Tennant 6500 Service Manual Download Page 19

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GENERAL INFORMATION

1-17

6500/6550 330275 (5--01)

MACHINE JACKING

Empty the hopper before jacking the machine.

You can jack up the machine for service at the

designated locations. Use a hoist or jack that will

support the wieght of the machine. Always stop

the machine on a flat, level surface and block the

tires before jacking the machine up.

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 middle flat bottom

edge of the rear bumper between the taillights.

FOR SAFETY: When servicing machine,

block machine tires before jacking

machine up.

FOR SAFETY: When servicing machine,

jack machine up at designated locations

only. Block machine up with jack

stands.

08029

08030

Summary of Contents for 6500

Page 1: ...6500 6550 330275 Rev 02 5 02 Service Manual Gas LP Diesel 330275 ...

Page 2: ...t instrument panel replacement and electrical troubleshooting Hydraulics Valve replacement repair motor replacement repair cylinder replacement repair pump replacement repair filter replacement and hydraulics troubleshooting Engine G LPG Air filter replacement oil changing cooling system maintenance repair fuel system maintenance repair governor adjustment repair engine repair engine troubleshooti...

Page 3: ...1 10 MAINTENANCE CHART GAS LP 1 10 MAINTENANCE CHART DIESEL 1 12 PUSHING TOWING AND TRANSPORTING THE MACHINE 1 14 PUSHING OR TOWING THE MACHINE 1 14 TRANSPORTING THE MACHINE 1 14 MACHINE JACKING 1 17 STORING MACHINE 1 18 TO STORE MACHINE UP TO 30 DAYS 1 18 TO STORE MACHINE 30 TO 90 DAYS 1 18 TO STORE MACHINE FOR MORE THAN 90 DAYS 1 19 HARDWARE INFORMATION 1 20 STANDARD BOLT TORQUE CHART 1 20 METRI...

Page 4: ...nd fan Keep away FOR SAFETY 1 Do not operate machine Unless trained and authorized Unless operator manual is read and understood If it is not in proper operating condition In flammable or explosive areas unless designed for use in those areas In areas with possible falling objects unless equipped with overhead guard 2 Before starting machine Check for fuel oil and liquid leaks Keep sparks and open...

Page 5: ...contact with battery acid Avoid contact with hot engine coolant Allow engine to cool Keep flames and sparks away from fuel system service area Keep area well ventilated Use cardboard to locate leaking hydraulic fluid under pressure Use TENNANT supplied or approved replacement parts 7 When loading unloading machine onto off truck or trailer Turn off machine Use truck or trailer that will support th...

Page 6: ...install a new label in its place HOPPER LIFT ARMS LABEL LOCATED ON BOTH HOPPER LIFT ARMS HOPPER SUPPORT BAR LABEL LOCATED ON THE HOPPER SUPPORT BAR AND ON BOTH HOPPER LIFT ARMS ENGINE FAN AND BELT LABEL LOCATED ON THE RADIATOR SHROUD EMISSIONS LABEL LOCATED ON THE SIDE PANEL OF THE OPERATOR COMPARTMENT 07748 FOR SAFETY LABEL LOCATED ON THE SIDE PANEL OF THE OPERATOR COMPARTMENT ...

Page 7: ...install a new label in its place HOPPER LIFT ARMS LABEL LOCATED ON BOTH HOPPER LIFT ARMS HOPPER SUPPORT BAR LABEL LOCATED ON THE HOPPER SUPPORT BAR AND ON BOTH HOPPER LIFT ARMS ENGINE FAN AND BELT LABEL LOCATED ON THE RADIATOR SHROUD EMISSIONS LABEL LOCATED ON THE SIDE PANEL OF THE OPERATOR COMPARTMENT 07522 FOR SAFETY LABEL LOCATED ON THE SIDE PANEL OF THE OPERATOR COMPARTMENT ...

Page 8: ...th width with side brush 1560 mm 61 5 in Main brush pattern width 50 to 65 mm 2 0 to 2 5 in Hopper weight capacity 6500 with plastic hopper 409 kg 900 lb Hopper weight capacity 6500 with metal hopper 545 kg 1200 lb Hopper weight capacity 6550 545 kg 1200 lb Hopper volume capacity 396 L 14 cu ft Dust filter area 7 2 m2 77 sq ft GVWR 6500 1927 kg 4250 lb GVWR 6550 2064 kg 4550 lb Sound level 80 dBa ...

Page 9: ...00 50 rpm 2400 50 rpm Spark plug gap Firing order Valve clearance cold 1 mm 0 04 in 1 2 4 3 counterclockwise rotation 0 20 mm 0 008 in intake 0 50 mm 0 020 in exhaust Engine lubricating oil with filter 3 3 L 3 5 qt 10W 30 SAE SG SH Engine Diesel Type Ignition Cycle Aspiration Cylinders Bore Stroke Kubota V1505 B Piston Diesel 4 Natural 4 78 mm 3 07 in 78 4 mm 3 08 in Displacement Net power governe...

Page 10: ...luid Type Hydraulic reservoir 24 6 L 6 5 gal TENNANT part no 65869 above 7_ C 45_ F Hydraulic total N A L N A gal p TENNANT part no 65870 below 7_ C 45_ F BRAKING SYSTEM Type Operation Service brakes Mechanical drum brakes 2 one per front wheel cable actuated Parking brake Utilize service brakes cable actuated TIRES Location Type Size Pressure Front 2 Solid 5 x 18 in Rear 1 Pneumatic 6 x 19 in 790...

Page 11: ...GENERAL INFORMATION 1 9 6500 6550 330275 5 98 2080 mm 82 in 2360 mm 93 in 1590 mm 62 5 in TOP VIEW SIDE VIEW FRONT VIEW 1475 mm 58 in 1135 mm 44 75 in 1560 mm 61 5 in 350662 MACHINE DIMENSIONS ...

Page 12: ...indicator 1 y g Empty dust cap 1 6 Engine crankcase Check oil level EO 1 8 Brush compartment skirts Check for damage wear and adjustment 5 12 Hopper lip skirts Check for damage wear and adjustment 3 12 Hopper side skirt Check for damage and wear 1 13 Main brush Check for damage wear and adjustment 1 Check brush pattern 1 11 Side brush Check for damage wear and adjustment 1 Check brush pattern 1 50...

Page 13: ...l bearings Check lubricate and adjust SPL 2 6 Engine Check and adjust valve clear ance 8 Check and adjust idle speed 1 Check and adjust carburetor idle mixture 1 Clean or replace and adjust spark plugs 4 Replace oil fill cap PCV breather Clean PCV hose Fuel filters 2 800 Hours 3 Cooling system Flush WG 1 2 Hydraulic fluid reservoir Replace hydraulic breather 1 y Replace suction strainer 1 Change h...

Page 14: ...Engine air filter Check indicator 1 y g Empty dust cap 1 6 Engine crankcase Check oil level EO 1 8 Brush compartment skirts Check for damage wear and adjustment 5 12 Hopper lip skirts Check for damage wear and adjustment 3 12 Hopper side skirt Check for damage and wear 1 13 Main brush Check for damage wear and adjustment 1 Check brush pattern 1 11 Side brush Check for damage wear and adjustment 1 ...

Page 15: ...ort bear ings Lubricate SPL 2 17 Hopper bearings Lubricate SPL 2 11 Side brush guard Rotate 90_ 1 400 Hours 9 Front wheel bearings Check lubricate and adjust SPL 2 6 Fuel filter Replace cartridge 1 18 Fuel tank Remove sediment 1 800 Hours 3 Cooling system Flush WG 1 2 Hydraulic fluid reservoir Replace hydraulic breather 1 y Replace suction strainer 1 Change hydraulic fluid HYDO 1 5 Hydraulic fluid...

Page 16: ... exceed 1 6 kp h 1 mph The machine is NOT intended to be pushed or towed a long distance or at a high speed ATTENTION Do not push or tow machine for a long distance and without using the bypass valve or the machine hydraulic system may be damaged Turn the bypass valve 90_ from the normal position before pushing or towing the machine The illustration shows the bypass valve in the pushing or towing ...

Page 17: ...e winching chains in the holes at the bottom of the rear bumper If the machine has the optional rear tie down brackets attach the winching chains to them 4 Turn the bypass valve 90_ from the normal position before winching the machine onto the truck or trailer See PUSHING OR TOWING THE MACHINE section of this manual Make sure the machine is centered FOR SAFETY When loading machine onto truck or tr...

Page 18: ...e down brackets above the front tires attach the winching chains to them The rear tie down locations are in the holes at the bottom of the rear bumper If the machine has the optional rear tie down brackets use them to tie down the machine 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 ...

Page 19: ...el surface and block the tires before jacking the machine up 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 middle flat bottom edge of the rear bumper between the taillights FOR SAFETY When servicing machine block machine tires before jacking machine up FOR SAFETY When servicing machine jack machine...

Page 20: ...raulic fluid level It should be up to the FULL mark on the dipstick to prevent excessive condensation from forming in the reservoir TO STORE MACHINE 30 TO 90 DAYS 1 All of the above plus the following 2 Remove the spark plugs 3 Pour 90 cc 3 oz of clean engine oil into each spark plug hole 4 Remove the ignition coil high tension wire Operate the engine starter motor for at least a dozen revolutions...

Page 21: ...an 3 Drain the coolant from the radiator and engine block 4 Close the engine cooling system drain cocks 5 Drain gasoline from the carburetor fuel tank and the fuel lines 6 Seal the air cleaner inlet and the exhaust outlet with weatherproof masking tape 7 Tighten the engine oil filler cap the fuel tank cap and the radiator cap to make certain they are securely in place ...

Page 22: ...T TORQUE CHART Thread SAE Grade 5 SAE Grade 8 Size Torque ft lb Nm Torque ft lb Nm 0 25 in 7 10 9 14 10 13 14 38 0 31 in 15 20 20 27 20 26 27 35 0 38 in 27 35 37 47 36 47 49 64 0 44 in 43 56 58 76 53 76 72 103 0 50 in 65 85 88 115 89 116 121 157 0 62 in 130 170 176 231 117 265 159 359 0 75 in 215 280 291 380 313 407 424 552 1 00 in 500 650 678 881 757 984 1026 1334 NOTE Decrease torque by 20 when ...

Page 23: ...ALANT AND LOCKING COMPOUNDS Thread sealants and locking compounds may be used on this machine They include the following Locktite 515 sealant gasket forming material TENNANT Part No 75567 15 oz 440 ml cartridge Locktite 242 blue medium strength thread locking compound TENNANT Part No 32676 0 5 ml tube Locktite 271 red high strength thread locking compound TENNANT Part No 19857 0 5 ml tube ...

Page 24: ...GENERAL INFORMATION 6500 6550 330275 5 02 1 22 ...

Page 25: ... POSITION 6500 ONLY 2 4 TO ADJUST SEAT POSITION 6550 ONLY 2 4 STATIC DRAG CHAIN 2 4 BRAKES AND TIRES 2 5 SERVICE BRAKES 2 5 TO REPLACE BRAKE SHOES 2 5 TO ADJUST BRAKES 2 7 PARKING BRAKE 2 7 FRONT TIRES AND WHEELS 2 8 TO REPACK FRONT WHEEL BEARINGS 2 8 REAR TIRE AND WHEEL AND WHEEL SUPPORT 2 9 TO REPLACE REAR WHEEL HOUSING PIVOT BEARINGS 2 9 ...

Page 26: ...CHASSIS 6500 6550 330275 6 98 2 2 ...

Page 27: ... Surface Set Parking Brake Turn Off Machine And Remove Key 1 Tilt the seat assembly forward 2 Slide the seat prop rod up and out of the rod slot 3 Pull the hair cotter pin out of the pivot shaft 4 Lift and slide the seat sideways off the machine TO REPLACE SEAT ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Slide th...

Page 28: ...he seat support Reinstall the hair pin clip in the tapered pin and the prop rod back in the slot TO ADJUST SEAT POSITION 6550 ONLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key The operator seat is a fixed back style with a forward backward adjustment Adjust Pull the lever out slide the seat backward or forward to the desired...

Page 29: ...eat assembly 3 Turn the parking brake knurled knob counterclockwise until it stops 4 Remove the battery to gain access to the floor plate bolts 5 Remove the floor plate from the operators compartment 6 Remove the cotter pin and clevis pin from the end of the brake rod yoke 7 Thread the brake rod yoke away from the threaded rod to reduce the tension on the brake cable 8 Jack up one front corner of ...

Page 30: ...o nearest cotter pin hole 19 Insert a new cotter pin through nut and hole 20 After making sure the wheel spins freely carefully reinstall the hub cap 21 Remove the jackstands and lower the machine 22 Repeat the procedure on the other wheel 23 Go in the operators compartment and thread the brake cable clevis yoke away from the threaded rod until the brake pedal travels 25 50 mm 1 2 in before engagi...

Page 31: ... the clevis and cotter pin in the end of the brake rod yoke 8 Reinstall the floor plate 9 Reinstall the battery and battery cables 10 Reinstall the seat assembly 11 Adjust the parking brake PARKING BRAKE The parking brake is set with the parking brake lever that activates the service brakes Adjust the parking brake whenever it becomes very easy to set when the machine rolls after setting the parki...

Page 32: ...re jacking machine up Jack machine up at designated locations only Block machine up with jack stands 3 Remove the hub cap in the center of front wheel 4 Remove the cotter pin slotted nut flat washer and bearing cone 5 Slide the wheel assembly off the axle 6 Pack the wheel bearings with Lubriplate EMB grease 7 Slide the wheel assembly back on the axle 8 Slide the outer bearing flat washer and nut o...

Page 33: ... 115 5 psi Torque the rear wheel nuts in a star pattern to 122 to 150 Nm 90 to 110 ft lb after the first 50 hours of operation and every 800 hours there after TO REPLACE REAR WHEEL HOUSING PIVOT BEARINGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Engage parking brake block front tires 2 Jack up rear of machine Use jack s...

Page 34: ... cotter pin from the large slotted nut on top of the rear housing pivot pin Remove the slotted nut 12 Loosen the two M10 socket head bolts 13 Drop the pivot pin down and out of the machine 14 Slide the wheel housing out of the main frame 15 Replace the pressed in bearing cups 16 Pack the bearing cones with Lubriplate EMB grease Coat bearing cups with grease 17 Position the new bearings in the hous...

Page 35: ...85 ft lb 26 Reconnect the hydraulic hoses See schematic in the HYDRAULICS section 27 Reinstall the hose clamp to the wheel housing Tighten the M8 hex screws to 18 5 24Nm 15 20 ft lb NOTE Make sure the square key is installed on the motor shaft before installing the wheel hub 28 Mount the hub to the tapered motor shaft 6500 Tighten the slotted nut to 270 Nm 200 ft lb Install the cotter pin 6550 Tig...

Page 36: ...CHASSIS 6500 6550 330275 6 98 2 12 ...

Page 37: ...RINGS 3 24 TO REPLACE BRUSH SHAFT BEARINGS For all 6550 and 6500 model machines below serial number 20000 3 25 TO REPLACE BRUSH SHAFT BEARINGS For 6500 model machines serial number 20000 and above 3 27 Page SIDE BRUSH 3 29 TO REPLACE SIDE BRUSH 3 30 SIDE BRUSH GUARD 3 31 TO ROTATE OR REPLACE SIDE BRUSH GUARD 3 31 SKIRTS AND SEALS 3 32 HOPPER LIP SKIRTS 3 32 TO REPLACE HOPPER LIP SKIRTS 3 32 BRUSH ...

