Tennant 6200E Service Manual Download

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330415

Rev. 01 (12--01)

Service Manual

6200E

Summary of Contents for 6200E

Page 1: ...330415 Rev 01 12 01 Service Manual 6200E...

Page 2: ...ne pushing or towing and hardware information Chassis Tire wheel replacement brake adjustment and replacement steering adjustment and replacement Sweeping V belt replacement brush replacement bearing...

Page 3: ...G TOWING AND TRANSPORTING THE MACHINE 1 10 PUSHING OR TOWING THE MACHINE 1 10 TRANSPORTING THE MACHINE 1 10 MACHINE JACKING 1 12 STORING MACHINE 1 12 HARDWARE INFORMATION 1 13 STANDARD BOLT TORQUE CHA...

Page 4: ...GENERAL INFORMATION 6200E 330415 6 99 1 2...

Page 5: ...available before raising hopper Move machine with care if hopper is raised Do not carry riders on machine Always follow safety and traffic rules Report machine damage or faulty operation immediately...

Page 6: ...damaged or illegible install a new label in its place FOR SAFETY LABEL LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT BATTERY CHARGING LABEL LOCATED IN BATTERY COMPARTMENT HOPPER SUPPORT LABEL LOCATE...

Page 7: ...h width with one side brush 1070 mm 42 in Sweeping path width with two side brushes 1400 mm 55 in Main sweeping brush pattern width 65 mm 2 5 in Hopper weight capacity 135 kg 300 lb Hopper volume capa...

Page 8: ...36 20 60 1 240 STEERING Type Power source Emergency steering Front wheel manual controlled Manual steering Manual HYDRAULIC SYSTEM System Capacity Fluid Type Hydraulic reservoir 53 L 14 gal TENNANT p...

Page 9: ...GENERAL INFORMATION 1 7 6200E 330415 12 01 TOP VIEW SIDE VIEW 1783 mm 70 in 1067 mm 42 in 2035 mm 80 in FRONT VIEW 1435 mm 56 5 in 1397 mm 55 in 352945 MACHINE DIMENSIONS...

Page 10: ...5 14 Side skirts Check for damage wear and adjustment 2 10 Main brush Check for damage wear and dj t t 1 g adjustment 1 8 Side brush es Check for damage or wear 1 Check brush pattern 1 12 Hopper dust...

Page 11: ...belt Check for wear 1 200 Hours 5 Brakes Check and adjust travel 1 4 Steering gear chain Lubricate EO 1 8 Side brush es guard Check for damage or wear 1 2 3 Battery terminals and cables HCheck and cle...

Page 12: ...the machine at the loading edge of the truck or trailer FOR SAFETY Use truck or trailer that will support the weight of the machine NOTE Empty the hopper before transporting the machine 2 If the loadi...

Page 13: ...the holes in the front of the machine frame The rear tie down locations are the holes in the sides of the machine frame near the rear bumper 6 If the loading surface is not horizontal or is higher tha...

Page 14: ...evel surface set parking brake turn off machine and remove key The front jacking locations are on the flat bottom edge of the front of the machine frame The rear jacking locations are on the corners o...

Page 15: ...291 380 313 407 424 552 1 00 in 500 650 678 881 757 984 1026 1334 NOTE Decrease torque by 20 when using a thread lubricant METRIC BOLT TORQUE CHART Thread Size Class 8 8 Torque ft lb _Nm Class 10 9 To...

Page 16: ...ft lb 12 Nm 0 38 0 56 18 20 ft lb 27 Nm 0 50 0 75 16 30 ft lb 41 Nm 0 62 0 88 14 40 ft lb 54 Nm 0 75 1 12 12 70 ft lb 95 Nm 1 0 1 31 12 90 ft lb 122 Nm HYDRAULIC O RING FITTING TORQUE CHART Tube O D i...

Page 17: ...cuum fan failure Contact Tennant service personnel Thermo Sentryt tripped Reset Thermo Sentryt Hopper door partially or completely closed Open hopper door Poor sweeping performance Brush bristles worn...

Page 18: ...GENERAL INFORMATION 1 16 6200E 330415 12 01...

Page 19: ...CASTER BEARING ASSEMBLY 2 16 TO REMOVE FRONT DRIVE ASSEMBLY 2 17 TO INSTALL FRONT DRIVE ASSEMBLY 2 19 TO REPLACE DRIVE ASSEMBLY CASTER BEARING AND THRUST WASHERS 2 21 TO REPLACE DRIVE ASSEMBLY PIVOT C...

Page 20: ...CHASSIS 2 2 6200E 330415 6 99...

Page 21: ...CHASSIS 2 3 6200E 330415 6 99 INTRODUCTION This section includes information on the main chassis related components for example the seat steering front drive assembly brakes and tires...

Page 22: ...perators seat is a fixed back style with a forward backward adjustment Adjust Pull the lever in slide the seat backward or forward to the desired position and release the lever to lock the seat in pla...

Page 23: ...s touching the floor at all times BRAKES AND TIRES SERVICE BRAKES The service brake is located on the front wheel assembly It is actuated with a foot brake pedal in the operators compartment PARKING B...

