Tennant 6100 G/LP Service Manual
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Tennant 6100 G/LP Service Manual

Tennant 6100 G/LP Service Manual

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6100 G/LP
Service Manual
330235
Rev. 02 (9- -01)

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  • Page 1 6100 G/LP Service Manual 330235 Rev. 02 (9- -01)
  • Page 2 Engine - - G/LP: Air filter replacement, oil changing, cooling system maintenance/repair, engine troubleshooting, engine removal, and engine repairs. Manual Number -- 330235 Revision: 02 Published: 9--01 Copyright E 2000, 2001 TENNANT, Printed in U.S.A.

  • Page 3: Table Of Contents

    ... 1--14 HYDRAULIC O--RING FITTING TORQUE CHART ....1--14 1-- 1 6100 G/LP 330235 (9- -01)
  • Page 4 GENERAL INFORMATION 1-- 2 6100 G/LP 330235 (9- -01)

  • Page 5: Safety Precautions

    - - Use cardboard to locate leaking - - Unless trained and authorized. hydraulic fluid under pressure. - - Unless operation manual is read and - - Use Tennant supplied or equivalent understood. replacement parts. - - In flammable or explosive areas unless designed for use in those areas.
  • Page 6 FOR SAFETY LABEL - - LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT. FLYING DEBRIS LABEL - - LOCATED ABOVE HOPPER EMISSIONS LABEL - - Located Below The Operator’s Seat. 352182 1-- 4 6100 G/LP 330235 (9- -00)

  • Page 7: Specifications

    (3 mph) Minimum aisle turn 1830 mm (72 in) Minimum turning radius 1725 mm (68 in) Maximum rated incline with empty hopper 10_ / 17.6% Maximum rated incline with full hopper 8_ / 14.1% 1-- 5 6100 G/LP 330235 (9- -00)

  • Page 8: Power Type

    Manual steering Manual HYDRAULIC SYSTEM System Capacity Fluid Type Hydraulic reservoir TENNANT part no. 65869--above 7° C (45° F) Hydraulic total TENNANT part no. 65870--above 7° C (45° F) BRAKING SYSTEM Type Operation Service brakes Mechanical disc brake (1), one front wheel, cable...

  • Page 9: Machine Dimensions

    GENERAL INFORMATION 1524 mm (60 in) 813 mm (32 in) TOP VIEW 1270 mm (50 in) SIDE VIEW FRONT VIEW 352185 MACHINE DIMENSIONS 1-- 7 6100 G/LP 330235 (9- -01)

  • Page 10: Maintenance

    Clean air filter element 50 Hours Engine oil Change Engine air filter Replace Vacuum fan belt Check tension and wear Main brush Rotate end-for-end Check brush pattern QuickMoptbroom (Option) Rotate or wash sweep heads 1-- 8 6100 G/LP 330235 (2- -99)
  • Page 11 SAE 10W--30 Engine oil HYDO TENNANT or approved hydraulic fluid NOTE: More frequent intervals may be required in extremely dusty conditions. NOTE: Also check procedures indicated (H) after the first 50 hours of operation. 1-- 9 6100 G/LP 330235 (2- -99)

  • Page 12: Pushing, Towing, And Transporting The Machine

    Do not drive the machine onto the truck or trailer unless the loading surface is horizontal AND is 380 mm (15 in) or less from the ground. 1-- 10 6100 G/LP 330235 (9- -01)
  • Page 13 FOR SAFETY: When unloading machine off truck or trailer, use winch. Do not drive the machine off the truck or trailer unless the loading surface is horizontal AND 380 mm (15 in) or less from the ground. 1-- 11 6100 G/LP 330235 (9- -01)

  • Page 14: Machine Jacking

    Block machine up with jack stands. STORING MACHINE Before storing the machine for an extended time, the machine needs to be serviced to lessen the chance of rust, sludge, and other undesirable deposits from forming. 1-- 12 6100 G/LP 330235 (9- -01)

  • Page 15: Hardware Information

    They include the following: 0.75 in 215--280 313--407 (291--380) (424--552) Locktite 515 sealant -- gasket forming material. TENNANT Part No. 75567,15 oz 1.00 in 500--650 757--984 (440 ml) cartridge. (678--881) (1026--1334) NOTE: Decrease torque by 20% when using a Locktite 242 blue -- medium strength thread thread lubricant.