Page 38: ...SWEEPING 6500 6550 330275 5 02 3 2 ...

Page 39: ...0275 6 98 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 40: ...oppers TO REMOVE HOPPER FROM MACHINE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Engage the machine parking brake 2 Start the engine and raise the hopper high enough to position two 4 tall blocks on the floor under the hopper Lower the hopper down onto these blocks Shut off the engine 3 Raise hopper cover and disconnect t...

Page 41: ...ees on the back of the hopper NOTE Do not start engine with any hydraulic hoses disconnected 7 Disconnect the hopper wire harness from main harness 8 Remove the cotter pin and clevis pin from the side brush lift cable at the side brush motor bracket 9 Loosen the M8 hex screws holding the side brush lift cable to the hopper Remove the cable from the pulleys 10 The hopper can now be removed from the...

Page 42: ...manual for proper harness connections 4 The machine can now be started and carefully inched forward 5 The hopper must go in until the rubber pads on the bumper hit the machine frame NOTE Be careful not to pinch hydraulic hoses or electrical wires during this procedure 6 Remove the filter tray from hopper 7 Align the holes in lift arms with holes in hopper sides It may be necessary to use a pry bar...

Page 43: ... side brush lift cable with the side brush assembly using the clevis pin and cotter pin 12 Position the filter tray back in the hopper 13 Reconnect the vacuum fan hose to the back of the filter tray using the worm drive clamp 14 Reconnect wires to the filter shaker and Thermo Sentryt 15 Start engine and check for proper operation of hopper vacuum fan dump door side brush rotation and side brush up...

Page 44: ...ull the filter carrier out far enough to disconnect the worm drive clamp holding the vacuum fan rubber duct to the back of the tray Remove the filter carrier from the machine 4 Loosen the six M12 hex screws and nyloc nuts holding lift arms to hopper Make sure hopper arms drop down to their lowest level The hopper must be all the way back against the main frame 5 Re tighten the six M12 hex screws a...

Page 45: ...s with the plastic hopper 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 2 Disconnect the Thermo Sentryt wire harness from hopper harness NOTE The Thermo Sentryt is located on the underside of the hopper hood on 6500 model machines with the plastic hopper 3 Remove the two bolts...

Page 46: ...SHAKING Press the filter shaker switch D TAPPING Tap the filter gently on a flat surface with the dirty side down Do not damage the edges of the filter element or the filter will not seat properly in the filter frame D AIR Always wear eye protection when using compressed air Blow air through the dust filter opposite the direction of the arrows Never use more than 690 kPa 100 psi of air pressure an...

Page 47: ...urface set parking brake turn off machine and remove key 2 Open the hopper cover 3 For machines with the metal hopper remove the four knobs washers and the two retaining brackets from the filter cover 4 Disconnect the filter shaker wire For machines with the metal hopper lift the dust filter cover for access to the wire 5 Lift the dust filter element assembly out from the hopper ...

Page 48: ...he dust filter element 8 Clean or discard the dust filter element as required 9 Remove the shipping tab from the dust filter element if a new element will be inserted into the machine 10 Place the filter shaker plate onto the new or cleaned dust filter element Make sure the lip on the filter shaker plate is fastened over the lip on the dust filter element ...

Page 49: ...noid then tighten the screws 13 Place the dust filter element assembly into the hopper and reconnect the filter shaker wire Fasten the assembly to the element with two new cable ties 14 For machines with the metal hopper center the dust filter cover over the element then push the cover back until the rear vacuum fan seal is pressed against the hopper insert 15 For machines with the metal hopper fa...

Page 50: ...ETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Measure the opening between the inside of the dump door to the inside lower corner of the hopper This dimension should be 10 5 5 Use the two adjustment screws on the dump door to achieve this dimension TO REMOVE HOPPER DUMP DOOR 1 Make sure the hopper is emptied of all debris Engage th...

Page 51: ...ngage the hopper safety arm WARNING Raised Hopper May Fall Engage Hopper Support Bar 7 Loosen the two adjustment bolts on the dump door pivot rod 8 Using a vice grip and a pry bar remove the three springs from the dump door 9 Open the hopper cover and remove the four M8 hex screws and flange nuts holding the bearing pivot hubs to the side of the hopper Remove both hubs 10 Slide the dump door all t...

Page 52: ...nter the door in the hopper 5 Reinstall both bearing pivot blocks using four M8 hex head screws and flange nuts Tighten to 18 24 Nm 13 18 ft lb 6 Reconnect the three tension springs from eye bolts in hopper to the holes in brackets on dump door Use a vice grips and a pry bar to hook the springs in the holes 7 Set the adjustment bolts on dump door to 750 from the head of bolt to edge of the bracket...

Page 53: ...sh position lever Rotate the main brush end for end every 50 hours of operation for maximum brush life and best sweeping performance Replace the main brush when the remaining bristles measure 30 mm 1 25 in in length For 6500 model machines serial number 20000 and above Adjust the main brush pattern by setting the main brush adjustment plate NOTE Note the length of the main brush bristles with the ...

Page 54: ...e main brush access door 4 Unlatch and remove the brush idler plate 5 Grasp the main brush pull it off the brush drive plug and out of the main brush compartment 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 ...

Page 55: ...e right side main brush access door 4 Unscrew and remove the mounting knob and brush idler plate 5 Grasp the main brush pull it off the brush drive plug and out of the main brush compartment 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...

Page 56: ...rush 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 5 Raise the main brush 6 Stop the main brush 7 Drive the machine off the test area 8 Observe the width of the brush pattern ...

Page 57: ...he taper with the taper adjustment bracket at the drive end of the brush A Loosen the bracket mounting bolts B Turn the taper adjustment nut counter clockwise to increase the pattern width at the brush drive end and clockwise to decrease the pattern width at the brush drive end Tighten the mounting bolts C Check the main brush pattern and readjust as necessary Then adjust the width of the main bru...

Page 58: ...g 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 5 Raise the main brush 6 Stop the main brush 7 Drive the machine off the test area 8 Observe the width of the brush pattern The proper brush pattern width is 50 t...

Page 59: ...tapered more than 15 mm 0 5 in on one end than the other adjust the taper with the taper adjustment bracket at the drive end of the brush A Loosen the shaft bearing bracket mounting bolts B Move the bracket up or down in the slots and tighten the mounting bolts C Check the main brush pattern and readjust as necessary Set the main brush adjustment knob to match the same color band as the brush idle...

Page 60: ... Remove the shaft and cover Save the hardware 6 Remove the bearing seal plate retainer and bearing 7 Clean the inside of the idler plug 8 Place a new bearing the seal plate and the retainer in the idler 9 Thread the four screws and flat washers into place 10 Install the idler shaft and tighten the four bolts to 8 10 Nm 6 8 ft lb 11 Slide the idler plug on the idler arm shaft Secure it with the har...

Page 61: ...brush shaft out of the machine 7 Hammer the brush hub roll pins out of the brush hubs 8 Slide the brush hubs off the ends of the shaft 9 Remove the hardware holding the bearing collars in place 10 Loosen the set screws in the locking collars and slide the bearings off the shaft 11 Slide the new bearings on the shaft with the locking collars facing out Be sure to have a bearing retainer on both sid...

Page 62: ...m 16 20 ft lb 17 Center the brush shaft in the machine Tighten the bearing locking collar set screws 18 Reconnect the main brush lift cable to the brush shaft arm with the clevis and cotter pin 19 Check main brush pattern for taper and width Adjust as necessary See TO CHECK AND ADJUST MAIN BRUSH PATTERN ...

Page 63: ...chine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Remove the main brush and idler arm from the machine 2 Remove the brush motor arm assembly from the machine 3 Remove the brush lift cable clevis from brush shaft arm 4 Remove the two bolts holding the brush shaft to the bearings and set aside 5 Pull the brush shaft out of the machine ...

Page 64: ... the hardware as shown Tighten hardware to 22 27 Nm 16 20 ft lb 8 Align the hole in the bearings with the hole in the brush shaft then mount the brush shaft with the two bolts removed earlier 9 Reconnect the main brush lift cable to the brush shaft arm with the clevis and cotter pin 10 Reconnect the brush motor arm assembly 11 Replace the main brush and idler arm 12 Check main brush pattern for ta...

Page 65: ...hen the brush is in motion Adjust the side brush pattern by the side brush down pressure knob Turn the knob 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 measur...

Page 66: ...pulling the pin keeper off and over the end of the 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...

Page 67: ...on Replace 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...

Page 68: ...pper 2 Set the machine parking brake 3 Raise the hopper engage the hopper support bar and lower the hopper onto the support bar Shut off the engine 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 hopper lip retaining strip mounting hardware 5 Remove the hoppe...

Page 69: ... machine on a smooth level surface 2 Stop the engine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the main brush doors 4 Remove the brush door skirt retaining bolts 5 Remove the skirt retaining strip and door skirts 6 Position the new long door skirt on the brush door 7 Place the new ...

Page 70: ...0 12 to 0 25 in Secure the two bolts holding only one skirt 10 Adjust the inner half length skirt so the front edge of it is 5 mm 0 25 in above the long skirt and the back half just touches the floor tighten all four bolts to 6 8 ft lb 8 10 Nm 11 Repeat for the other brush door 5 mm 0 25 in 3 mm to 5 mm 0 12 to 0 25 in ...

Page 71: ...he engine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the main brush doors 4 Remove the main brush 5 Remove the retaining strip and floor skirt Discard the old skirt 6 Position the new skirt on the machine 7 Thread the mounting bolts through the machine frame the rear floor skirt and...

Page 72: ... main brush doors 17 Operate the machine and check for proper operation BRUSH DOOR SEALS The brush door seals are located on both main brush doors and on corresponding portions of the main frame They seal the main brush compartment Inspect the seals for wear or damage every 100 hours of operation HOPPER SEALS The hopper seals are located on the top and side portions of the machine frame that conta...

Page 73: ...the main brush 6 Remove the skirt retainer and skirt from each side of the machine Remove the plastic hardware by prying under the head 7 Position the new skirt and existing retainer on the front of the machine frame Secure with plastic push in hardware 8 Pull the new skirt around inside of frame Push the skirt all of the way in its slots Secure with existing angle retainer and two M6 bolts flat w...

Page 74: ...uld be oriented with the nyloc nuts on the top side of the door Check the seals for wear or damage every 100 hours of operation TO REPLACE HOPPER DOOR SEALS 1 Park the machine on a smooth level surface and open the hopper dump door 2 Stop the engine and set the machine parking brake WARNING Raised Hopper May Fall Engage Hopper Support Bar 3 Raise hopper and engage hopper support bar FOR SAFETY Bef...

Page 75: ... holding dump door side seals and retainers to each side Note the direction of the hardware Discard the old seals 8 Align the holes in seal with holes on dump door and retainer Reinstall M6 hex screws and nyloc nuts Tighten to 3 3 4 4 Nm 30 39 In lb Make sure seals are lined up with edge of hopper when tightening 9 Start machine and lower hopper 10 Operate the machine and check the dump door for p...

Page 76: ... hours of operation You can reach the seal by removing the hopper insert HOPPER VACUUM FAN SEAL The hopper vacuum fan seal is mounted on the neck of the filter cover around the vacuum fan inlet Check the seal for wear or damage every 100 hours of operation You can reach the seal by removing the hopper insert HOPPER FILTER SEALS The hopper filter seals are mounted on both sides of the hopper dust f...

Page 77: ...emove the debris hopper See TO REMOVE HOPPER FROM MACHINE instructions 4 Remove the M10 nyloc nut holding the hopper up speed limiter rod to the lift arm Disconnect the rod from the lift arm 5 Remove the retaining rings on the upper hopper lift cylinder pin 6 Raise up slightly on the lift arm to take pressure off the cylinder pin Remove the pin 7 Remove the socket screws holding the hopper pivot p...

Page 78: ...ll the lift arm pins into 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 with the hole in the pin boss on the tower Install the socket head screws and tighten to 18 24 Nm 13 18 ft lb 6 Align the small fiberglide bearing with the hole in the clevis on the hopper lift cylinder Reinsta...

Page 79: ...e machine parking brake Raise the hopper and engage hopper up safety arm FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Remove the large hose connected to the vacuum fan inlet 4 Remove the four M8 hex screws holding the front panel to the front of the machine Remove the panel 5 Disconnect and plug the three hydraulic hoses l...

Page 80: ...he machine parking brake Raise the hopper and engage hopper up safety arm FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Bring the fan assembly in from the front of the machine under the lift arms 4 Align the holes in fan isolators with the holes in the fan transition mount bracket 5 Install the three M10 hex screws washers ...

Page 81: ...fan to the hopper flex hose 10 Start the machine and operate the vacuum fan Check for leaks and proper operation TO REPLACE VACUUM FAN IMPELLER 1 Park the machine on a smooth level surface 2 Stop the engine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Remove vacuum fan from machine See TO ...

Page 82: ...eller Make sure the square key is in place on the motor shaft Slide the impeller all the way on and spin it slowly If the impeller rubs on the housing remove it and place a 0 38 in flat washer on the motor shaft under the impeller and re assemble the impeller 9 Hold the new impeller from turning and firmly tighten the 0 31 in flex lock nut 10 Reinstall the inlet plate with the four 0 25 in hex scr...

Page 83: ...m fan failure Contact TENNANT service personnel Hopper door partially or completely closed Open the hopper door Thermo Sentryt tripped Reset Thermo Sentryt Poor sweeping performance Brush bristles worn Replace brushes Main and side brushes not adjusted properly Adjust main and side brushes Debris caught in main brush drive mechanism Free drive mechanism of debris Main brush drive failure Contact T...

Page 84: ...SWEEPING 6500 6550 330275 6 98 3 48 ...

Page 85: ... number 20000 and for ALL 6550 G LP Models 4 32 ENGINE WIRE HARNESS GROUP Gas LP For 6500 G LP Model machines below serial number 20000 and for ALL 6550 G LP Models 4 39 Page WIRE HARNESS GROUP Diesel 1 of 7 For 6500D Model machines below serial number 20000 and for ALL 6550D Models 4 40 MAIN WIRE HARNESSES GROUP Gas LP 1 of 2 For 6500 G LP Model machines serial number 20000 and above 4 47 MAIN WI...

Page 86: ...L TEST PLUG IN ROTATING LIGHT TEST 3 4 87 HOURMETER CIRCUIT 4 88 HOURMETER DOES NOT WORK 4 89 HOURMETER TEST 1 4 90 HEADLIGHT CIRCUIT 4 91 HEADLIGHT FAILURE 4 92 HEADLIGHT TEST 1 4 94 INSTRUMENT PANEL TEST PLUG IN HEADLIGHTS TEST 3 4 95 LOW L P FUEL CIRCUIT 4 96 LOW LP FUEL LIGHT 4 97 ...

Page 87: ... hours after that clean and tighten the battery connections Periodically clean the top surface of the batteries and the terminals and check for loose connections Use a strong solution of baking soda and water Brush the solution sparingly over the battery tops terminals and cable clamps Do not allow any baking soda solution to enter the batteries Use a wire brush to clean the terminal posts and the...

Page 88: ...id are not thoroughly mixed the readings may not be accurate Check the hydrometer readings against the following chart to determine the remaining battery charge level SPECIFIC GRAVITY BATTERY at 27_ C 80_ F CHARGE 1 260 1 280 100 Charged 1 230 1 250 75 Charged 1 200 1 220 50 Charged 1 170 1 190 25 Charged 1 110 1 160 Discharged NOTE If the readings are taken when the battery electrolyte is any tem...