Page 24: ...s to the drive support The beginning adjustment should be 1 375 in of conduit showing on the cable end 3 Turn the steering wheel all the way to the right NOTE Spin the tire wheel assembly to make sure...

Page 25: ...to the drive support The beginning adjustment should be 1 375 in of conduit showing on the cable end 3 Turn the steering wheel all the way to the right NOTE Spin the tire wheel assembly to make sure...

Page 26: ...op On Level Surface Block Rear Wheels 1 Raise the seat support and unplug the battery connectors 2 Raise the front of the machine and place jack stands under the frame 3 Mark and remove the electrical...

Page 27: ...he drive assembly This will expose the brake shoes 10 Loosen the two jam nuts on the brake cable where it attaches to the drive support casting Pull the brake cable off the drive assembly 11 Remove th...

Page 28: ...g 15 Reinstall the outer bearing and hex sleeve assembly this is a left hand thread nut Tighten to at least 100 ft lbs and then back off the hex sleeve to 0 ft lbs Re torque hex sleeve to 30 ft lbs 16...

Page 29: ...gging with the brake pedal NOT engaged 20 Go to the other side of the drive assembly and install the planetary gear box outer plate and motor assembly into the wheel assembly and onto the pins of the...

Page 30: ...Set Parking Brake 1 Jack up the rear corner of the machine where the tire needs to be removed NOTE Do not raise both rear wheels off the floor at the same time The machine will become unstable becaus...

Page 31: ...the hole in the wheel bearing with the axle hole in the frame NOTE The lug nuts must face the outside of the machine 2 Install the axle shaft in the machine from the outside of the frame NOTE The axle...

Page 32: ...e 1 Remove the rear wheel assembly See TO REMOVE REAR TIRE instructions 2 Remove the three lug nuts holding the bearing housing to the wheel assembly Remove the bearing housing 3 Use a press to remove...

Page 33: ...on the bearing housing coining on wheel facing lug nuts Tighten the three lug nuts to 58 76 Nm 43 56 ft lb NOTE The lug nuts must face the outside of the machine 6 Reinstall the rear wheel assembly i...

Page 34: ...teering The brakes are actuated with a cable and uses a sprocket and chain assembly for the steering Forward and reverse is accomplished with an electric motor and planetary gearbox FRONT WHEEL SUPPOR...

Page 35: ...support and unplug the battery connectors 2 Raise the front of the machine and place jack stands under the frame 3 Mark and remove the electrical cables leading to the drive motor 4 Go in operators co...

Page 36: ...the wheel support Remove the brake cable from the wheel support 8 Position a floor jack or transmission jack under the drive wheel This will support the drive assembly when the hardware is removed 9 G...

Page 37: ...sition the drive assembly under the machine in front 5 Raise the drive assembly up until the mount holes in the floor plate are aligned with the mount holes in the upper swivel plate weldment on top o...

Page 38: ...The beginning adjustment should be 1 375 in of conduit showing on the cable end Note Spin the tire wheel assembly to make sure the brakes are not dragging with the brake pedal NOT engaged 12 Reinstal...

Page 39: ...n Level Surface Set Parking Brake 1 Remove the drive assembly from the machine See TO REMOVE FRONT DRIVE ASSEMBLY instructions 2 Remove the four hex screws holding the outer plate motor and planetary...

Page 40: ...assembly to the drive assembly 5 Remove the sprocket from the pivot assembly 6 Remove the cotter pin and castle nut from the upper swivel plate weldment 7 Remove the flat washer and cone bearing from...

Page 41: ...ion the new caster bearing on top of the new lower thrust washer 12 Reinstall the second new thrust washer on top of the new caster bearing 13 Reinstall the bottom swivel plate on the upper swivel pla...

Page 42: ...Reduce torque if necessary 16 Reinstall the sprocket on the front drive assembly 17 Reinstall the pivot and sprocket assembly on the drive assembly Reinstall the four screws and tighten to 68 81 Nm 50...

Page 43: ...he drive assembly in the machine See TO INSTALL FRONT DRIVE ASSEMBLY instructions 21 Operate the machine and check for smooth steering operation Check the brakes for proper operation Adjust if necessa...

Page 44: ...Surface Set Parking Brake 1 Remove the drive assembly from the machine See TO REMOVE FRONT DRIVE ASSEMBLY instructions 2 Remove the four hex screws holding the outer plate motor and planetary gear bo...

Page 45: ...ut from the upper swivel plate weldment 7 Remove the flat washer and old cone bearing from the bottom swivel plate 8 Install the new cone bearing and flat washer on the bottom swivel plate Make sure t...

Page 46: ...motor assembly into the wheel assembly and onto the pins of the drive assembly 13 Install the 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 14 Reinstall the drive assembly in the machine Se...

Page 47: ...ont tire TO REMOVE PLANETARY GEAR BOX FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Raise the seat support and unplug the battery connectors 2 Raise the fron...

Page 48: ...holding the outer plate to the main drive assembly 6 Remove the 6 socket screws holding the outer plate to the planetary gear box Remove the outer plate 7 Pull the old planetary gear box out of the dr...

Page 49: ...he planetary gearbox is made from a softer grade of cast iron and the threads could strip out 2 Reinstall the outer motor mount plate and gear box on the drive assembly Tighten the four screws to 18 2...