  • Page 16: Hydraulic Fitting Information

    (122 Nm) 0.62 0.88--14 40 ft lb (54 Nm) NOTE: Do not use sealant on o- -ring threads. 0.75 1.12--12 70 ft lb (95 Nm) 1.31--12 90 ft lb (122 Nm) *Aluminum bodied components 1-- 14 6100 G/LP 330235 (3- -97)
  • Page 17 DIRECTIONAL PEDAL ... . . 2--55 TO ADJUST DIRECTIONAL PEDAL LINKAGE ... . 2--55 2-- 1 6100 G/LP 330235 (9- -00)
  • Page 18 CHASSIS 2-- 2 6100 G/LP 330235 (9- -00)

  • Page 19: Introduction

    CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat, steering, brakes, and tires. 2-- 3 6100 G/LP 330235 (9- -00)

  • Page 20: Brakes And Tires

    2. Go under the front of the machine and locate the disc brake caliper assembly. 3. Remove the small cotter pin from the caliper lever pin. 2-- 4 6100 G/LP 330235 (9- -00)

  • Page 21: To Adjust Parking Brake

    Retighten the hardware. TO ADJUST PARKING BRAKE The parking brake adjustment is made at the same time as the service brake. See TO ADJUST SERVICE BRAKE instructions. 2-- 5 6100 G/LP 330235 (9- -00)

  • Page 22: To Replace Brake Pads

    2. Remove the tension spring from the brake caliper lever and wheel housing. 3. Remove the nuts from the shoulder screws holding the brake caliper to the wheel housing. 2-- 6 6100 G/LP 330235 (9- -00)
  • Page 23 5. Remove the two shoulder screws from the caliper assembly. 6. Pull the two brake pads out of the caliper assembly. Note the orientation of the pads. 7. Install the new pads into the caliper assembly in the same orientation. 2-- 7 6100 G/LP 330235 (9- -00)
  • Page 24 11. Reinstall the front tire and wheel assembly. See TO INSTALL FRONT TIRE AND WHEEL instructions in this section. 12. Operate the machine and check the brakes for proper operation. 2-- 8 6100 G/LP 330235 (9- -00)

  • Page 25: Rear Tires And Wheels

    Surface, Set Parking Brake. 1. Remove the debris hopper from the rear of the machine. 2. Jack up the machine at the rear jack point. Place a jack stand under the machine frame. 2-- 9 6100 G/LP 330235 (9- -00)
  • Page 26 4. Support the rear wheel and remove the axle shaft. 5. Remove the rear tire assembly from the machine. 6. Remove the three hex screws and nuts holding the wheel hub to the tire assembly. 2-- 10 6100 G/LP 330235 (9- -00)
  • Page 27 CHASSIS 7. Remove the hub assembly from the tire assembly. 2-- 11 6100 G/LP 330235 (9- -00)

  • Page 28: To Install Rear Tire Assembly

    Note the “D” shape of the frame mount hole and the “ D” on the axle shaft. Line these two up and push the axle all the way into the mount hole. 2-- 12 6100 G/LP 330235 (9- -00)
  • Page 29 37 -- 48 Nm (26 -- 34 ft lb). 5. Spin the tire assembly to make sure it turns freely. 6. Remove the jack stand and lower the machine to the floor. 7. Operate the machine for proper operation. 2-- 13 6100 G/LP 330235 (9- -00)