Page 89: ...op rod 2 Disconnect the battery cables 3 Remove the battery hold down strap 4 Lift the battery out of the machine using a battery lifting device 5 Make sure that both posts are clean on the new battery Position the new battery in the machine 6 Reinstall the battery hold down strap 7 Reconnect the positive then the negative battery cables 8 Lower the seat assembly and start the machine to test the ...

Page 90: ...ove the two M8 hex screws and two M6 hex screws holding the dash panel to the machine frame 4 Pull the dash panel back away from machine 5 Remove the four M5 pan head screws holding the instrument touch panel to the dash panel 6 Loosen the allen head screw in center of wire harness plug Unplug the harness 7 Remove the instrument touch panel from the dash panel 8 Install the new instrument touch pa...

Page 91: ...ase A new O ring gasket can be installed if necessary 4 To disassemble the touch panel case further remove the four smaller pan head screws from the center of the case box 5 Remove the case box from the circuit board touch panel assembly 6 The O ring and connector gaskets can now be replaced in the case box if necessary 7 Remove the eight pan head screws Unplug the flat connector and ground strap ...

Page 92: ...ot in the board Plug in and reconnect the ground strap 2 Reinstall the eight pan head screws and hand tighten lightly 3 Turn the circuit board assembly over and place it back in the case box 4 Reinstall the four smaller pan head screws in center of case box 5 Reinstall the touch panel case on the outer case 6 Reinstall the twelve pan head screws and hand tighten lightly 7 The instrument touch pane...

Page 93: ... the main harness and remove it from the bad relay 5 Remove the hex nut holding the relay to the panel Remove and discard the relay 6 Position the new relay on the panel stud Reinstall the hex nut and hand tighten 7 Plug the main harness in the new relay See TO REPLACE INSTRUMENT TOUCH PANEL instructions NOTE The harness plug will only fit in the new relay in one direction 8 Reinstall the circuit ...

Page 94: ...low until the problem is corrected For all 6550 and 6500 models below serial number 20000 the circuit breakers are located in the operator compartment CB 10 is located in the cab control panel The chart lists the circuit breakers and the electrical components they protect CIRCUIT BREAKER AMP RATING CIRCUIT PROTECTED CB 1 15 AMP ENGINE AND THROTTLE CB 2 15 AMP VACUUM FAN AND FILTER SHAKER CB 3 15 A...

Page 95: ...trical components they protect Circuit Breaker Rating Circuit Protected CB 1 gas Open CB 1 diesel 40 A Glow plugs CB 2 15 A Engine start CB 3 15 A Engine cntrl panel CB 4 15 A Horn Hazard lights CB 5 15 A Vacuum fan filter shaker CB 6 2 5 A Operating light side brush light CB 7 15 A Backup alarm beacon lights CB 8 15 A Cab heater defrost dome light wiper motor options CB 9 15 A Cab pressurizer fan...

Page 96: ...e electrical schematic to locate the circuit breaker that needs to be replaced Disconnect the wires leading to the bad circuit breaker 4 The metal ring must be removed in order to remove the old circuit breaker It may need to be cut off to remove 5 Remove the old circuit breaker and discard 6 Position the new circuit breaker in the hole in the panel NOTE The circuit breaker will only fit in the ho...

Page 97: ...cate the circuit breaker that needs to be replaced Disconnect the wires leading to the bad circuit breaker then replace it FUSE Diesel only Fuses are a one time protection device designed to stop the flow of current in the event of a circuit overload Never substitute higher valve fuses than specified The fuse is located in the operator compartment under the steering column FUSE RATING CIRCUIT PROT...

Page 98: ... panel and to the left of the steering control motor 4 Unplug the control box from the main harness 5 Go around the front of the machine and remove the four hex nuts holding the control box to the machine frame Remove the control box Retain the two plate weldments 6 Position the new control box in the machine Reinstall the two plate weldments and hex screws Hand tighten 7 Connect the new control b...

Page 99: ...ews holding the shaker motor to the shaker plate Remove the shaker motor 10 Install the new shaker motor on the shaker plate Note the orientation 11 Reinstall the four screw and tighten hand tight 12 Reinstall the tension spring from the end of the shaker motor pin assembly to the mount hole in the shaker mount plate 13 Reinstall the shaker motor mount plate onto the filter assembly Make sure the ...

Page 100: ...ELECTRICAL 6500 6550 330275 5 02 4 16 ELECTRICAL SCHEMATIC Gas LP 1 of 4 For all 6500 G LP Model machines below serial number 20000 and for ALL 6550 G LP Models 1 2 7 3 4 5 6 351772 G LP ...

Page 101: ...ELECTRICAL 4 17 6500 6550 330275 5 02 ELECTRICAL SCHEMATIC Gas LP 2 of 4 For all 6500 G LP Model machines below serial number 20000 and for ALL 6550 G LP Models 1 2 7 3 4 5 6 351772 G LP ...

Page 102: ...ELECTRICAL 6500 6550 330275 5 02 4 18 ELECTRICAL SCHEMATIC Gas LP 3 of 4 For all 6500 G LP Model machines below serial number 20000 and for ALL 6550 G LP Models 1 2 351772 G LP ...

Page 103: ...ELECTRICAL 4 19 6500 6550 330275 5 02 ELECTRICAL SCHEMATIC Gas LP 4 of 4 For all 6500 G LP Model machines below serial number 20000 and for ALL 6550 G LP Models 1 2 351772 G LP ...

Page 104: ...ELECTRICAL 6500 6550 330275 5 02 4 20 ELECTRICAL SCHEMATIC Diesel 1 of 4 For 6500D Model machines below serial number 20000 and for ALL 6550D Models 1 2 3 351773 D ...

Page 105: ...ELECTRICAL 4 21 6500 6550 330275 5 02 ELECTRICAL SCHEMATIC Diesel 2 of 4 For 6500D Model machines below serial number 20000 and for ALL 6550D Models 1 2 3 351773 D ...

Page 106: ...ELECTRICAL 6500 6550 330275 5 02 4 22 ELECTRICAL SCHEMATIC Diesel 3 of 4 For 6500D Model machines below serial number 20000 and for ALL 6550D Models 1 2 3 351773 D ...

Page 107: ...ELECTRICAL 4 23 6500 6550 330275 5 02 ELECTRICAL SCHEMATIC Diesel 4 of 4 For 6500D Model machines below serial number 20000 and for ALL 6550D Models 1 2 3 351773 D ...

Page 108: ...ELECTRICAL 6500 6550 330275 5 02 4 24 ELECTRICAL SCHEMATIC Gas LP 1 of 4 For all 6500 G LP Model machines serial number 20000 and above 1 2 3 4 353657 6500 G LP ...

Page 109: ...ELECTRICAL 4 25 6500 6550 330275 5 02 ELECTRICAL SCHEMATIC Gas LP 2 of 4 For all 6500 G LP Model machines serial number 20000 and above 1 2 3 4 6 7 5 353657 6500 G LP ...

Page 110: ...ELECTRICAL 6500 6550 330275 5 02 4 26 ELECTRICAL SCHEMATIC Gas LP 3 of 4 For all 6500 G LP Model machines serial number 20000 and above 6 7 5 9 10 8 353657 6500 G LP ...

Page 111: ...ELECTRICAL 4 27 6500 6550 330275 5 02 ELECTRICAL SCHEMATIC Gas LP 4 of 4 For all 6500 G LP Model machines serial number 20000 and above 9 10 8 353657 6500 G LP ...

Page 112: ...ELECTRICAL 6500 6550 330275 5 02 4 28 ELECTRICAL SCHEMATIC Diesel 1 of 4 For all 6500D Model machines serial number 20000 and above 1 2 3 353658 6500 D ...

Page 113: ...ELECTRICAL 4 29 6500 6550 330275 5 02 ELECTRICAL SCHEMATIC Diesel 2 of 4 For all 6500D Model machines serial number 20000 and above 4 5 6 1 2 3 353658 6500 D ...

Page 114: ...ELECTRICAL 6500 6550 330275 5 02 4 30 ELECTRICAL SCHEMATIC Diesel 3 of 4 For all 6500D Model machines serial number 20000 and above 7 8 9 4 5 6 353658 6500 D ...

Page 115: ...ELECTRICAL 4 31 6500 6550 330275 5 02 ELECTRICAL SCHEMATIC Diesel 4 of 4 For all 6500D Model machines serial number 20000 and above 7 8 9 353658 6500 D ...

Page 116: ...DER BROWN 62C YEL 62B YEL 13HH BLK 13II BLK 13A BLK 43 BLU 62C YEL BROWN 13II BLK SEE OPTIONS SHT 6 FUEL SENDER 42A ORA 13LLL BLK 1 RED BATTERY GAS AND DIESEL LOCATION TO ENGINE 13 BLK FUEL PUMP 4 YEL 5 YEL 4A YEL 5A YEL 13K BLK 40 YEL PRESSURE SWITCH HORN SWITCH 15B BLU 13B BLK 16 GRN 13M BLK 44 GRY D I S ENGINE HARNESS GOV ACTUATOR OIL PRESSURE SWITCH L P SWITCH 13F BLK 18C ORA 71C YEL 72C YEL 1...

Page 117: ...ORA 13AA BLK SHAKER MODULE 3 2 1 LIFT ARM SWITCH 6550 ONLY B 32 GRY 24 PUR JUMPER HARNESS 6500 ONLY HOPPER DOOR SWITCH B A B B A B A B A B A D A D C B A A B C B A A B CONNECT FOR LP SEE CHART 13R BLK 13S BLK 13U BLK 27 YEL 13H BLK 38 PUR CLOGGED FILTER SWITCH VAC FAN SOLENOID GOVERNOR CONTROL 13BB BLK 13AA BLK 30 GRY 24C PUR 23C GRY THERMO SENTRY 39A GRY 13J BLK SEE SHT 6 L H HEADLIGHT 13BB BLK 13...

Page 118: ... ORA 13QQ BLK 13RR BLK 13RR BLK 111 ORA 13EE BLK 90 GRY 89 BRN BLK RED BACKUP HORN 76B ORA 13LL BLK REV FLSH LIGHT LRC TO MAIN HARNESS REV FLSH LIGHT OHG CAB 76B ORA 13LL BLK 13JJ BLK 93 ORA 13QQ BLK LIGHT L X P 76A ORA 76 ORA 13KK BLK 76A ORA 119 YEL 120 ORA YEL RED ORA PRESSURIZER BLK 13AAA BLK RED RED 13XX BLK 13WW BLK 13CCC BLK FLASHER HEATER FAN 115 GRN I I H TO MAIN HARNESS BRAKE SWITCH REV ...

Page 119: ... YEL WIPER 112 PUR X S P H L TO KEY SWITCH L L O O N N SIDE BRUSH LIGHT 87B PUR 87A PUR 13HH BLK 13GG BLK 79 YEL 80 BLU L X P CAB SWITCHES M M DEFROST FAN 111B ORA 111 ORA 13EEE BLK 13DDD BLK BLACK RED BLACK RED DOME LIGHT 116 BLU 13DDD BLK 13CCC BLK TO CAB HARNESS FOR PRESSURIZER K K J J 88 GRN 13EE BLK 13GG BLK 13FF BLK 88A GRN 87A PUR 88A GRN 13FF BLK TURN LIGHT LEFTHAND 110 YEL 109 BRN A B A B...

Page 120: ...ELECTRICAL 6500 6550 330275 5 02 4 36 WIRE HARNESSES GROUP Gas LP 5 of 7 For 6500 G LP Model machines below serial number 20000 and for ALL 6550 G LP Models ...

Page 121: ...CUIT CB 9 AUXILARY SIDE BRUSH 111 ORA CB 6 2 5A MAIN HARNESS MAIN HARNESS AUXILIARY SIDE BRUSH TO MAIN HARNESS VIEW A A 108B GRY 108C GRY CB 8 CB 7 CB 5 CB 4 CB 3 CB 2 CB 1 74A PUR 74 PUR 81 YEL 1E RED 22 YEL 1C RED 4 YEL 4A YEL 26A ORA 26 ORA 18D ORA 18 ORA 20C BLU 20B BLU 20A BLU 20 BLU M6 M4 M3 M2 M5 SECTION B B 85 COIL 86 COIL 30 COMMON CONTACT 87 N O CONTACT 87A N C CONTACT RELAYS M2 IGNITION...

Page 122: ...IEW M M CAB SWITCH PANEL REAR VIEW 111C ORA 111U ORA 112 PUR 111B ORA 113 YEL 116 BLU 115 GRN 119 BRN 120 GRY 20F BLU 118 YEL TO HARNESS TO HARNESS TO HARNESS TO HARNESS TO HARNESS WIPER DOME LIGHT HEATER PRESSURIZER MED ON ON L H OFF OFF H 1B RED 1A RED 1C RED 2 ORA 13A BLK MANDO ALTERNATOR 60559 TO MAIN HARNESS TO ENGINE BLOCK E S EXC L2 B P 351775 6550 G LP NA ...

Page 123: ...ELECTRICAL 4 39 6500 6550 330275 5 02 ENGINE WIRE HARNESS GROUP Gas LP For 6500 G LP Model machines below serial number 20000 and for ALL 6550 G LP Models ...

Page 124: ...LK 43 BLU 62C YEL BROWN 13II BLK SEE OPTIONS FUEL SENDER 42A ORA 13LLL BLK 1 RED BATTERY GAS AND DIESEL LOCATION TO ENGINE 13 BLK 14A YEL 13PPP BLK FUEL PUMP 4 YEL 5 YEL 4A YEL 5A YEL 13K BLK 40 YEL PRESSURE SWITCH HORN SWITCH 86 PUR 84 GRN ACTUATOR OIL PRESSURE SWITCH 13N BLK 13Z BLK 13LL BLK 13P BLK OPTIONS CIRCUIT BREAKERS AND RELAYS MAIN HARNESS FUEL HARNESS E E D D A B 24 23 22 21 20 19 75 60...

Page 125: ...R MODULE 3 2 1 LIFT ARM SWITCH 6550 ONLY B 32 GRY 24 PUR JUMPER HARNESS 6500 ONLY HOPPER DOOR SWITCH B B A B 13H BLK 38 PUR CLOGGED FILTER SWITCH NC C NO A B A D A D A B A B A B C B A C B A A B 7 YEL 8 GRN CONNECT FOR LP SEE CHART 13R BLK 13S BLK 13U BLK 27 YEL 13W BLK VAC FAN SOLENOID GOVERNOR CONTROL 13BB BLK 13AA BLK 30 GRY 24C PUR 23C GRY THERMO SENTRY 39A GRY 13J BLK SEE SHT 6 L H HEADLIGHT 1...

Page 126: ...ELECTRICAL 6500 6550 330275 5 02 4 42 WIRE HARNESS GROUP Diesel 3 of 7 For 6500D Model machines below serial number 20000 and for ALL 6550 Models ...

Page 127: ... CAB HARNESS 111 ORA CB 6 2 5A MAIN HARNESS MAIN HARNESS AUXILIARY SIDE BRUSH TO MAIN HARNESS VIEW A A 108B GRY 108C GRY CB 8 CB 7 CB 5 CB 4 CB 3 CB 2 CB 1 20D BLU 74A PUR 74 PUR 81 YEL 1E RED 22 YEL 1C RED 4 YEL 4A YEL 26A ORA 26 ORA 18D ORA 18 ORA 20C BLU 20B BLU 20A BLU 20 BLU M6 M4 M3 M2 M5 SECTION B B 85 COIL 86 COIL 30 COMMON CONTACT 87 N O CONTACT 87A N C CONTACT RELAYS M2 IGNITION M3 INSTR...