Page 50: ...00E 330415 6 99 4 Reconnect the electrical cables to the drive motor 5 Remove the jack stands and lower the machine 6 Reconnect the battery cables 7 Operate the machine and check the new gearbox for p...

Page 51: ...and place jack stands under the frame 3 Mark and remove the electrical cables leading to the drive motor 4 Remove the four hex screws holding the outer plate motor and planetary gear box to the main...

Page 52: ...inner bearing axle shaft and tire wheel assembly can now be removed from the drive assembly Use a press to remove the inner bearing from the existing tire wheel assembly 10 Install the inner bearing...

Page 53: ...Re torque hex sleeve to 30 ft lbs 13 Install the lock bolt in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft lb while holding the hex sleeve from turning 14 Reinstall the hub cap in...

Page 54: ...e 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 17 Reconnect the electrical cables to the drive motor 18 Remove the jack stands and lower the machine 19 Reconnect the battery cables 20 Driv...

Page 55: ...he frame 3 Go to the side of the drive assembly opposite the drive motor and remove the hub cap This will expose the outer bearing hex sleeve and lock bolt 4 Remove the lock bolt this is a right hand...

Page 56: ...ve to 0 ft lbs Re torque hex sleeve to 30 ft lbs 8 Install the lock bolt this is a right hand thread screw in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft lb while holding the hex...

Page 57: ...chine and place jack stands under the frame 3 Mark and remove the electrical cables leading to the drive motor 4 Remove the four hex screws holding the outer plate motor and planetary gear box to the...

Page 58: ...and tire wheel assembly can now be removed from the drive assembly Use a press to remove the inner bearing from the existing tire wheel assembly Discard the old wheel bearing 10 Press a new inner whee...

Page 59: ...Re torque hex sleeve to 30 ft lbs 13 Install the lock bolt in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft lb while holding the hex sleeve from turning 14 Reinstall the hub cap in...

Page 60: ...e 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 17 Reconnect the electrical cables to the drive motor 18 Remove the jack stands and lower the machine 19 Reconnect the battery cables 20 Driv...

Page 61: ...d by following the adjustment procedure listed below TO ADJUST STEERING CHAIN FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Go into the operators compartment...

Page 62: ...the frame 3 Go under the machine and locate the steering chain 4 Rotate the steering wheel until the master link on the chain is accessible 5 Remove the chain master link Remove the steering chain fro...

Page 63: ...ive assembly from the machine See TO REMOVE FRONT DRIVE ASSEMBLY instructions 2 Remove the four hex screws holding the pivot and sprocket assembly to the drive assembly 3 Remove the old sprocket from...

Page 64: ...procket assembly on the drive assembly Reinstall the four screws and tighten to 68 81 Nm 50 60 ft lb 6 Reinstall the drive assembly in the machine See TO INSTALL FRONT DRIVE ASSEMBLY instructions 7 Op...

Page 65: ...t of the machine and place jack stands under the frame 3 Go into the operators compartment and locate the lower steering shaft mount assembly Loosen the two screws and pull the mount back to give the...

Page 66: ...the new small sprocket on the lower steering shaft Firmly tighten the set screws 9 Route the steering chain around both steering sprockets Install the master link 10 Adjust the steering chain See TO A...

Page 67: ...under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the steering U joint Loosen the two set screws on the top of the steering U join...

Page 68: ...Locate the master link on the steering chain Remove the master link and steering chain from the small steering sprocket 8 Remove the steering housing from the machine 9 Loosen the two set screws hold...

Page 69: ...scard the bearings Retain the short shaft Note the orientation of the shaft in the housing 12 Use the arbor press to install the new bearings into the steering housing 13 Use the arbor press to instal...

Page 70: ...chain around the small steering sprocket Reinstall the master link 19 Turn the steering wheel all the way to the left and then to the right Find the point in the rotation where the steering chain is t...

Page 71: ...Install jack stands under the machine frame 2 Go to the operators compartment and locate the steering U joint Loosen the two set screws on the top of the steering U joint 3 Pull the steering wheel and...

Page 72: ...re key on the top of the steering housing Tighten the set screws tight 6 Position the long steering shaft and steering wheel into the top of the steering U joint Tighten the set screws tight 7 Operate...

Page 73: ...NGS 3 19 TO REPLACE MAIN BRUSH DRIVE BELT IDLER PULLEY 3 24 SIDE BRUSH 3 26 TO REPLACE SIDE BRUSH 3 26 SIDE BRUSH GUARD 3 28 SIDE BRUSH PIVOT 3 28 TO REPLACE SIDE BRUSH LIFT CABLE 3 29 SKIRTS AND SEAL...

Page 74: ...SWEEPING 3 2 6200E 330415 6 99...

Page 75: ...section includes information on the sweeping operation of the model 6200E The side brush sweeps debris in front of the machine and the main brush sweeps the debris into the hopper The vacuum fan pulls...

Page 76: ...ehind the battery compartment The hopper is raised and lowered with an hydraulic lift cylinder The lift cylinder is provided hydraulic flow from a electro hydraulic unit The electro hydraulic unit is...

Page 77: ...witch to the Filter shaker position D TAPPING Remove the filter and tap the filter gently on a flat surface with the dirty side down Do not damage the edges of the filter element and seals or the filt...

