUMBING OK REPAIR OR REPLACE CYLINDER ORIFICE OR PLUMBING YES NO NO LIFT CYLINDER CLEVIS PINS SEALS OK REPAIR OR REPLACE LIFT CYLINDER OR CLEVIS PINS NO YES PUMP OUTLET FLOW PRESSURE OK REPAIR OR REPLACE PUMP NO YES RV1 RELIEF PRESSURE OK REPAIR OR REPLACE RELIEF VALVE CARTRIDGE YES NO ...

Page 241: ...R MANUAL CONTROL VALVE SPOOL SHIFTING OK REPAIR OR REPLACE MANUAL CONTROL VALVE CYLINDER ORIFICE PLUMBING OK REPAIR OR REPLACE CYLINDER ORIFICE OR PLUMBING YES NO NO LIFT CYLINDER CLEVIS PINS SEALS OK REPAIR OR REPLACE LIFT CYLINDER OR CLEVIS PINS NO YES ...

Page 242: ... 7 99 HOPPER DOES NOT HOLD UP POSITION LIFT CYLINDER SEALS OK REPAIR OR REPLACE LIFT CYLINDER MANUAL CONTROL VALVE SPOOL SHIFTING OK REPAIR OR REPLACE MANUAL CONTROL VALVE YES NO NO CAN SAFETY LEG BE PUT IN PLACE SYSTEM OK NO YES ...

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Page 291: ...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 292: ...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 293: ...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 294: ...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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