Page 128: ... BLK 13AAA BLK 90 GRY 89 BRN BLK RED BACKUP HORN 76B ORA 13LL BLK REV FLSH LIGHT LRC TO MAIN HARNESS REV FLSH LIGHT OHG CAB 76B ORA 13LL BLK A B 13JJ BLK 93 ORA A B A B 13QQ BLK LIGHT L X P 76A ORA 76 ORA 13KK BLK A B A B 13KK BLK 76A ORA 119 YEL 120 ORA YEL RED ORA PRESSURIZER BLK 13AAA BLK RED RED 13XX BLK 13WW BLK 13CCC BLK FLASHER HEATER FAN 115 GRN I I H TO MAIN HARNESS BRAKE SWITCH REV SWITC...

Page 129: ... KEY SWITCH L L O O N N SIDE BRUSH LIGHT 87B PUR 87A PUR 13HH BLK 13GG BLK 79 YEL 80 BLU TO CIRCUIT BREAKERS SEE SHT 5 108C GRY 108B GRY L X P CAB SWITCHES SEE SHT 5 M M DEFROST FAN 111B ORA 111 ORA 13EEE BLK 13DDD BLK BLACK RED BLACK RED DOME LIGHT 116 BLU 13DDD BLK 13CCC BLK TO CAB HARNESS FOR PRESSURIZER K K J J 87 GRN 88 GRN 13EE BLK C AB 13GG BLK 13FF BLK 88A GRN B A 87A PUR 88A GRN 13FF BLK ...

Page 130: ...EW M M CAB SWITCH PANEL REAR VIEW 111C ORA 111U ORA 112 PUR 111B ORA 113 YEL 116 BLU 115 GRN 119 BRN 120 GRY 20F BLU 118 YEL TO HARNESS TO HARNESS TO HARNESS TO HARNESS TO HARNESS WIPER DOME LIGHT HEATER PRESSURIZER MED ON ON L H OFF OFF H 1B RED 1A RED 1C RED 2 ORA 13A BLK MANDO ALTERNATOR TO MAIN HARNESS TO ENGINE BLOCK E S EXC L2 B P 351777 6500 D NA ...

Page 131: ...ELECTRICAL 4 47 6500 6550 330275 5 02 MAIN WIRE HARNESSES GROUP Gas LP 1 of 2 For 6500 G LP Model machines serial number 20000 and above 353645 6500 G LP ...

Page 132: ...ELECTRICAL 6500 6550 330275 5 02 4 48 MAIN WIRE HARNESSES GROUP Gas LP 2 of 2 For 6500 G LP Model machines serial number 20000 and above 353645 6500 G LP ...

Page 133: ...ELECTRICAL 4 49 6500 6550 330275 5 02 MAIN WIRE HARNESSES GROUP Diesel 1 of 2 For 6500D Model machines serial number 20000 and above 353648 6500 D NA ...

Page 134: ...ELECTRICAL 6500 6550 330275 5 02 4 50 MAIN WIRE HARNESSES GROUP Diesel 2 of 2 For 6500D Model machines serial number 20000 and above 353648 6500 D NA ...

Page 135: ...ELECTRICAL 4 51 6500 6550 330275 5 02 HOPPER WIRE HARNESS GROUP For 6500 Gas LP D Model machines serial number 20000 and above 353648 6500 D NA ...

Page 136: ...ELECTRICAL 6500 6550 330275 5 02 4 52 ENGINE WIRE HARNESS GROUP For 6500 Gas LP Model machines serial number 20000 and above 353647 6500 G LP ...

Page 137: ...00 6550 330275 6 98 TROUBLESHOOTING The troubleshooting charts that follow are organized so they lead you through the circuits They include flow charts and instructions for you as to where to insert your test instruments ...

Page 138: ...A ACC 19 30 BATT C 50 17 SE 2 SE 1 FUEL SENDER COOLANT TEMP SENDER ELECTRONIC INSTRUMENT PANEL CLOSES AT 225 F A B C D E F G H 18T ORA 18C ORA 86 PUR 84 GRN 83 BRN 85 BLU 18A ORA 14 YEL 15 BLU 20 BLU 16 GRN 42 ORA 44 GRY 12V 540 C C A 18D ORA 71C YEL 72C GRY L P GND 16 GRN 1B RED L2 1 5 12 13 17 18 22 A 2 ORA 1D RED 55A MAX CHARGE 15A BLU C D 13F BLK 13E BLK C 15A BLU 13R BLK 13S BLK 13T BLK 13L B...

Page 139: ...BLK 13A BLK SENSE 15A ACC 19 30 BATT 50 17 ELECTRONIC INSTRUMENT PANEL 20 BLU 12V 540 C C A 1B RED L2 2 ORA 1D RED 55A MAX CHARGE 13T BLK 23A GRY 30 87 M3 22 YEL 86 85 M3 1E RED C B 1 CB 6 IGNITION SWITCH S 3 ALTERNATOR FAULT 18E ORA 19 BLU P1 1 P1 14 PANEL LAMP A 23 11 B 2 5A ...

Page 140: ...0 6550 330275 6 98 4 56 ALTERNATOR CHECK VOLTAGE ACROSS PLUG 1 P1 P14 1 VOLT TURN KEY ON LIGHT OFF REPLACE BULB ON REPLACE ALTERNATOR AFTER CHECKING THE BATTERY AND ITS CONNECTIONS 0 VOLTS RETEST BATTERY START ENGINE ...

Page 141: ...STRUMENT PANEL 12V 540 C C A 22 YEL 1E RED CB 6 FUEL SENDER CIRCUIT SE 1 FUEL SENDER 42 ORA 13L BLK 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU ACC 19 30 BATT 50 17 1D RED IGNITION SWITCH S 3 P1 13 P1 1 PANEL LAMP 0 TO 90 OHMS 90 OHMS FULL B 23 11 13T BLK 2 5A ...

Page 142: ... LIGHT REPLACE BULB TURN KEY ON CHECK RESISTANCE SE 1 NO RESISTANCE REPLACE GAUGE CHECK CONNECTIONS CONTINUITY OF 42 ORA AND 13L BLK OR VARIATION YES NO TEST VOLTAGE P1 TO P13 REPAIR AS NECESSARY REPLACE BOARD BATTERY VOLTAGE VARIABLE 90 TO 0 OHMS 4 SECONDS ...

Page 143: ... ACC 19 30 BATT C 50 17 ELECTRONIC INSTRUMENT PANEL 18A ORA 14 YEL 15 BLU 20 BLU 12V 540 C C A 16 GRN 1D RED 13T BLK M2 23A GRY 30 87 M3 22 YEL 86 85 13B BLK 18B ORA M3 1E RED C B 1 CB 6 13P BLK S 4 IGNITION SWITCH S 3 OIL PRESSURE 18E ORA 19 BLU P1 1 P1 2 PANEL LAMP 23 B 11 N C ENGINE OFF SHOWN IN LIGHT ON POSITION ...

Page 144: ... 50 17 ELECTRONIC INSTRUMENT PANEL 20 BLU 12V 540 C C A 1D RED 13T BLK 22 YEL 1E RED C B 1 CB 6 IGNITION SWITCH S 3 THERMAL SENTRYt 18E ORA 24 PUR 24A PUR 19 BLU M3 85 86 M3 87 30 23A GRY S 5 23B GRY HOPPER THERMAL SW P1 1 P1 6 PANEL LAMP 11 23 B THERMAL OPEN 0 VOLTS LIGHT ON ...

Page 145: ...0275 6 98 BATTERY 13 BLK 15A ACC 19 30 BATT 50 17 ELECTRONIC INSTRUMENT PANEL 20 BLU 12V 540 C C A 23 1D RED 13T BLK C B 1 IGNITION SWITCH S 3 2 5A 11 19 BLU CB 6 1E RED M3 18E ORA 85 86 22 YEL M3 87 30 23A GRY 1 POWER UP CIRCUIT ...

Page 146: ... NO CONT NEXT PAGE REPLACE M3 WITH KNOWN GOOD RELAY LIGHTS ON LIGHTS OFF REPLACE M3 CHECK VOLTAGE 22 YEL TO BATT NEG 0 VOLTS BATTERY VOLTAGE BATTERY VOLTAGE NO VOLTAGE A OR B BATTERY A ONLY REPLACE CB 6 BATTERY VOLTAGE A B CHECK CB 6 REPLACE 1E RED TEST 2 VOLTAGE REPAIR OR REPLACE 22 YELLOW REPAIR OR REPLACE 23A GRAY 19 BLUE CHECK VOLTAGE 23A GRAY BATT NEG BATTERY VOLTAGE YES GROUND TEST ALL ACCES...

Page 147: ...POWER UP TEST 1 Volts D C Volts D C battery voltage battery voltage C B 1 C B 1 A B 20 BLUE 20 BLUE 18A ORANGE 18A ORANGE Volts D C Volts D C POWER UP TEST 2 battery voltage battery voltage C B 6 C B 6 A B 1E RED 1E RED 22 YELLOW 22 YELLOW ...

Page 148: ... 3 7 13 12 18 19 2021 222324 Volts D C Volts D C 4 5 6 1 2 3 7 13 12 18 192021 222324 Key on Key off 5 volt battery voltage 4 5 6 1 2 3 7 13 12 18 192021 2223 24 Ohms D C Ohms D C 4 5 6 1 2 3 7 13 12 18 192021 22 2324 Switch on Switch off 100 1 meg INSTRUMENT PANEL TEST PLUG IN POWER UP TEST 4 ...

Page 149: ...ELECTRICAL 4 65 6500 6550 330275 6 98 Volts D C C B 6 1E RED 22 YELLOW ...

Page 150: ...30 GRY 30A GRY CB 2 ELECTRONIC INSTRUMENT PANEL 1 16 29 GRN 13T BLK 86 85 M4 23A GRY 30 87 M3 22 YEL 23C GRY 1E RED CB 6 SHAKER MOTOR RELAY BATTERY 13 BLK START ACC 19 30 BATT 50 17 20 BLU 20A BLU 1D RED IGNITION SWITCH S 3 SHAKER MOTOR CIRCUIT 15A 86 85 18E ORA M3 C B 1 M 19 BLU 23 B 11 2 5A ...

Page 151: ...G REPLACE M4 NO REPAIR CONNECTION REPLACE WIRE KEY OFF CHECK CONTINUITY 30A GRAY 30 GRAY YES BATTERY VOLTAGE CHECK CONTINUITY OF 29 GREEN REPAIR OR REPLACE LET COOL 3 MIN CHECK RESISTANCE 100 OHMS SWITCH ON OUT OF SPEC REPLACE BOARD PLUG 1 P16 P23 TEST 4 CHECK VOLTAGE ACROSS PLUG 1 P 16 P 23 TEST 3 NO 0 VOLTS BATTERY VOLTAGE REMOVE M4 RELAY WITH SWITCH OFF INSERT TEST HARNESS CHECK CONTINUITY OF 2...

Page 152: ...8 SHAKER TEST 1 P21 7 HOUR METER P21 7 HOUR METER Ohms D C Ohms D C Switch held on Switch off Open 100 P2 UNPLUGGED Volts D C Volts D C SHAKER TEST 2 battery voltage battery voltage C B 2 C B 2 A B 20A BLUE 20A BLUE 26A ORANGE 26A ORANGE ...

Page 153: ... 12 18 192021 222324 Volts D C Volts D C 4 5 6 1 2 3 7 13 12 18 192021 222324 Switch held on Switch off 0 volts battery voltage 4 5 6 1 2 3 7 13 12 18 192021 222324 Ohms D C Ohms D C INSTRUMENT PANEL TEST PLUG IN SHAKER TEST 4 4 5 6 1 2 3 7 13 12 18 192021 222324 Switch held on Switch off 100 1 meg ...

Page 154: ...UMENT PANEL 12V 540 C C A 22 YEL 1E RED CB 6 COOLANT SENDER CIRCUIT SE 2 COOLANT TEMP SENDER CLOSES AT 225 F 43 BLU P1 5 P1 1 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU ACC 19 30 BATT 50 17 1D RED IGNITION SWITCH S 3 PANEL LAMP 80 OHMS ON 85 OHMS OFF 23 B 11 2 5A ...

Page 155: ...NT TEMPERATURE REPAIR CHECK WIRE REPLACE BOARD REMOVE WIRE FOR SENSOR REPLACE SENSOR OFF ON OK 43 BLUE INSERT TEST HARNESS TURN KEY ON LIGHT REPLACE BULB ON OFF GROUNDED CHECK VOLTAGE P1 TO P5 BATTERY VOLTAGE FOR GROUND TO FRAME SHORT 4 SECONDS ...

Page 156: ...PANEL FAN SOL VALVE HOPPER THERMAL SW 20 BLU 20A BLU 25 BRN 24A PUR 6 21 1D RED 86 85 13T BLK M5 22 YEL 1E RED CB 6 IGNITION SWITCH S 3 M5 FAN SOL VALVE 15 AMP 30 87 26 ORA 20A BLU 13W BLK 27 YEL CB 2 1 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU 23 11 B S 5 LIFT ARM SW 32 YEL N O H C S 6 24 PUR 23B GRY 2 5A ...

Page 157: ...CTRONIC INSTRUMENT PANEL 12V 540 C C A 22 YEL 1E RED CB 6 HOPPER DOOR 39 GRY 13J BLK 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU ACC 19 30 BATT 50 17 1D RED IGNITION SWITCH S 3 PANEL LAMP P1 1 P1 4 23 B 11 13T BLK S 8 CLOSED 1 HOPPER DOOR CLOSED 2 PANEL LAMP ON 2 5A S 8 ...

Page 158: ... NOT COME ON TURN KEY ON JUMPER ACROSS S8 CHECK VOLTAGE PLUG 1 P1 P4 INSERT TEST HARNESS CHECK CONNECTIONS AND CONTINUITY OF 39 GRAY 13J BLK REPAIR OR REPLACE ON OFF OFF REPLACE SWITCH TURN KEY ON LIGHT ON REPLACE BULB REPLACE BOARD OFF ON LIGHT ON FOR 4 SECONDS ...

Page 159: ...NT PANEL 12V 540 C C A 22 YEL 1E RED CB 6 DOWN FORCE CIRCUIT DN FORCE 40 YEL 13K BLK 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU ACC 19 30 BATT 50 17 1D RED IGNITION SWITCH S 3 P1 1 P1 7 PANEL LAMP B 23 11 13T BLK S 9 CLOSED EXCESSIVE BRUSH DOWN FORCE EXISTS 2 5A S 9 ...

Page 160: ...8 4 76 DOWN FORCE CIRCUIT OFF ON LIGHT TURN KEY ON REPLACE BULB JUMP S 8 REPLACE S 8 ON OFF INSERT TEST HARNESS CHECK VOLTAGE P1 1 TO P1 7 CHECK CONNECTIONS CONTINUITY OF 40 YEL 13K BLK REPLACE BOARD BATTERY VOLTAGE 0 VOLTS 4 SECONDS ...

Page 161: ...HOPPER DIFFERENTIAL PRESSURE SWITCH 13H BLK 38 PUR S 6 ACC 19 30 BATT 50 17 1D RED IGNITION SWITCH S 3 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU PANEL LAMP P1 1 P1 3 REMOVE WIRE 38 PURPLE PLACE JUMPER TO GROUND LIGHT WILL COME ON 23 11 B 13T BLK N O VACUUM IN HOPPER 2 5A CLOGGED FILTER SWITCH CIRCUIT FILTER CLOGGED ...