Page 78: ...fore leaving or servicing machine stop on level surface set parking brake turn off machine and remove key 2 Unlatch and remove hopper cover 3 Unplug the filter shaker from the main harness NOTE Carefu...

Page 79: ...releasing tension from the shaking mechanism 6 Lift the VCSt system filter shaker off of the filter 7 Clean or discard the Instant Accesst filter as required 8 Replace the VCSt system filter shaker U...

Page 80: ...loose it will not function properly 10 The filter shaker should lay flat against the filter Check to make sure the comb tab is not caught below the filter shaker plate 11 Check the shaker solenoid gap...

Page 81: ...SWEEPING 3 9 6200E 330415 12 01 13 Reconnect the main harness to the shaker mechanism 14 Check the dust filter seals 15 Replace hopper cover and secure with latches...

Page 82: ...in brush in the lowered position Rotate the main brush end for end after every 50 hours of operation for maximum brush life and best sweeping performance Replace the main brush when the remaining bris...

Page 83: ...r next to the access door 6 Slide the main brush onto the drive plug Rotate the brush until it engages the drive plug and push it all the way onto the plug 7 Check that the recirculation skirt is tuck...

Page 84: ...o 20 seconds while keeping a foot on the brakes to keep the machine from moving NOTE If chalk or other material is not available allow the brushes to spin on the floor for two minutes A polish mark wi...

Page 85: ...her adjust the taper as follows A Loosen the brush shaft bearing bracket mounting bolt and the idler arm securing head B Allow the brush to operate and float into position for approximately 30 seconds...

Page 86: ...IN BRUSH DRIVE BELT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Remove the four screws holding the right hand brush door to the machine frame Remove the ri...

Page 87: ...e old drive belt 6 Position the new main brush drive belt onto the motor and brush drive pulleys 7 Move the idler pulley forward in the slot until the belt is tight Tighten the hex nut to 18 24 Nm 15...

Page 88: ...Stop On Level Surface Set Parking Brake 1 Open the left hand side brush door 2 Remove the main brush idler mount plate See TO REPLACE MAIN BRUSH instructions in this sections 3 Remove the idler arm f...

Page 89: ...screws holding the bearing retainer to the idler plug Remove the retainer 7 Remove and discard the idler ball bearing from the idler plug 8 Position the new ball bearing into the idler plug 9 Reinsta...

Page 90: ...w washer and nyloc nut Tighten to 37 48 Nm 26 34 ft lb 11 Reinstall the idler arm onto the brush lift plate 12 Reinstall the main brush idler mount plate See TO REPLACE MAIN BRUSH instructions in this...

Page 91: ...e jack points Install jack stands under the machine frame 2 Open the left hand side brush door Remove the right hand brush door 3 Remove the main brush idler mount plate See TO REPLACE MAIN BRUSH inst...

Page 92: ...left hand thread nut 7 Remove the main brush V belt pulley larger one from the main brush shaft Make sure to retain the washer from behind the pulley 8 Hold the main brush drive plug from turning Rem...

Page 93: ...w driver or punch to remove the remaining outer bearing from the main brush housing Discard the bearing 14 Use an arbor press to remove the bearing from the main brush shaft Discard the bearing 15 Ins...

Page 94: ...ten tight 19 Reinstall the washer and V belt pulley recess to inside onto the outside of the main brush shaft Reinstall the left hand nut Tighten to 52 67 Nm 39 51 ft lb 20 Reinstall the main brush dr...

Page 95: ...23 6200E 330415 6 99 22 Reinstall the right hand brush door and close the left hand brush door 23 Remove the jack stands and lower the machine 24 Operate the machine and check the main brush for prope...

Page 96: ...our screws holding the right hand brush door to the machine frame Remove the right hand side brush door 2 Locate the main brush drive belt idler pulley between the small motor drive pulley and the lar...

Page 97: ...the hex bolt Reinstall the hex nut Leave loose for now 8 Reinstall the V belt around the two drive pulleys and on top of the idler pulley 9 Pull down on the idler pulley until the belt is tight Tighte...

Page 98: ...Move the pulley mount bracket up or down to achieve the proper side brush pattern Retighten the hex screw The side brush should be replaced when it no longer sweeps effectively for your application A...

Page 99: ...retaining pin through the side brush hub and shaft 6 Secure the pin by clipping the pin keeper over the end of the pin 7 Adjust the side brush pattern by loosening the hex screw located above the sid...

Page 100: ...r every 200 hours of operation Replace the brush guard after it begins to show serious wear SIDE BRUSH PIVOT The side brush pivot should be checked for excessive movement after every 200 hours of oper...

Page 101: ...2 Go under the front of the machine near the side brush Locate the side brush lift cable clevis under the brush pivot hex nut Remove the nut only Pull the side brush lift cable off the hex screw 3 Go...

Page 102: ...proper re assembly 5 Go up under the instrument panel and remove the hex screw and nut holding the end of the side brush lift cable to the lift handle Remove the side brush lift cable from the machine...

Page 103: ...the new side brush lift cable to the side brush pivot screw Hand tighten the hex nut Cable should pivot on the hardware 9 Connect the side brush lift cable to the lift handle 10 Raise the side brush...

Page 104: ...09 in The recirculation skirt requires no adjustment Check the skirts for wear or damage and adjustment daily NOTE The recirculation skirt must be folded in between the brush and the machine frame be...

Page 105: ...toward the main brush curl back should be 3 4 inch 1 8 inch Sweeping performance will be adversely affected if this skirt does not contact the floor Check the skirt for wear or damage after every 100...

Page 106: ...of the rear lip of the hopper door and seals the inside lip of the hopper door with the hopper Check the seal for wear or damage after every 100 hours of operation FRONT SKIRT The front skirt is loca...

Page 107: ...sst filter The vacuum fan is powered by an electric motor and driven with a V belt VACUUM FAN BELT Check the vacuum fan belt tension and wear after every 100 hours of operation The correct tension is...

Page 108: ...n drive belt remove the right hand side panel Start by lifting up on the panel pop the brush lift slot over the black knob then move the panel backward and off the machine 2 Remove the right hand side...

Page 109: ...emove the old V belt from the machine 7 Install the new vacuum fan V belt over both pulleys 8 Pull the vacuum fan assembly toward the back of the machine to tighten the V belt Tighten the five mounts...

Page 110: ...SWEEPING 3 38 6200E 330415 6 99 10 Reinstall the right hand machine cover 11 Reinstall the right hand brush door 12 Operate the machine Check the vacuum fan for proper operation...

Page 111: ...black knob then move the panel backward and off the machine 2 Loosen the four hex screws holding the vacuum fan housing to the machine frame 3 Pull the vacuum fan assembly toward the back of the mach...

Page 112: ...ove the right hand side panel Start by lifting up on the panel pop the brush lift slot over the black knob then move the panel backward and off the machine 3 Loosen the five hex screws holding the vac...

Page 113: ...the bottom two hex screws 9 Place the assembly on a work bench with the vacuum fan inlet plate facing up 10 Remove the five hex screws and nuts holding the vacuum fan inlet plate to the bearing housi...

Page 114: ...plate onto the bearing housing plate Reinstall the five steel sleeves hex screws and nuts Center the hole in the plate over the impeller fins Tighten the hardware to 18 24 Nm 15 20 ft lb 15 Position t...

Page 115: ...belt The correct tension is when the belt deflects 8 38 mm 0 33 in from a force of 42 kg 90 to 95 lb at belt midpoint 18 Tighten the five mounts screws hand tight 19 Reinstall the V belt cover Tighten...

Page 116: ...SWEEPING 3 44 6200E 330415 6 99 22 Start the machine raise the hopper disengage the prop arm Lower the hopper 23 Operate the machine Check the vacuum fan for proper operation...

Page 117: ...N IMPELLER instructions to remove the vacuum fan assembly from the machine and and the impeller from the housing NOTE Once the vacuum fan impeller has been removed go to step 2 2 Loosen the two set sc...

Page 118: ...he wide flange NOTE Make sure the bearings are pressed down tight The fan will be noisy if there is any play in the bearings The retaining rings must be tight to the housing 6 Reinstall the bearing ho...

Page 119: ...einstall the vacuum fan impeller onto the fan shaft Make sure to reinstall the square key on the fan shaft 9 See TO REMOVE VACUUM FAN IMPELLER instructions to install the vacuum fan impeller and the v...

Page 120: ...fan failure Contact Tennant service personnel Thermo Sentryt tripped Reset Thermo Sentryt Hopper door partially or completely closed Open hopper door Poor sweeping performance Brush bristles worn Repl...

Page 121: ...EDAL ASSEMBLY 4 26 TO REPLACE DIRECTIONAL CONTROL UNIT 4 28 ELECTRIC MOTORS 4 30 TO REPLACE FRONT DRIVE WHEEL MOTOR 4 30 TO REPLACE MAIN BRUSH MOTOR 4 32 TO REPLACE VACUUM FAN MOTOR 4 37 TO REPLACE SI...

Page 122: ...ELECTRICAL 4 2 6200E 330415 6 99...

Page 123: ...ELECTRICAL 4 3 6200E 330415 5 99 INTRODUCTION The 6200E electrical system consists of the batteries instrument panel drive motor switches relays and circuit breakers...

Page 124: ...ow any baking soda solution to enter the batteries Use a wire brush to clean the terminal posts and the cable connectors After cleaning apply a coating of clear battery post protectant to the terminal...

Page 125: ...If the readings are taken when the battery electrolyte is any temperature other than shown the reading must be temperature corrected Add or subtract to the specific gravity reading 0 004 4 points for...

Page 126: ...connector 7 Plug the connector from the batteries into the battery charger connector WARNING Batteries emit hydrogen gas Explosion or fire can result Keep sparks and open flame away Keep covers open w...

Page 127: ...before the batteries are fully charged and the charger has not automatically shut off turn off the charger before disconnecting 9 After the charger has turned off unplug the charger connector from the...

Page 128: ...CE BATTERIES FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries 3 Remove the five...

Page 129: ...fting loop at each end of the battery 6 Pull the four batteries nearest the front of the machine toward the rear of the battery tray Remove these batteries next 7 Install the four front batteries firs...