Page 162: ... THERMAL SW 20 BLU 20A BLU 25 BRN 12V 540 C C A 24A PUR 6 21 1D RED 86 85 13T BLK M5 22 YEL 1E RED CB 6 IGNITION SWITCH S 3 M5 FAN SOL VALVE 15 AMP 30 87 26 ORA 20A BLU 13W BLK 27 YEL CB 2 VACUUM FAN CIRCUIT 1 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU 23 11 B S 5 LIFT ARM SW 32 YEL N O H C S 6 24 PUR 23B GRY 2 5A ...

Page 163: ...F NECESSARY CONT NEXT PAGE PLUG 2 PIN 4 TO 7 100 OHMS ON TEST 1 ACTIVATE SWITCH CIRCUIT BOARD 4 SECONDS BY PASS THERMAL SENSOR MOTOR RUNS MOTOR OFF LIFT ARM SWITCH RESET OR REPLACE THERMAL SENSOR OR LIFT ARM SWITCH CONT NEXT PAGE REMOVE M5 RELAY CHECK VOLTAGE 32 YEL TO BATT NEG YES NO CHECK CONTINUITY 24 PUR TO 32 YEL OK REPAIR OR REPLACE 23B GRAY NO REPAIR OR REPLACE AS NEEDED TEST FOR MAGNETISM ...

Page 164: ...CHECK CONTINUITY OF 25 BRN REPAIR AS NECESSARY 100 OHMS SWITCH ON TEST 4 BATTERY VOLTAGE O VOLTS INSERT TEST HARNESS SWITCH OFF CHECK VOLTAGE AT CB 2 TEST 2 BOTH SIDES NO VOLTAGE A OR B BATTERY VOLTAGE A ONLY REPAIR OR REPLACE 20A BLUE REPLACE CB 2 BATTERY A B VOLTAGE CONT NEXT PAGE CHECK VOLTAGE 26 ORA AT M5 RELAY REPLACE M5 WITH KNOWN GOOD RELAY MOTOR OPERATES NOT OPERATING REPLACE M5 REPAIR OR ...

Page 165: ...UM FAN TEST 1 P21 7 HOUR METER P21 7 HOUR METER Ohms D C Ohms D C Switch held on Switch off 100 4 4 Open P2 UNPLUGGED Volts D C Volts D C VACUUM FAN TEST 2 battery voltage battery voltage C B 2 C B 2 A B 20A BLUE 20A BLUE 26A ORANGE 26A ORANGE ...

Page 166: ... 7 13 12 18 192021 222324 Volts D C Volts D C 4 5 6 1 2 3 7 13 12 18 192021 222324 Switch on Switch off 0 volts battery voltage 4 5 6 1 2 3 7 13 12 18 192021 222324 Ohms D C Ohms D C 4 5 6 1 2 3 7 13 12 18 192021 222324 Switch on Switch off 100 1 meg INSTRUMENT PANEL TEST PLUG IN VACUUM FAN TEST 4 ...

Page 167: ...V 540 C C A 1D RED 13T BLK 22 YEL 1E RED CB 6 IGNITION SWITCH S 3 ROTATING LIGHT CIRCUIT 15 AMP 76 ORA 76A ORA 76B GRN FLASHING LIGHT ROTATING LIGHT 30 87 20C BLU M7 74 PUR 13KK BLK 13LL BLK CB 4 19 75 BRN 86 85 M7 23B GRY 23E GRY ROT LIGHTS RELAY 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU 1 11 B 23 2 5A ...

Page 168: ...RCUIT BOARD 4 SECONDS CHECK VOLTAGE BATTERY VOLTAGE NO YES REPLACE 13LL BLK R CONT NEXT PAGE 76B GRN 13LL BLK R REPLACE ROTATING LIGHT BATTERY VOLTAGE CHECK VOLTAGE BATT TO 13LL BLK R NO YES 76A ORA 13KK BLK F BATT TO 13KK BLK F REPLACE 13KK BLK F OR FLASHING REMOVE M7 RELAY CHECK VOLTAGE AT 23E GRAY 0 VOLTS REPLACE 23E GRAY BATTERY VOLTAGE CHECK VOLTAGE 74 PUR BATT NEG BATTERY VOLTAGE 0 VOLTS AT ...

Page 169: ...OL 3 MIN CHECK RESISTANCE 100 OHMS SWITCH ON OUT OF SPEC REPLACE BOARD PLUG 1 P19 P23 TEST 3 TEST 4 INSERT TEST HARNESS CHECK CONTINUITY 76 ORA 76B GRN R REPAIR OR REPLACE REPLACE M7 WITH KNOWN GOOD RELAY MOTOR OPERATES NO OPERATION REPLACE M4 NO YES WIRE 76 ORA 76A ORA F WITH SWITCH OFF REMOVE M7 RELAY BATTERY VOLTAGE 0 VOLTS ...

Page 170: ...ING LIGHT TEST 1 P21 7 HOUR METER P21 7 HOUR METER Ohms D C Ohms D C Switch held on Switch off 100 Open P2 UNPLUGGED Volts D C Volts D C ROTATING LIGHT TEST 2 battery voltage battery voltage C B 4 C B 4 A B 20C BLUE 20C BLUE 74 PURPLE 74 PURPLE ...

Page 171: ... 7 13 12 18 192021 222324 Volts D C Volts D C 4 5 6 1 2 3 7 13 12 18 192021 222324 Switch on Switch off 0 volts battery voltage 4 5 6 1 2 3 7 13 12 18 192021 222324 Ohms D C Ohms D C 4 5 6 1 2 3 7 13 12 18 192021 222324 Switch on Switch off 100 1 meg INSTRUMENT PANEL TEST PLUG IN ROTATING LIGHT TEST 4 ...

Page 172: ... 87 15A ACC 19 30 BATT C 50 17 ELECTRONIC INSTRUMENT PANEL 18A ORA 14 YEL 15 BLU 20 BLU 12V 540 C C A 1D RED 13T BLK M2 23A GRY 30 87 M3 22 YEL 86 85 13B BLK 18B ORA M3 1E RED C B 1 CB 6 13P BLK S 4 IGNITION SWITCH S 3 HOURMETER CIRCUIT 18E ORA 15 19 BLU 15A BLU N C 23 11 N O ENGINE RUNNING 1 B HM 2 5A ...

Page 173: ...OES NOT WORK OK OK NO NO TEST OIL PRESSURE SWITCH REPLACE REPLACE CHECK HOURMETER REPLACE HOURMETER CHECK CONTINUITY OF WIRE 15A BLUE THE HOURMETER RUNS WHEN THE ENGINE IS RUNNING ONLY NOT WITH THE KEY ON WON T RUN TEST 2 TEST 1 REPLACE PC BOARD RUNS ...

Page 174: ... 98 4 90 HOURMETER TEST 1 Volts D C Volts D C battery voltage Engine running Not running N O C S 4 OIL SWITCH S 4 OIL SWITCH N O C N C N C 0 volts P21 7 HOUR METER Volts D C Engine Running HOURMETER TEST 2 Battery Voltage UNPLUGGED ...

Page 175: ... 12V 540 C C A 23 20 1D RED 60 GRN 13T BLK 86 85 M6 22 YEL 23D GRY 1E RED CB 6 IGNITION SWITCH S 3 HEAD LIGHTS RELAY HEADLIGHT R H HEADLIGHT L H 15 AMP 62 YEL 30 87 13BB BLK 13CC BLK 20B BLU 59 ORA M6 62E YEL 62D YEL 62A YEL CB 3 HEADLIGHT CIRCUIT 1 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 11 19 BLU B 2 5A ...

Page 176: ...REPAIR SHORTED WIRE CHECK VOLTAGE BATTERY VOLTAGE 62E YEL 13BB BLK RH 62D YEL 13CC BLK LH YES NO 10 1 AMP CIRCUIT BOARD 4 SECONDS NO YES CHECK CONTINUITY 62 YEL 62A YEL CHECK VOLTAGE AT CB 3 TEST 2 BOTH SIDES NO VOLTAGE A OR B BATTERY VOLTAGE A ONLY BATTERY VOLTAGE A B BATTERY VOLTAGE CHECK VOLTAGE BATT TO 13BB BLK REPLACE M6 WITH KNOWN GOOD RELAY OPERATE NO REPLACE M6 REPLACE CB3 13CC BLK REPLACE...

Page 177: ...TAGE ACROSS PLUG 1 P 20 P 23 LET COOL 3 MIN CHECK RESISTANCE 50 OHMS SWITCH ON OUT OF SPEC REPLACE BOARD PLUG 1 P20 P23 TEST 3 TEST 4 INSERT TEST HARNESS BATTERY VOLTAGE REMOVE M6 RELAY BATTERY VOLTAGE 0 VOLTS CHECK VOLTAGE ACROSS PLUG 1 P 20 P 23 SWITCH OFF SWITCH ON TEST 3 ...

Page 178: ...HEADLIGHT TEST 1 P21 7 HOUR METER P21 7 HOUR METER Ohms D C Ohms D C Switch held on Switch off 100 Open P2 UNPLUGGED Volts D C Volts D C HEADLIGHT TEST 2 battery voltage battery voltage C B 3 C B 3 A B 20B BLUE 59 ORANGE 20B BLUE 59 ORANGE ...

Page 179: ... 7 13 12 18 192021 222324 Volts D C Volts D C 4 5 6 1 2 3 7 13 12 18 192021 222324 Switch on Switch off 0 volts battery voltage 4 5 6 1 2 3 7 13 12 18 192021 222324 Ohms D C Ohms D C 4 5 6 1 2 3 7 13 12 18 192021 222324 Switch on Switch off 100 1 meg INSTRUMENT PANEL TEST PLUG IN HEADLIGHTS TEST 4 ...

Page 180: ...MENT PANEL 12V 540 C C A 22 YEL 1E RED CB 6 LOW L P FUEL CIRCUIT LOW L P FUEL 44 GRY 13M BLK N C H O 23A GRY 30 87 M3 15A 86 85 18E ORA M3 C B 1 19 BLU ACC 19 30 BATT 50 17 1D RED IGNITION SWITCH S 3 PANEL LAMP P1 1 L P GND 12 22 13R BLK 13S BLK 13T BLK B 11 23 2 5A S 10 ...

Page 181: ...13M BLK 0 VOLTS REPAIR OR REPLACE 13M BLK BATTERY VOLTAGE BATTERY VOLTAGE REPLACE LAMP NO NO LIGHT REPLACE FUEL GAUGE CHECK CONTINUITY 44 GRAY REPAIR OR REPLACE 44 GRAY OK CHECK VOLTAGE PLUG 1 P1 P23 BATTERY VOLTAGE 0 VOLTS RECHECK WIRES AND GAUGE BATTERY VOLTAGE REPLACE BOARD REPLACE BULB TURN KEY ON OFF ON PANEL WARNING LIGHTS ON 4 SECONDS GROUND 44 GRAY ON ...

Page 182: ...ELECTRICAL 6500 6550 330275 5 02 4 98 ...

Page 183: ...19 TO REPLACE CONTROL VALVE 5 19 TO REPLACE MAIN BRUSH MOTOR 5 20 TO REPLACE SIDE BRUSH MOTOR 5 21 TO REPLACE VACUUM FAN MOTOR 5 22 TO REPLACE REAR DRIVE MOTOR 5 24 6500 HYDRAULIC SCHEMATIC METAL HOPPER 5 26 6500 HYDRAULIC SCHEMATIC PLASTIC HOPPER 5 28 6550 HYDRAULIC SCHEMATIC 5 30 6500 HYDRULIC HOSE GROUP METAL HOPPER 5 32 6500 HYDRULIC HOSE GROUP PLASTIC HOPPER 5 33 6550 HYDRULIC HOSE GROUP 5 34...

Page 184: ...HYDRAULICS 6500 6550 330275 6 98 5 2 ...

Page 185: ... the hydraulic breather after every 800 hours of operation Check the hydraulic fluid level at operating temperature every 100 hours of operation Make sure the hopper is down when checking hydraulic fluid level The end of the dipstick is marked with FULL and ADD levels to indicate the level of hydraulic fluid in the reservoir Lubricate the filler cap gasket with a film of hydraulic fluid before put...

Page 186: ...ity and should not be used at the lower temperatures Damage to the hydraulic pumps may occur because of improper lubrication The lower temperature fluid is a thinner fluid for colder temperatures If a locally available hydraulic fluid is used make sure the specifications match TENNANT hydraulic fluid specifications Using substitute fluids can cause premature failure of hydraulic components Europea...

Page 187: ...erly discard the old fluid 4 Unthread and discard the hydraulic fluid filter element Hydraulic fluid will drain through the filter head Discard the used hydraulic fluid Loosen the breather filler cap NOTE Be aware the hydraulic filter is lower than the reservoir All fluid will drain from the reservoir Discard all hydraulic fluid drained from the system The fluid may contain foreign material harmfu...

Page 188: ...ormal operating temperature Always allow for expansion when filling the reservoir 5 Put the reservoir breather filler cap on the reservoir 6 Start engine and operate all the hydraulic components 7 Recheck the hydraulic fluid level 8 Check for leaks Correct any leaks found HYDRAULIC HOSES Check the hydraulic hoses every 800 hours of operation for wear or damage Fluid escaping at high pressure from ...

Page 189: ... and the hydraulic fluid filter TO REPLACE PROPEL PUMP 1 Raise the hopper and engage the safety arm FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Remove the front dust panel from the machine 3 Remove the two 0 375 in hex screws holding the accessary pump to the propel pump 4 Pull the accessary pump straight out of the prope...

Page 190: ... the bellhousing 8 Pivot the propel pump clockwise until the directional control arm is clear of the centering spring arms 9 The propel pump can now be pulled straight back and out of the pump coupling 10 Place the propel pump in a vice and remove the hydraulic fittings Remove the fittings and install in the new pump in the same orientation 11 Remove the 0 31 in hex screw holding the directional c...

Page 191: ...ise until the directional control arm is down between the centering spring arms 16 Reinstall the two M10 hex screws and hand tighten tight 17 Reinstall the control rod balljoint and rod to the directional control arm Reinstall the M8 nyloc nut and tighten to 18 24 Nm 15 20 ft lb 18 Reconnect the hydraulic hoses to the propel pump Use the schematic in this section 19 Position the accessary pump bac...

Page 192: ...he two 0 375 in hex screws holding the accessary pump to the propel pump 5 The accessary pump can now be removed from the machine 6 Place the accessary pump in a vice and remove the hydraulic fittings Install the fittings in the new pump in the same orientation 7 Position the accessary pump back in the end of the propel pump NOTE Make sure the rubber O ring is in place on the accessary pump Reinst...

Page 193: ...g the clevis pin in place 2 Remove the clevis pin 3 Position the top portion of the directional pedal at the desired angle 4 Align the holes and slide the clevis pin through 5 Secure the pin with a hair cotter pin TO ADJUST DIRECTIONAL CONTROL LINKAGE 1 Engage the parking brake 2 Jack up the rear of the machine Place jack stands under the frame and lower the machine down 3 Open engine hood and sid...

Page 194: ... hopper and engage hopper support bar 13 The machine should travel 1 6 kmh 1 mph maximum forward speed To adjust turn the speed control rod directional control rod with a balljoint and a vibration isolator Turning the rod clockwise as viewed from above will slow machine Turning it counterclockwise will speed machine 14 Lower the hopper and stop the engine 15 Check the gap between the speed limiter...