Page 130: ...0 Reinstall the connector assembly onto the batteries 11 Reconnect the battery connect to the machine connector 12 Disengage the prop rod and lower the seat support 13 Start the machine and check the...

Page 131: ...ELECTRICAL 4 11 6200E 330415 5 99 BATTERY INSTALLATION ARRANGEMENT CORRECT BATTERY CABLE INSTALLATION...

Page 132: ...and instruments needed to run the machine functions TO ACCESS CIRCUIT BREAKER OR INSTRUMENT PANEL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat...

Page 133: ...d 5 Pivot the circuit breaker panel back away from the front shroud 6 With the circuit breaker panel pivoted down electrical components on the circuit breaker panel and the main instrument panel can b...

Page 134: ...ICAL 4 14 6200E 330415 5 99 8 Open the seat support and engage the prop rod 9 Reconnect the batteries 10 Disengage the prop rod and lower the seat support 11 Start the machine and check for proper ope...

Page 135: ...Surface Set Parking Brake 1 Pull the instrument panel back away from the front shroud for better access to the circuit breakers See TO ACCESS CIRCUIT BREAKER OR INSTRUMENT PANEL instructions 2 Locate...

Page 136: ...ker out of the hole Discard the circuit breaker 7 Position the new circuit breaker into the mount hole NOTE The mount hole has a D shape to match the shape of the circuit breaker 8 Install the black t...

Page 137: ...ivot the instrument panel back onto the front shroud Reinstall the hardware and hand tighten tight See TO ACCESS CIRCUIT BREAKER OR INSTRUMENT PANEL instructions 12 Start the machine and check the new...

Page 138: ...t Parking Brake 1 Pull the instrument panel back away from the front shroud for better access to the 80 amp See TO ACCESS CIRCUIT BREAKER OR INSTRUMENT PANEL instructions 2 Locate the 80 amp fuse abov...

Page 139: ...rew Remove and discard the fuse 5 Install the new fuse under the two hex screws Hand tighten the hex screws tight 6 Pivot the instrument panel back onto the front shroud Reinstall the hardware and han...

Page 140: ...a one time protection devices designed to stop the flow of current in the event of a circuit overload Never substitute higher value fuses than specified The fuse is located behind the circuit breaker...

Page 141: ...e overload that caused the circuit breaker to trip is still there the circuit breaker will continue to stop current flow until the problem is corrected Circuit breakers 1 through 9 are located above t...

Page 142: ...Surface Set Parking Brake 1 Pull the instrument panel back away from the front shroud for better access to the propel controller See TO ACCESS CIRCUIT BREAKER OR INSTRUMENT PANEL instructions 2 Locate...

Page 143: ...the same orientation as the old one Reinstall the hardware and hand tighten NOTE Do not over tighten 6 Reconnect the wires to the new controller See schematic in this section 7 Pivot the instrument p...

Page 144: ...ed of the machine with the pressure of your foot on the pedal the harder you press the faster the machine travels Use the brake pedal to stop the machine TO REMOVE DIRECTIONAL PEDAL ASSEMBLY FOR SAFET...

Page 145: ...ectional pedal 5 Disconnect the directional pedal connector from the main harness Remove any plastic ties holding the directional pedal harness to the main harness 6 Go the the operators compartment a...

Page 146: ...Parking Brake 1 Position the directional pedal assembly in the machines operators compartment 2 Feed the pedal harness down through the access hole in the floor plate 3 Line up the mount holes in the...

Page 147: ...or leading from the directional pedal 6 Reconnect the directional pedal connector to the main harness Reinstall any plastic ties that were holding the directional pedal harness to the main harness 7 R...

Page 148: ...1 Remove the directional pedal assembly from the machine See TO REMOVE DIRECTIONAL PEDAL ASSEMBLY instructions in this section 2 Loosen the hex screw and nut holding the accelerator lever to the poten...

Page 149: ...elerator lever onto the shaft of the potentiometer Hand tighten the hex screw and nut 7 Check the length of the threaded rod ball joint assembly Measure the distance between the ball joint centers The...

Page 150: ...TOR FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Raise the seat support and unplug the battery connectors 2 Raise the front of the machine and place jack st...

Page 151: ...tall the new drive motor on the drive assembly Make sure to line up the splines on the motor shaft with the splines of the planetary gear box Tighten the 4 hex screws to 18 24 Nm 15 20 ft lb 6 Reconne...

Page 152: ...Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Lower the main brush lever 3 Op...

Page 153: ...brush pulley 7 Loosen the hex nut in the center of the idler pulley 8 Push the idler pulley back in the slot 9 Remove the main brush drive belt from the two remaining pulleys Remove the main brush dr...

Page 154: ...n brush motor from the machine NOTE Note the orientation of the motor and electrical wires 15 Install the new main brush motor into the machine NOTE Make sure to orientate the motor so the wires are p...

Page 155: ...onto the new main brush motor shaft Line up the small V belt pulley with the larger V belt pulley Make sure the square key is installed on the shaft Hand tighten the two set screws tight 21 Position...

Page 156: ...415 5 99 24 Reconnect the batteries 25 Disengage the prop rod and lower the seat support 26 Remove the jack stands and lower the machine to the floor Operate the machine and check the new main brush m...