Page 195: ...of the lift cylinder Remove the grooved pin 6 Remove and retain one of the C clips from the grooved pin in the lower clevis of the lift cylinder Remove the grooved pin Remove the old lift cylinder from the machine 7 Remove the fittings from the old cylinder and install in the new cylinder in the same orientation 8 Position the new cylinder in the machine with the rod end pointing to the front of t...

Page 196: ...it attaches to the pivot yoke 6 Remove the old cylinder from the hopper 7 Remove the fittings from the old cylinder and install in the new cylinder in the same orientation 8 Position the new cylinder in the machine with the rod end pointing to the rear of the machine hopper 9 Slip the piston end of the new cylinder over the pin on the hopper Reinstall the retaining ring 10 Reinstall the clevis pin...

Page 197: ...ne cover and side door 3 Disconnect the battery cables and remove the battery from the machine 4 Open the right rear machine casting 5 LPG machines Disconnect the LP tank and remove it 6 Gas and Diesel machines Disconnect the fuel lines at the tank Remove the two tank straps Remove the fuel tank from the machine 7 Turn the steering wheel to the left so the rear drive casting can be accessed from t...

Page 198: ...d to the machine frame 12 Remove the clamp holding the drive motor hydraulic hoses to rear casting Move the hoses to gain access to the steering cylinder 13 Remove the 0 750 in nyloc nut holding the steering cylinder rod end balljoint to the rear drive casting 14 Disconnect and cap the two hydraulic hoses leading to the steering cylinder NOTE Always observe hydraulic cleanliness requirements when ...

Page 199: ...c lines 21 Reinstall the lower inside panel on the machine Tighten the two M6 pan head screws to 11 14 Nm 7 10 ft lb and the four M8 hex screws to 18 24 Nm 15 20 ft lb 22 Reinstall the floor plate in the machine Tighten the four M8 hex screws to 18 24 Nm 15 20 ft lb 23 Reconnect the directional control pedal to the control rod balljoint Hand tighten tight 24 Reinstall the clamp holding the drive m...

Page 200: ...e the two M6 pan head screws holding the plastic steering valve cover to the tilt bracket Remove the steering valve cover from the machine 7 Tilt the steering wheel to the lowest position 8 Remove and plug the four hydraulic hoses on the steering control motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 9 Remove the four 0 375 in hex screws holding the hydraulic st...

Page 201: ...Hand tighten lightly 15 Reconnect the hydraulic hoses to hydraulic steering valve See the schematic in this section 16 Reinstall the plastic steering cover and two M6 pan head screws Tighten to 11 14 Nm 7 10 ft lb 17 Reinstall the steering wheel on the steering column Tighten the wheel nut to 18 24 Nm 15 20 ft lb 18 Reinstall the rubber steering wheel cover 19 Reconnect the battery cables and star...

Page 202: ...raulic cleanliness requirements when opening hydraulic lines 5 Remove the two M6 hex 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 Install the new valve back on the valve mount bracket Make sure the handles go through the handle bellows in t...

Page 203: ...h drive plug from tapered shaft on the main brush motor 7 Remove the four 375 hex screws holding the main brush motor to the brush arm 8 Remove the hydraulic fittings from old motor and install in the new motor in the same orientation 9 Install the new main brush motor in the brush arm Tighten the 375 hex screws to 27 53 ft lb Make sure the corners of brush motor line up with the slots in brush ar...

Page 204: ...ulic lines 7 Remove the four 375 hex screws holding the side brush motor to the mount bracket Remove the side brush guard and side brush motor from machine 8 Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation 9 Install the new side brush motor and the side brush guard on the mount bracket Tighten the four hex screws to 27 35 ft lb 10 Reconnect the...

Page 205: ...et plate 6 Hold the old impeller from turning and remove the 0 31 in hex nut from the center of the fan motor shaft 7 Pull the impeller off the fan motor shaft The impeller may have to be lightly pried off Be careful not to loose the square key 8 Remove the four M10 nyloc nuts holding the hydraulic motor plate to the vacuum fan housing 9 Remove the motor and plate assembly and clamp it in a vice 1...

Page 206: ...peller Make sure the square key is in place on the motor shaft Slide the impeller all the way on and spin it slowly If the impeller rubs on the housing remove it and place a 0 38 in flat washer on the motor shaft under the impeller and re assemble the impeller 15 Hold the new impeller from turning and firmly tighten the 0 31 in flex lock nut 16 Reinstall the inlet plate with the four 0 25 in hex s...

Page 207: ...tire and wheel assembly from the drive motor hub 4 Remove the cotter pin and slotted nut from drive wheel shaft 5 Drive the hub off the tapered motor shaft A puller must be used 6 Disconnect the hydraulic hoses from the drive motor NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 7 Remove the four motor mounting bolts 8 Slide the motor out of the rear wheel housing 9 Re...

Page 208: ... schematic in the HYDRAULICS section 13 Mount the drive hub to the tapered motor shaft Tighten the castle nut to 270 Nm 200 ft lb and put new 0 125 x 2 50 cotter pin through slotted nut 14 Install the rear tire Tighten the nuts to 122 150 Nm 90 110 ft lb 15 Lower the machine ...

Page 209: ...HYDRAULICS 5 27 6500 6550 330275 5 02 ...

Page 210: ...HYDRAULICS 6500 6550 330275 6 01 5 28 6500 HYDRAULIC SCHEMATIC METAL HOPPER 1 2 3 4 5 ...

Page 211: ...HYDRAULICS 5 29 6500 6550 330275 6 01 6500 HYDRAULIC SCHEMATIC METAL HOPPER 1 2 3 4 5 351757 6500 NA ...

Page 212: ...HYDRAULICS 6500 6550 330275 6 01 5 30 6500 HYDRAULIC SCHEMATIC PLASTIC HOPPER 1 2 3 4 5 ...

Page 213: ...HYDRAULICS 5 31 6500 6550 330275 6 01 6500 HYDRAULIC SCHEMATIC PLASTIC HOPPER 1 2 3 4 5 351757 6500 NA ...

Page 214: ...HYDRAULICS 6500 6550 330275 6 01 5 32 6550 HYDRAULIC SCHEMATIC 1 2 7 3 4 5 6 351758 6550 ...

Page 215: ...HYDRAULICS 5 33 6500 6550 330275 6 01 6550 HYDRAULIC SCHEMATIC 1 2 7 3 4 5 6 351758 6550 ...

Page 216: ...HYDRAULICS 6500 6550 330275 6 01 5 34 6500 HYDRULIC HOSE GROUP METAL HOPPER E C A B D F IN OUT BYD R P L T IN OUT ...

Page 217: ...HYDRAULICS 5 35 6500 6550 330275 6 01 6500 HYDRULIC HOSE GROUP PLASTIC HOPPER E C A B D F IN OUT BYD R P L T IN OUT ...

Page 218: ...HYDRAULICS 6500 6550 330275 6 01 5 36 6550 HYDRULIC HOSE GROUP IN A B D F C E BYD R P L T IN OUT 351758 ...

Page 219: ...50 330275 6 98 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 220: ...MAIN BRUSH VAC FAN PRESSURE RETURN SUCTION BROOMS MAIN BROOM ACCESSORY PUMP RESERVOIR STRAINER RV4 3 PSI FILTER RV7 25 PSI HEAT EXCHANGER VACUUM FAN RV 8 1800 PSI CV 2 12V DC A IN RV 5 2500 PSI 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM 1600 PSI 1000 PSI ...

Page 221: ...6500 6550 330275 6 98 6550 MAIN BRUSH PRESSURE RETURN SUCTION BROOMS MAIN BROOM ACCESSORY PUMP RESERVOIR STRAINER RV4 3 PSI FILTER RV7 25 PSI HEAT EXCHANGER A IN RV 5 2500 PSI 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM 600 PSI ...

Page 222: ...N 6500 SIDE BRUSH MAIN VAC FAN HEAT EXCHANGER FILTER RESERVOIR STRAINER ACCESSORY PUMP VACUUM FAN SIDE BROOM MAIN BROOM BROOMS CV 2 12V DC RV 8 1800 PSI CV1A 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM RV 4 3 PSI RV 7 25 PSI B A 1800 PSI 1600 PSI 1000 PSI RV 5 2500 PSI IN ...

Page 223: ... 6 98 6550 MAIN SIDE BRUSH HEAT EXCHANGER FILTER RESERVOIR STRAINER ACCESSORY PUMP SIDE BROOM MAIN BROOM BROOMS CV1A 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM RV 4 3 PSI RV 7 25 PSI B A 800 PSI 600 PSI RV 5 2500 PSI IN PRESSURE RETURN SUCTION ...

Page 224: ...AC FAN HEAT EXCHANGER FILTER RESERVOIR STRAINER ACCESSORY PUMP VACUUM FAN SIDE BROOM MAIN BROOM BROOMS CV 2 12V DC RV 8 1800 PSI CV1A 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM RV 4 3 PSI RV 7 25 PSI B A 1800 PSI 1600 PSI 1000 PSI RV 5 2500 PSI IN PRESSURE RETURN SUCTION ...

Page 225: ...MAIN BRUSH VAC FAN BROOMS MAIN BROOM ACCESSORY PUMP RESERVOIR STRAINER RV4 3 PSI FILTER RV7 25 PSI HEAT EXCHANGER VACUUM FAN RV 8 1800 PSI CV 2 12V DC A IN RV 5 2500 PSI 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM 1600 PSI 1000 PSI PRESSURE RETURN SUCTION ...

Page 226: ... 6550 330275 6 98 5 44 6550 VAC FAN ACCESSORY PUMP RESERVOIR STRAINER RV4 3 PSI FILTER RV7 25 PSI HEAT EXCHANGER VACUUM FAN RV 8 1800 PSI CV 2 12V DC 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM 1000 PSI PRESSURE RETURN SUCTION ...

Page 227: ...00 6550 330275 6 98 6500 6550 LOWER HOPPER RESERVOIR STRAINER ACCESSORY PUMP FILTER 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM RV 4 3 PSI RV 7 25 PSI OUT E CV1C CYLINDER LIFT LIFT HEAT EXCHANGER RESTRICTOR PRESSURE RETURN SUCTION ...

Page 228: ...HYDRAULICS 6500 6550 330275 6 98 5 46 6500 6550 RAISE HOPPER CYLINDER LIFT ACCESSORY PUMP STRAINER RESERVOIR CV1C E LIFT 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM RESTRICTOR RV 4 3 PSI PRESSURE RETURN SUCTION ...

Page 229: ...HYDRAULICS 5 47 6500 6550 330275 6 98 6500 6550 OPEN DOOR FILTER HEAT EXCHANGER RV 7 25 PSI RESERVOIR STRAINER RV 4 3 PSI OUT C CV1B DOOR CYLINDERS ACCESSORY PUMP OPEN OPEN PRESSURE RETURN SUCTION ...

Page 230: ...275 6 98 5 48 DOOR CYLINDERS ACCESSORY PUMP OUT C CV1B RV 5 2500 PSI IN 5 1 GPM 2000 RPM 6 2 GPM 2400 RPM CLOSE CLOSE HEAT EXCHANGER FILTER RV 7 25 PSI RV 4 3 PSI RESERVOIR STRAINER 6500 6550 CLOSE DOOR PRESSURE RETURN SUCTION ...

Page 231: ...0 330275 6 98 6500 6550 RIGHT TURN HEAT EXCHANGER FILTER RV 7 25 PSI ACCESSORY PUMP STRAINER RESERVOIR RV 4 3 PSI 3 9 GPM 2000 RPM 4 7 GPM 2400 RPM CV3 R L 550 PSI CK5 T P RV 6 STEERING SYSTEM CYLINDER PRESSURE RETURN SUCTION ...

Page 232: ...0275 6 98 5 50 6500 6550 LEFT TURN CYLINDER STEERING SYSTEM HEAT EXCHANGER FILTER RV 7 25 PSI RESERVOIR STRAINER ACCESSORY PUMP RV 4 3 PSI 3 9 GPM 2000 RPM 4 7 GPM 2400 RPM R L RV 6 550 PSI P T CK5 CV3 PRESSURE RETURN SUCTION ...

Page 233: ...No 7 118 May 1999 Char Lynn Disc Valve Motor 4000 Series Geroler Motors Std Whl and Brgl 004 Std and Whl 006 Repair Information ...

Page 234: ...oler Shaft Face Seal Bearingless Motor Mounting Flange Bearing Housing Wheel Motor Back up Washer if supplied O ring Poppet Spring Spring Sleeve Dash Pot Sleeve Dash Pot Shaft Seal Shuttle Two Way Shuttle Valve Location when Applicable Dust Seal Dust Seal Seal Guard Shaft and Bearing Kit 1 1 4 inch Straight Shaft and Bearing Kit 1 5 8 inch Tapered Shaft and Bearing Kit 1 1 4 inch 14 Tooth Splined ...

Page 235: ... Shaft seal installation tool 2 1 4 inch socket Torq wrench required for eight mounting flange screws replacement screws or 006 design No E10 The following tools are not necessary for disassembly and reassembly but are extremely helpfull Alignment studs 2 see dimensions below Available by special order contact Eaton Corp Hydraulics Division Service Dept 200 mm 8 inch Approx 13 5 6 3 25 Grind Flat ...

Page 236: ...otective device on vise such as special soft jaws pieces of hard rubber or board Although not all drawings show the motor in a vise it is recom mended that you keep the motor in the vise during disassembly Follow the clamping procedures explained throughout the manual 2 Remove 4 bolts from the valve housing 3 Lift valve housing straight up If done carefully the springs and balance ring subassembly...

Page 237: ... bearing housing 17 Remove shaft seal back up ring if used and dust seal from flange Use a small screwdiver to remove dust seal Do not damage bore of flange 16 Use a stud remover or vise grips to remove studs earlier models only Clamp bearing housing in vise as shown in Figure 7 Loosen 8 screws Remove screws washers discard washers as they are not required for reassembly and mounting flange see Fi...

Page 238: ... improperly installed shaft face seal could cause internal lubrication loss and subsequent parts wear 22 Install shaft and bearing assembly in bearing housing see Figure 12 Do not damage seal in bore of housing You may need a press to install shaft and bearing assembly 18 Remove shaft and bearing assembly You may need a press to remove shaft and bearing assembly see Figure 10 19 Remove shaft face ...

Page 239: ...Figure 13 If a press is not available use a plastic or rubber hammer to tap dust seal in place 25 Install 92 1 3 62 ID seal back up ring and shaft seal in retainer Flat or smooth side of shaft seal must face toward retainer as shown in Figure 13 Apply petroleum jelly to inside diameter of shaft seal after installing seal 26 Before installing retainer place a protective sleeve of bullet see note be...

Page 240: ...vides standard timing when pressurized as shown in Figure 17 39 Apply clean grease on balance ring assembly springs Install springs in 2 holes located inside bore face of valve housing see Figure 18 41 Apply a light film of petroleum jelly on 82 3 mm 3 24 inch I D seal Install seal in outside seal groove of valve housing 42 Apply petroleum jelly on inner and outer face seals Install seals on balan...

Page 241: ...g housing and retainer The mounting flange replaces the bearing housing see Figure 25 Follow same disassembly and reassembly procedures as rear section of standard motor Important Loctite information for bearingless motor on page 10 44 Insert your finger through port of housing Apply pressure to side of balance ring assembly Hold ring in position until valve housing is in place see Figure 21 Align...