Page 157: ...ved See TO REPLACE MAIN BRUSH MOTOR instructions in this section 2 To access the vacuum fan drive belt remove the right hand side panel Start by lifting up on the panel pop the brush lift slot over th...

Page 158: ...uum fan V belt pulley to the motor shaft Pull the pulley off the shaft Retain the square key 7 Remove the four hex screws holding the vacuum fan motor to the mount bracket 8 Go under the front of the...

Page 159: ...front of the machine 11 Reconnect the vacuum fan motor to the main harness 12 Line up the mount holes in the new motor with the mount holes in the motor mount bracket Reinstall the four hex screws Ti...

Page 160: ...Pull the vacuum fan assembly toward the back of the machine to tighten the V belt Tighten the four mounts screws hand tight 15 Reinstall the right hand machine cover 16 Reinstall the right hand side b...

Page 161: ...19 The main brush motor must be reinstalled after the vacuum fan motor has been replaced See TO REPLACE MAIN BRUSH MOTOR instructions in this section 20 Remove the jack stands and lower the machine to...

Page 162: ...el Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Lower the side brush 3 Remove the side brush from the motor assembly See...

Page 163: ...he brush guard 7 Position the new side brush motor onto the motor mount bracket The motor is positioned to the rear of the machine 8 Line up the holes in the motor assembly with the mount holes in the...

Page 164: ...ELECTRICAL 4 44 6200E 330415 5 99 11 Reinstall the side brush See TO REPLACE SIDE BRUSH instructions in the SWEEPING section 12 Operate the machine Check the new side brush motor for proper operation...

Page 165: ...top On Level Surface Set Parking Brake 1 Place a wood block under the hopper dump door Turn on the key and open the door until the two cables one each side of the hopper go slack 2 Un latch and remove...

Page 166: ...main harness 5 Remove the hair pin and clevis pin from each end of the actuator Remove the actuator from the machine 6 Install the new dump door actuator into the machine in the same orientation as t...

Page 167: ...r actuator to the main electrical harness 9 Reinstall the hopper cover and latch it down 10 Turn on the key and close the dump door Remove the wood block from under the dump door 11 Operate the machin...

Page 168: ...s an electrical device used to detect excess heat or fire in the hopper filter area If fire is detected in the hopper filter area the Thermo Sentryt sends a signal to the vacuum fan electric motor The...

Page 169: ...AFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Un latch and remove the hopper filter cover 2 Locate the Thermo Sentryt at the back side of the 90 degree section of...

Page 170: ...lding the Thermo Sentryt to the vacuum tube 5 Install the new Thermo Sentryt onto the vacuum tube Reinstall the hardware and hand tighten Make sure the gasket is installed under the Thermo Sentryt 6 R...

Page 171: ...ELECTRICAL 4 51 6200E 330415 12 01...

Page 172: ...ELECTRICAL 4 52 6200E 330415 12 01 ELECTRICAL SCHEMATIC 000000 002089 1 2 3 4 352868 E...

Page 173: ...ELECTRICAL 4 53 6200E 330415 12 01 ELECTRICAL SCHEMATIC 000000 002089 1 2 3 4 352868 E...

Page 174: ...ELECTRICAL 4 54 6200E 330415 12 01 ELECTRICAL SCHEMATIC 002090 1 2 3 4 352868 E...

Page 175: ...ELECTRICAL 4 55 6200E 330415 12 01 ELECTRICAL SCHEMATIC 002090 1 2 3 4 352868 E...

Page 176: ...ELECTRICAL 4 56 6200E 330415 12 01 MAIN WIRE HARNESS GROUP...

Page 177: ...ELECTRICAL 4 57 6200E 330415 12 01 MAIN WIRE HARNESS GROUP 352868 E...

Page 178: ...ELECTRICAL 4 58 6200E 330415 12 01 MAIN WIRE HARNESS GROUP 352868 E...

Page 179: ...ELECTRICAL 4 59 6200E 330415 12 01 MAIN WIRE HARNESS GROUP 352868 E...

Page 180: ...ELECTRICAL 4 60 6200E 330415 12 01 MAIN WIRE HARNESS GROUP 352868 E...

Page 181: ...ELECTRICAL 4 61 6200E 330415 12 01 HOPPER WIRE HARNESS GROUP 352868 E...

Page 182: ...ELECTRICAL 4 62 6200E 330415 12 01...

Page 183: ...200E 330415 6 99 TROUBLESHOOTING The troubleshooting charts that follow are organized so they lead you through the circuits They include flow charts and instructions for you as to where to insert your...

Page 184: ...rom terminal 50 of the key switch to the reverse polarity diode D1 and finally to pin 16 at the propel motor controller The M1 contactor coil also receives 36 volts from the key switch 2 Propel motor...

Page 185: ...ELECTRICAL 4 65 6200E 330415 6 99 Fig 1...

Page 186: ...ELECTRICAL 4 66 6200E 330415 6 99 Fig 2...

Page 187: ...ELECTRICAL 4 67 6200E 330415 6 99 Fig 3...

Page 188: ...ow from the B terminal to A1 and through the armature of the propel motor From the negative side of the propel motor A2 current flow continues to M at the controller To complete the path back to the b...

Page 189: ...ol from terminal B black white wire and is fed into terminal 11 at the motor controller 3 Speed reference input signal see Fig 6 The motor controller uses a 0 5 volt signal at terminal 6 at the motor...

Page 190: ...ELECTRICAL 4 70 6200E 330415 6 99 Fig 4...

Page 191: ...ELECTRICAL 4 71 6200E 330415 6 99 EITHER THE FOR WARD OR REVERSE CIR CUIT BUT NOT BOTH Fig 5...

Page 192: ...ELECTRICAL 4 72 6200E 330415 6 99 Fig 6...

Page 193: ...ELECTRICAL 4 73 6200E 330415 6 99 REDUCE SPEED WHEN HOPPER IS RAISED REDUCE SPEED WHEN SWEEP ING Fig 7...

Page 194: ...short Pot low wire open or shorted Throttle pot wire broken or shorted Wrong throttle type installed or programmed Contactor coil output driver overcurrent or field short 1 Main contactor coil shorted...

Page 195: ...in sweeping brush motor to operate the machine must be started with the M1 contactor energized The hopper should be lowered completely allowing the hopper down switch to close Engaging the main brush...

Page 196: ...ELECTRICAL 4 76 6200E 330415 6 99 Fig 8...

Page 197: ...ELECTRICAL 4 77 6200E 330415 6 99 Fig 9...

Page 198: ...vacuum fan motor to operate the machine must be started with the M1 contactor energized The hopper should be lowered completely allowing the hopper down switch to close Engaging the Fan shake filter...

Page 199: ...ELECTRICAL 4 79 6200E 330415 6 99 Fig 10...

Page 200: ...ELECTRICAL 4 80 6200E 330415 6 99 Fig 11...

Page 201: ...vacuum fan motor to operate the machine must be started with the M1 contactor energized The hopper should be lowered completely allowing the hopper down switch to close Engaging the Fan shake filter...

Page 202: ...ELECTRICAL 4 82 6200E 330415 6 99 Fig 12...

Page 203: ...ELECTRICAL 4 83 6200E 330415 6 99 Fig 13...

Page 204: ...ELECTRICAL 4 84 6200E 330415 6 99...

Page 205: ...INTRODUCTION 5 3 HYDRAULIC FLUID RESERVOIR 5 4 HYDRAULIC FLUID 5 4 HYDRAULIC HOSES 5 5 TO REPLACE HOPPER LIFT CYLINDER 5 6 TO REPLACE ELECTRO HYDRAULIC LIFT UNIT 5 9 HYDRAULIC TROUBLESHOOTING 5 12 HYD...

Page 206: ...HYDRAULICS 5 2 6200E 330415 6 99...

Page 207: ...HYDRAULICS 5 3 6200E 330415 6 99 INTRODUCTION The hydraulic system on the model 6200E consists of the electro hydraulic pump reservoir hoses and hopper lift cylinder...

Page 208: ...ain and refill the hydraulic fluid reservoir with new hydraulic fluid after every 800 hours of operation The hydraulic fluid filter is located under the engine compartment Replace the filter element a...

Page 209: ...rication Malfunctions accelerated wear and damage will result if dirt or other contaminants enter the hydraulic system HYDRAULIC HOSES Check the hydraulic hoses after every 800 hours of operation for...

Page 210: ...vel Surface Set Parking Brake Turn Off Machine And Remove Key 1 Un latch and remove the hopper filter cover 2 Locate the hopper lift cylinder at the rear center of the machine 3 Mark disconnect and pl...

Page 211: ...cotter pin and clevis pin from the hopper lift cylinder Remove the lift cylinder from the machine 6 Remove the hydraulic fittings from the existing lift cylinder and install in the new cylinder in th...

Page 212: ...200E 330415 6 99 8 Reconnect the two hydraulic hoses to the new hopper lift cylinder 9 Reinstall the hopper cover and engage both latches 10 Operate the machine Check the new hopper lift cylinder for...

Page 213: ...Parking Brake Turn Off Machine And Remove Key 1 Un latch and remove the hopper filter cover 2 Locate the hopper lift electro hydraulic unit at the rear left side of the machine 3 Mark disconnect and p...

Page 214: ...he lift arm panel Remove the unit from the machine Make sure to retain the two spacers 6 Remove the two hydraulic fittings from the existing electro hydraulic unit Install the two fittings into the ne...

Page 215: ...raulic unit 9 Connect the plug from the main electrical harness into the connector from the new unit 10 Check the hydraulic fluid reservoir tank 11 Reinstall the hopper cover and engage both latches 1...

Page 216: ...MBING OK No Yes RELIEF PRESSURE OK No REPAIR REPLACE POWER UNIT CHECK RESERVOIR FLUID LEVEL CIRCUIT FLOW OK No Yes CHECK ELECTRICAL SYSTEM ELECTRICAL POWER OK No Yes Yes REPAIR REPLACE ELECTRIC MOTOR...

Page 217: ...HYDRAULICS 5 13 6200E 330415 6 99 HYDRAULIC SCHEMATIC...

Page 218: ...HYDRAULICS 5 14 6200E 330415 12 01 HYDRAULIC HOSE GROUP...

Page 219: ...ve 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...

Page 220: ...E 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 145...

Page 221: ...ve 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...

Page 222: ...E 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 145...

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