Page 242: ... no 290 at top of threaded holes see Figure 26 Note Allow Loctite 5 minutes for thread penetration before installing motor on gear case Reassembly Figure 26 Attention Do not use more than 3 drops of Loctite on threaded portion Motors with Shuttle and or Seal Guard Piston Poppet Dash Pot Plug O ring S A 9 16 18 Torque to 41 Nm 360 lb in Lubricated Thread Enlarged Parts Drawing Plug O ring S A 9 16 ...

Page 243: ...0 9 9 205 12 5 245 15 0 310 19 0 395 24 0 495 30 0 110 6 7 625 38 0 109 1114 1115 1116 1117 1118 1119 1120 Ports 1 5 8 Inch Tapered 110 1081 1082 1083 1084 1085 1086 1087 1116 111 1033 1034 1035 1036 1037 1038 1039 1062 1 1 16 O ring Bearingless Wheel Motor 1 1 4 Inch 14 T Splined 111 1057 1 1 16 O ring 1 1 16 O ring 1 1 16 O ring 1215 1117 1063 109 1184 1185 1227 1224 1225 1189 1190 40 mm Straigh...

Page 244: ...73 184 Eaton Hydraulics Shanghai Co Ltd 388 Aidu Road Waigaogiao FTZ Pudong New Area Shanghai 200137 Peoples Republic of China Telephone 86 21 5046 0758 Fax 86 21 5046 0767 Eaton B V Boeing Avenue 11 1119 PC Schiphol Rijk The Netherlands Telephone 31 0 20 655 6776 Fax 31 0 20 655 6800 Jining Eaton Hydraulic Co Ltd 6 Ji Da Road Jining City Shandong Province 272131 Peoples Republic of China Telephon...

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Page 273: ...95 Eaton Medium Duty Piston Pump Repair Information Model 70142 70144 20 3 cm3 r 1 24 in3 r Displacement and 70145 23 6 cm3 r 1 44 in3 r Displacement Variable Displacement Piston Pump design code 01 02 with Valve Plate ...

Page 274: ...ess is extremely important Clean the port areas thoroughly before disconnecting the hydraulic lines Plug the pump ports and cover the open hydraulic lines immediately after they re disconnected Drain the oil and clean the exterior of the pump before making repairs Wash all metal parts in clean solvent Use compressed air to dry the parts Do not wipe them dry with paper towels or cloth The compresse...

Page 275: ...ton Pumps 23 6 cm3 r 1 44 in3 r with Gear Pump A B C D Single Pump Product Number 7 0 1 4 2 R A A 0 1 Required Tools 7 16 in Hex Key Allen 9 16 in End Wrench 1 in End Wrench 9 16 in Socket 1 2 in Socket Internal Retaining Ring Pliers straight 090 tip External Retaining Ring Pliers straight 070 tip O ring Pick Torque Wrench 135 6 N m 100 lbf ft capacity Hammer soft face Light Petroleum Jelly Seal D...

Page 276: ... assembly for rear pump of tandem Shaft assembly for single pump or front pump of tandem 50 50 1 51 51 1 1 7 7 8 8 8 8 9 10 10 9 10 10 11 11 13 13 14 15 15 16 17 17 22 23 24 25 30 29 48 12 6 Model 70142 70144 and 70145 Parts Drawing Figure 1 1 Right Side Left Side ...

Page 277: ...37 K4 4 2 1 2 2 26 26 21 20 18 19 19 1 19 19 1 18 2 27A 27B 28A 49 1 49 49 2 49 3 49 4 49 5 37 35 36 49 1 49 49 2 49 3 49 4 49 5 34 34 1 32 K2 1 K2 2 K2 3 32 K3 1 31 K3 2 33 K3 3 K3 K2 32 K4 1 K4 2 K4 3 K4 K1 1 32 K2 2 K2 3 K2 4 K1 46 46 No Groove design code 02 design code 01 design code 02 ...

Page 278: ...e for Port C 21 1 Relief Valve for Port D 22 1 Inner Race 23 1 Seal Cover 24 1 Trunnion Cover 25 1 Cover O ring 26 2 Dowel Pin 27 2 Cap Screws 5 16 18 50 8 mm 2 in Long 28 2 Cap Screws 5 16 18 63 5 mm 2 5 in Long 29 1 Key Drive Shaft 30 1 Key Camplate Trunnion 31 1 Cover Plate In K3 kit 32 1 O ring In K1 K2 K3 K4 kit 33 2 Cap Screws Cover Plate In K3 kit 34 1 Plug Assembly 34 1 1 O ring 2 21 mm Di...

Page 279: ... Dia x 468 in ID Mounting Kits K1 1 Tandem Piston Pump Mounting Kit K1 1 1 35T Coupler 36 8 mm 1 45 in long K1 2 1 O ring 1 59 mm Dia x 101 6 mm ID 0625 in Dia x 4 in ID K1 3 2 Cap Screws K1 4 2 Washer K2 1 Gear Pump Mounting Kit K2 1 1 O ring 1 59 mm Dia x 82 55 mm ID 0625 in Dia x 3 25 in ID K2 2 2 Washer K2 3 2 Cap Screws K3 1 Cover Plate Kit K3 1 1 O ring 1 59 mm Dia x 82 55 mm ID 0625 in Dia ...

Page 280: ...Flange End of Housing Figure 1 4 12 Discard the shaft seal gaskets and o rings from all assemblies Replace with new seals upon reassembly Disassembly The following instructions apply to a variable displacement piston pump with or without a gerotor charge pump A tandem pump assembly should be separated into individual pumps before disassembly 1 Position the pump into a protected jaw vise clamping o...

Page 281: ... with camplate Check all parts for proper position before proceeding 9 Clamp pump assembly in a protected jaw vise with the open end of the housing up Install gasket and two dowel pins onto housing 10 If necessary press new bearing and roll pin in backplate to dimension shown in figure 1 3 Bearing installed with the numbered end outward Roll pin installed with split oriented away from bearing 11 I...

Page 282: ... Gerotor Pocket 2 41 mm 095 in Flange Figure 1 2 Disassembly Charge Pump Adapter Assembly 1 Remove spring retainer spring and poppet from adapter assembly Inspection Inspect the charge pump relief valve seat inside the charge pump adapter Check to insure that seat is smooth and free of burrs or other defects Inspect the charge pump relief valve spring Inspect the bearing inside the charge pump ada...

Page 283: ...d the retaining ring should not be removed without compressing the spring safely The following parts are required to disassemble the piston block 2 ea 5 16 in I D x 15 16 in O D flat washers 1 ea 5 16 in x 2 7 8 in N C cap screw and 1 ea 5 16 in N C nut To remove spring place one of the flat washers over the 5 16 in x 2 7 8 in cap screw Put cap screw through the center of the piston block and appl...

Page 284: ...transmission problems Match the transmission symptoms with the problem statements and follow the action steps shown in the box diagrams This will give expedient aid in correcting minor problems eliminating unnecessary machine down time Following the fault logic diagrams are diagram action comments of the action steps shown in the diagrams Where applicable the comment number of the statement appear...

Page 285: ...vel Defective Below Level Repair or Replace Check System Pressure Reduce System Load High OK 9 Inspect Charge Relief Valve OK 11 Inspect Charge Pump 13 Inspect Motor 12 Inspect Inlet Screen or Filter Replace Clogged OK 8 Check Charge Pressure 10 Low OK OK Replace Pump Motor Inspect Dump Valve If used OK 7 Inspect Heat Exchanger By Pass Valve If used OK Defective Repair or Replace Defective Repair ...

Page 286: ...tom Operates in One Diection Only Inspect Servo Control If used OK OK OK 2 7 Defective Repair or Replace Inspect Motor 12 Replace Clogged Check Charge Pressure 10 Low OK Inspect Dump Valve If used Replace Pump Motor Defective Repair or Replace Inspect Inlet Screen or Filter OK OK OK 8 13 Defective Repair or Replace Inspect Charge Relief Valve 11 Inspect Charge Pump Defective Repair or Replace Defe...

Page 287: ...elief Valve OK 11 Inspect Charge Pump 13 Inspect Motor 12 Inspect Inlet Screen or Filter Replace Clogged OK 8 Check Charge Pressure 10 Low OK OK Replace Pump Motor Inspect Servo Control If used OK 2 Inspect Dump Valve If used OK Defective Repair or Replace Defective Repair or Replace Defective Repair or Replace Defective Repair or Replace Defective Repair or Replace High Reduce System Load Symptom...

Page 288: ...ent or broken c misadjusted damaged or broken neutral return spring 2 Inspect Servo Control Valve for if used a proper inlet pressure b misadjusted damaged or broken neutral return spring c galled or stuck control spool d galled or stuck servo piston 3 Inspect System Relief Valves for a improper pressure relief setting b damaged or broken spring c valve held off seat d damaged valve seat 4 Check O...

Page 289: ...injectors and turn the engine over for 15 seconds 5 Replace the coil wire or return the fuel flow to the injectors Place the transmission unit in the neutral position start the engine and run it at a low idle The charge pump should immediately pick up oil and fill the system If there is no indication of fill in 30 seconds stop engine and determine the cause 6 After the system starts to show signs ...

Page 290: ...18 18 Model 70142 70144 and 70145 Notes ...

Page 291: ...19 19 Model 70142 70144 and 70145 Notes ...

Page 292: ...4 Telephone 612 937 9800 Fax 612 937 7130 Hydraulics Division Eaton Ltd Glenrothes Fife Scotland KY7 4NW Telephone 44 592 771 771 Fax 44 592 773 184 Hydraulics Division Order parts from number 6 632 Parts Information booklet Each order must include the following information 1 Product and or Part Number 2 Serial Code Number 3 Part Name 4 Quantity ...

Page 293: ...SSURE SWITCH 6 13 LPG FUEL TROUBLESHOOTING 6 14 CYLINDER HEAD 6 14 VALVE TAPPET CLEARANCE 6 14 CRANKCASE VENTILATION SYSTEM 6 14 GOVERNOR TROUBLESHOOTING6 15 GOVERNOR 6 23 TO ADJUST GOVERNOR CONTROL BOX 6 23 DIGITAL CONTROLLER SET UP 6 24 IGNITION SYSTEM 6 25 SPARK PLUGS 6 25 TO REPLACE SPARK PLUGS 6 25 FORD DISTRIBUTORLESS IGNITION SYSTEM 6 26 RUN MODE 6 27 SERVICING AND TESTING 6 27 FAILURE MODE...

Page 294: ...ENGINE G LPG 6500 6550 330275 6 98 6 2 ...

Page 295: ...the engine oil level daily Change the engine oil and oil filter every 100 hours of machine operation Use 10W30 SAE SG SH rated engine oil Fill the engine with oil to the level indicated on the oil dipstick The engine oil capacity is 4 7 L 5 0 qt including the oil filter ...

Page 296: ...terior and hydraulic cooler fins for debris every 100 hours of operation Blow or rinse all dust which may have collected on the radiator in through the grille and radiator fins opposite the direction of normal air flow The grille and hydraulic cooler open for easier cleaning Be careful not to bend the cooling fins when cleaning Clean thoroughly to prevent the fins becoming encrusted with dust Clea...

Page 297: ... The indicator s red line may return to a lower reading on the scale when the engine shuts off The red line will return to a correct reading after the engine runs for a while Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element AIR FILTER The engine air filter housing has a dust cap and a dry cartridge type air fi...

Page 298: ...e element FOR SAFETY When Servicing Machine Wear Eye And Ear Protection When Using Pressurized Air Or Water 9 After cleaning the air filter element inspect it for damage by placing a bright light inside The slightest rupture requires replacement of the filter Clean and inspect the seals on the ends of the element They should be unbroken and flexible Remember to replace the element after cleaning i...

Page 299: ...l mixture and idle speed Check and adjust idle fuel mixture and idle speed every 400 hours of operation FOR SAFETY When Servicing Machine Keep Flames And Sparks Away From Fuel System Service Area Keep Area Well Ventilated The idle speed is controlled by a screw located on the side of the carburetor next to the throttle linkage Increase the engine speed by turning the screw clockwise Decrease the e...

Page 300: ...Pa 5 psi or greater the oil pressure switch permits an electrical current to open the fuel filter lock which allows LPG fuel to flow on to the vaporizer regulator The oil pressure switch is bypassed when the engine is being started allowing LPG fuel to flow The vaporizer section of the vaporizer regulator converts the liquid LPG fuel into a gaseous LPG fuel From the vaporizer section the gaseous L...

Page 301: ...they are defective replace them before operating the machine Frosting does not occur before the engine reaches operating temperature Check after engine reaches operating temperature Check routings of all LPG hoses Keep them away from sharp edges exhaust manifolds or other hot surfaces Check for signs of abrasion or deterioration Replace worn or damaged hoses LP FUEL TANKS The LPG fuel tanks should...

Page 302: ...r functioning thread condition and damaged or missing washers or o rings Safety Relief Valve Check for damage Check for the presence of the relief valve elbow and the proper direction of the elbow If the rain cap is missing check for foreign matter and replace the rain cap Do not tamper with the relief valve setting Magnetic Liquid Level Gauge Check the operation against the maximum filling point ...

Page 303: ...d near combustible materials or high temperature sources such as ovens and furnaces since the heat may raise the pressure of the fuel to a point where the safety relief valves would function Store the tanks in a way that if the safety relief valves do function they will relieve vapor and not liquid Valves on empty tanks must be closed during storage and transportation Similar precautions should be...

Page 304: ...tank and inspect it for damage or leaks NOTE Make sure the LPG fuel tank matches the fuel system liquid tank with liquid system 10 Carefully put the LPG tank in the machine so that the tank centering pin enters the aligning hole in the tank collar NOTE If you cannot line up the centering pin make sure you have the correct LPG fuel tank and then adjust the pin locator in or out 11 Fasten the tank h...

Page 305: ... the parts and replace where needed Carefully reassemble the vaporizer regulator with the seal repair kit Check for proper operation CARBURETOR If any malfunction is found completely disassemble the carburetor Clean all the parts in alcohol Inspect all the parts and replace where needed Carefully reassemble the carburetor with the seal repair kit OIL PRESSURE SWITCH The engine oil pressure switch ...

Page 306: ... tank with liquid withdrawal tank Plugged fuel filter Replace filter Kinked or restricted fuel line Straighten or replace fuel line Engine out of tune Tune up engine Restricted air filter Clean or replace air filter element Vaporizer regulator out of adjustment Adjust vaporizer regulator CYLINDER HEAD A three stage torque procedure should be used when reassembling the cylinder head Tighten the cyl...

Page 307: ...governor originate from the Ignition Control input leads They are the Yellow Wire 71 and the Yellow Wire 72 To test this use the governor test harness TENNANT Part No 66137 Once the harness is in place use a tach dwell meter to test for the proper RPM s and a flat ignition signal Test at the text plug at either Pin C or Pin D NOTE An inductive RPM pickup won t work for this test NOTE When checking...

Page 308: ...the governor opens the carburetor wide open and the engine loses speed the problem is not in the governor The fuel system is at fault The purpose of the governor is to open the carburetor and to bring the engine to set RPM s depending on where you have the speed control switch set at After you have verified that the ignition system and the fuel system are not at fault go to the next step ...

Page 309: ...8D ORA Ground 13E BLK D I S Ignition Module 72C YEL 71C YEL 84 GRN 83 BRN ELECTRONIC GOVERNOR WIRING PICTORIAL Throttle actuator 86 PUP 85 BLU Electronic Instrument Panel A B C D E F G H A B C D E F G H A B C D E F G H TO HARNESS TO GOVERNOR TEST PLUG NOTE The wire colors of the test harness do not necessarily match the machine harness ...

Page 310: ...the battery negative terminal To do this take your voltmeter and set it on the DC volts scale Then with your positive probe clamp it to battery positive Then with the negative probe move it to the above stated places on the machine The actuator is internally isolated and does not require that the cable be grounded 6 Start Up Check With the throttle switch in the engine start position turn the igni...

Page 311: ... throttle control switch If the engine doesn t respond go to the next step 8 Operating Voltage The following voltage checks are done with the machine not running and using a Fluke or Beckman digital multimeter and the governor test harness Throttle control switch in start idle position Pin A Battery Voltage 2 Pin B 0 this is a ground Pin C Battery Voltage 2 Pin D Battery Voltage 2 Pin E Battery Vo...

Page 312: ... the RPM checks The readings are taken with either a Fluke or Beckman digital multimeter Throttle control switch in the start idle position Pin C 675 100 RPM Pin D 675 100 RPM Pin E Battery Voltage 2 Pin F 6 to 6 5 VAC Throttle control switch in the normal sweep position Pin C 1100 25 RPM Pin D 1100 25 RPM Pin E Battery Voltage 2 Pin F 6 5 to 7 VAC Throttle control switch in the litter sweep posit...

Page 313: ... machine running and using a Fluke or Beckman digital multimeter At the terminal where Wire 84 green wire is hooked to Start Idle 6 to 6 5 VAC 2 Normal 6 5 to 7 VAC 2 Litter 7 to 7 5 VAC 2 At the terminal where Wire 86 purple wire is hooked to Start Idle 12 to 14 5 VDC 2 Normal 12 to 14 5 VDC 2 Litter 12 to 14 5 VDC 2 9 Control Box Adjustment If all the above aspects in particular the linkage have...

Page 314: ... the run speed should not be affected If the adjustment is too great the start speed will be affected Verify that the start speed is correct If too much sensitivity is adjusted in the engine will either hunt in a no load condition or over speed severely when the speed switch is actuated If too little sensitivity is adjusted in the engine will seem sluggish The engine speed will drop off when the l...

Page 315: ... FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 2 Start the engine and warm to operating temperature 3 Move the speed switch to idle all accessories off 4 Move the speed switch to the fast position 5 FOR ANALOG CONTROLLER If engine speed surges occur turn the surge adjustment screw located on back of governor ...

Page 316: ...ENGINE G LPG 6500 6550 330275 5 02 6 24 rocker down O F F Set DIP switches according to controller label before installing controller 1 2 3 4 5 6 7 8 DIGITAL CONTROLLER SET UP ...

Page 317: ... or used should have the gaps checked and reset if necessary The proper spark plug gap is 1 mm 0 040 in TO REPLACE SPARK PLUGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set The Parking Brake Turn Off Machine And Remove Key 1 Open the engine cover and side door 2 Remove the spark plug wires from the four spark plugs NOTE Clean any dirt from the spark plug seat area before...

Page 318: ...versal Electronic Spark Control UESC module which adjusts the timing of the engine The degree of timing change needed is determined by electrical and vacuum input to the UESC these are Engine Load From Pressure Reducer Located in the intake manifold Minimum 21 KPA 6 22 Hg Maximum 101 KPA 29 91 Hg Engine Temperature The Engine Coolant Temperature Sensor ECTS located in the intake manifold water jac...

Page 319: ...G Servicing 1 Every 400 hours remove the spark plugs and clean and adjust the electrode 2 Clean and visually check spark plug high tension leads and test for resistance The Ohm meter should read between 9 000 and 16 000 Ohms Testing Secondary Coil Testing Remove the four 4 spark plug wires and measure the secondary coil resistance by placing the meter into plug wire terminal 1 4 at the coil 2 3 at...

Page 320: ...the spark in varying degrees Under light to moderate load conditions no adverse effect will take place However run on or pre ignition may take place Term 4 10 Coolant Sensor Contrary to previous thoughts opening the lead doesn t noticeably affect the engine The timing only changes a few degrees Term 2 3 Crank Position Sensor Opening either of these leads kills the engine quickly and it will not st...

Page 321: ...e Engine Coolant Sensor chart 1 2 6 7 OCT2 OCT1 6 6 68 Brown Cut and ground to set octane retard spark advance 18T Orange 12 6 Volts D C 8 9 V Batt Power Ground 16M 16I 57 13PP Black Ignition switch on 13QQ Black Batt 12 6 V DC 11 12 0 5 1 0 Ohms CDO Phase A CDO Phase B 852 71 Yellow 72 Gray 850A 852A HT HT 1 4 HT HT 2 3 Distributorless Ignition Coil 12 6 Volts D C Remove the coil connector and pr...

Page 322: ...00 281 000 10 14 158 000 168 000 0 32 95 000 105 000 10 50 58 750 68 750 20 68 37 300 47 300 30 86 24 270 34 270 40 104 16 150 26 150 50 122 10 970 20 970 60 140 7 600 17 600 70 158 5 360 15 360 80 176 3 840 13 840 90 194 2 800 12 800 100 212 2 070 12 070 110 230 1 550 11 550 120 248 1 180 11 180 130 266 930 10 930 140 284 701 10 701 150 302 550 10 550 ...

Page 323: ...8 hex screw and nyloc nut holding the bottom of the alternator to the lower mount bracket 6 The alternator can now be removed from the machine Bring the alternator up and over the engine 7 If the new or rebuilt alternator needs a drive pulley remove the pulley from the old alternator Hold the pulley from turning and use an impact wrench to remove the hex nut 8 Install the pulley washer and hex nut...

Page 324: ...hydraulic oil tank to tighten the belt See adjustment in ENGINE FAN BELT description Tighten the hex screw to 18 24 Nm 13 18 ft lb 12 Tighten the bottom M8 hex screw to 18 24 Nm 15 20 ft lb 13 Reconnect the wires to the back of alternator See the schematic in the ELECTRICAL section 14 Reconnect the battery cables and start the engine Check the new alternator for proper operation ...

Page 325: ...s holding the starter to the engine bellhousing 5 Pull the starter straight out of the bellhousing and remove it from the machine 6 Install the new starter in the machine Align the three holes in the starter with the holes in the bellhousing Reinstall the three M10 hex screws and one M10 nyloc Tighten to 52 67 Nm 39 51 ft lb NOTE The bottom hex screw has a nyloc nut on the starter side 7 Reconnect...

Page 326: ...adiator hoses from the engine 7 Open the left rear machine casting 8 Remove the one M6 hex screw spacer and fender washer holding the top left side of the radiator to the mount bracket 9 Go under machine and remove the two 0 375 in nyloc nuts holding the bottom of the radiator to the mount bracket 10 Pull the radiator back so it clears the engine fan Remove the radiator assembly from the machine 1...

Page 327: ...emove the two M10 hex screws holding the right rear motor mount to the bellhousing Pull the centering spring assembly out of the way of the propel pump 17 Remove the two M10 hex screws holding the propel pump to the flywheel housing 18 Pull the propel pump back and out of the flywheel coupling 19 Remove the two M12 hex screws holding the remaining motor mounts to the rubber isolators 20 The engine...

Page 328: ...st hooked up and the hardware loose for now 4 Position the propel pump back in the bellhousing and drive coupling Reinstall the two M10 hex screws using blue loctite 242 and hand tighten tight NOTE Make sure the splines on pump line up with splines in coupler when installing pump 5 Position the centering spring assembly back on the pump directional arm 6 Align the holes in the right rear motor mou...

Page 329: ...sembly with the isolators in the mount bracket Reinstall the two 0 375 nyloc nuts and washers Lightly hand tighten 16 Reinstall the M6 hex screw washer and spacer to the upper left side of the radiator Hand tighten 17 Reinstall the radiator hoses to engine and fill the radiator with coolant 18 Reinstall the air cleaner mount bracket and air cleaner assembly on the rear of the bellhousing Use the t...

Page 330: ...ENGINE G LPG 6500 6550 330275 5 02 6 38 ...

Page 331: ...ILATION SYSTEM 7 7 GOVERNOR 7 8 TO ADJUST GOVERNOR 7 8 DIGITAL CONTROLLER SET UP 7 9 TO ADJUST TRANSDUCER MAGNETIC PICKUP 7 10 TO ADJUST THROTTLE LINKAGE 7 11 FUEL SYSTEM DIESEL 7 12 FUEL FILTER 7 12 TO REPLACE THE FUEL FILTER CARTRIDGE 7 12 FUEL LINES 7 13 PRIMING FUEL SYSTEM 7 13 TO PRIME FUEL SYSTEM 7 13 TO REPLACE ALTERNATOR 7 14 TO REPLACE STARTER 7 16 TO REMOVE ENGINE 7 17 TO INSTALL ENGINE ...

Page 332: ...ENGINE D 6500 6550 330275 6 98 7 2 ...

Page 333: ...filter every 100 hours of machine operation Use engine oil with a diesel rating above CD grade only The following recommended oil grades are for use in engines during changing seasonal temperatures SINGLE AND MULTI VISCOSITY OILS Below 32_F Below 0_ C 32_ to 77_ F 0_ to 25_ C Above 77_ F Above 25_ C 10W 20 30 10W30 08431 ...

Page 334: ...ection of normal air flow The grille and hydraulic cooler open for easier cleaning Be careful not to bend the cooling fins when cleaning Clean thoroughly to prevent the fins becoming encrusted with dust Clean the radiator and cooler only after the radiator has cooled to avoid cracking FOR SAFETY When Servicing Machine Wear Eye And Ear Protection When Using Pressurized Air Or Water Flush the radiat...

Page 335: ...for a while Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element AIR FILTER The engine air filter housing has a dust cap and a dry cartridge type air filter element Empty the dust cap daily The air filter must be replaced whenever the filter element is damaged or has been cleaned three times Machines with the heav...

Page 336: ...housing with a camp cloth Clean the element housing sealing surfaces 8 Using an air hose direct dry clean air maximum 205 kPa 30 psi up and down pleats on the inside of the filter Do not rap tap or pound dust out of the element FOR SAFETY When Servicing Machine Wear Eye And Ear Protection When Using Pressurized Air Or Water 9 After cleaning the air filter element inspect it for damage by placing a...

Page 337: ...rrows pointing up Tighten the clamp ring to hold it in place Check all intake hose connections for leaks or abrasions 12 Reset the air filter restriction indicator 13 Close the access doors CYLINDER HEAD VALVE TAPPET CLEARANCE The valve tappet clearance must be checked and adjusted if necessary every 400 hours of operation See Kubota Diesel Engine Workshop Manual for 78 4 mm Stroke Series CRANKCAS...

Page 338: ...ds under the frame FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set The Parking Brake 2 Start the engine and warm to operating temperature 3 Move the speed switch to idle all accessories off 4 Move the speed switch to fast position 5 FOR ANALOG CONTROLLER If engine speed surges occur turn the surge adjustment screw located on back of governor control box under hole plug cou...

Page 339: ...ENGINE D 7 9 6500 6550 330275 5 02 rocker down O F F Set DIP switches according to controller label before installing controller 1 2 3 4 5 6 7 8 DIGITAL CONTROLLER SET UP ...

Page 340: ... there is one tooth marked white for ease of visibility On new engines you may want to mark a tooth white in the vicinity of the mag pickup and then turn the flywheel until it is centered 2 Screw the new transducer mag pickup in until it lightly hits the tooth 3 Back the transducer mag pickup out 1 4 turn to 1 2 turn 015 or 005 in gap Tighten the jam nut 4 Slowly turn the engine over to make sure ...

Page 341: ...ctuator shaft mounting hole in the lever 3 Connect the lever to the actuator shaft loosely with the lever pointing down 4 Connect the other ball joint to the diesel throttle block rod and snug up the nut 5 Push the lever and throttle rod assembly toward the diesel throttle block until it stops and hold it there 6 Tighten the actuator lever to the actuator shaft 7 Remove the ball joint from the die...

Page 342: ...mes Excess fuel is returned to the fuel tank through an overflow pipe FUEL FILTER The fuel filter cartridge filters impurities from the fuel It is located on the left side of the engine Replace the fuel filter element every 400 hours of operation FOR SAFETY When servicing machine keep flames and sparks away from fuel system service area Keep area well ventilated TO REPLACE THE FUEL FILTER CARTRIDG...

Page 343: ...MING FUEL SYSTEM Typical diesel fuel systems require priming to remove pockets of air in the fuel lines and fuel components This is usually required after running out of fuel changing fuel filter elements or repairing a fuel system component Air in the fuel system prevents smooth engine operation This fuel system however is self priming The return line comes from the top of the injector which caus...

Page 344: ...hex screw and nyloc nut holding the bottom of the alternator to the lower mount bracket 6 The alternator can now be removed from the machine Bring the alternator up and over the engine 7 If the new or rebuilt alternator needs a drive pulley remove the pulley from the old alternator Hold the pulley from turning and use an impact wrench to remove the hex nut 8 Install the pulley washer and hex nut o...

Page 345: ...draulic oil tank to tighten the belt See adjustment in ENGINE FAN BELT description Tighten the hex screw to 18 24 Nm 13 18 ft lb 12 Tighten the bottom M8 hex screw to 18 24 Nm 15 20 ft lb 13 Reconnect the wires to the back of alternator See the schematic in the ELECTRICAL section 14 Reconnect the battery cables and start the engine Check the new alternator for proper operation ...

Page 346: ...starter 4 Remove the two M8 hex screws holding the starter to the engine bellhousing 5 Pull the starter straight out of the bellhousing and remove it from the machine 6 Install the new starter in the machine Align the two holes in the starter with the holes in the bellhousing Reinstall the two M8 hex screws Tighten to 18 24 Nm 15 20 ft lb 7 Reconnect the wires to the back of the starter See the sc...

Page 347: ...iator hoses from the engine 7 Open the left rear machine casting 8 Remove the one M6 hex screw spacer and fender washer holding the top left side of the radiator to the mount bracket 9 Go under machine and remove the two 0 375 in nyloc nuts holding the bottom of the radiator to the mount bracket 10 Pull the radiator back so it clears the engine fan Remove the radiator assembly from the machine 11 ...

Page 348: ... the right rear motor mount to the bellhousing Pull the centering spring assembly out of the way of the propel pump 17 Remove the two M10 hex screws holding the propel pump to the flywheel housing 18 Pull the propel pump back and out of the flywheel coupling 19 Remove the two M12 hex screws holding the remaining motor mounts to the rubber isolators 20 The engine can now be carefully lifted out NOT...

Page 349: ... hooked up and the hardware loose for now 4 Position the propel pump back in the bellhousing and drive coupling Reinstall the two M10 hex screws using blue loctite 242 and hand tighten tight NOTE Make sure the splines on pump line up with splines in coupler when installing pump 5 Position the centering spring assembly back on the pump directional arm 6 Align the holes in the right rear motor mount...

Page 350: ...e mount bracket Reinstall the two 0 375 nyloc nuts and washers Lightly hand tighten 15 Reinstall the M6 hex screw washer and spacer to the upper left side of the radiator Hand tighten 16 Reinstall the radiator hoses to engine and fill the radiator with coolant 17 Reinstall the air cleaner mount bracket and air cleaner assembly on the rear of the bellhousing Use the two M10 hex screws Tighten to 37...

Page 351: ...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 352: ...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 353: ...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 354: ...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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