  • Page 30: Front Drive Wheel, And Wheel Housing Support

    1. Jack up the front of the machine at the jack point. Install jack stands under the machine frame. 2. Remove the two nuts holding the chain guard to the wheel support. Remove the chain guard. 2-- 14 6100 G/LP 330235 (9- -00)
  • Page 31 NOTE: Try to keep the chain on the upper sprocket when removing the wheel. 5. Remove the large nut and washer from the wheel axle. 6. Support the front drive wheel. Remove the axle from the front wheel. 2-- 15 6100 G/LP 330235 (9- -00)
  • Page 32 Pull the brake disc off the hub. 9. Remove the three wheel nuts holding the tire to the front hub. 10. Remove the tire assembly from the hub. 2-- 16 6100 G/LP 330235 (9- -00)

  • Page 33: To Install Front Tire And Wheel

    Use red loctite (271) on the threads of the screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). Tighten these screws in a “criss--cross” pattern. Make sure the disc floats on the hub. 2-- 17 6100 G/LP 330235 (9- -00)
  • Page 34 Line these two up and push the axle all the way into the mount hole. 7. Install the washer and nyloc nut onto the axle shaft. Tighten to 64 -- 83 Nm (47 -- 61 ft lb). 2-- 18 6100 G/LP 330235 (9- -00)
  • Page 35 18 -- 24 Nm (15 -- 20 ft lb). 11. Remove the jack stands and lower the machine to the floor. Operate the machine and check for proper operation. 2-- 19 6100 G/LP 330235 (9- -00)

  • Page 36: To Replace Front Wheel Drive Chain

    Remove the chain guard. 3. Loosen the three nuts holding the hydraulic drive motor to the wheel support. Let the motor drop down so the drive chain has some slack. 2-- 20 6100 G/LP 330235 (9- -00)
  • Page 37 7. Push the hydraulic drive motor up until the chain is tight (+/- - 1/8 inch at mid- -point). Tighten nuts to 18 -- 24 Nm (15 -- 20 ft lb). 2-- 21 6100 G/LP 330235 (9- -00)
  • Page 38 18 -- 24 Nm (15 -- 20 ft lb). 9. Remove the jack stands and lower the machine to the floor. Operate the machine and check the new drive chain for proper operation. 2-- 22 6100 G/LP 330235 (9- -00)

  • Page 39: To Replace Front Wheel Hub Bearings

    Push the bearings down until they are seated flush against the housing. 4. Reinstall the front wheel assembly. See TO INSTALL FRONT TIRE AND WHEEL instructions in this section. 2-- 23 6100 G/LP 330235 (9- -00)

  • Page 40: To Adjust Steering Chain

    Loosen the two screws. 3. Turn the steering wheel all the way to the left and then to the right. Find the point in the rotation where the steering chain is the most tight. 2-- 24 6100 G/LP 330235 (9- -00)
  • Page 41 37 -- 48 Nm (26 -- 34 ft lb). 5. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering chain for proper operation. 2-- 25 6100 G/LP 330235 (9- -00)

  • Page 42: To Replace Steering Chain

    3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. 2-- 26 6100 G/LP 330235 (9- -00)
  • Page 43 Install a new master link in the new chain. 7. Turn the steering wheel all the way to the left and then to the right. Find the point in the rotation where the steering chain is the most tight. 2-- 27 6100 G/LP 330235 (9- -00)
  • Page 44 37 -- 48 Nm (26 -- 34 ft lb). 9. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering chain for proper operation. 2-- 28 6100 G/LP 330235 (9- -00)

  • Page 45: To Replace Steering Housing Bearings

    2. Turn the steering wheel all the way to the left. 3. Go to the operators compartment and locate the steering U--joint. Loosen the two set screws on the top of the steering U--joint. 2-- 29 6100 G/LP 330235 (9- -00)
  • Page 46 6. Go under the machine and locate the small steering chain sprocket. 7. Locate the master link on the steering chain. Remove the master link and steering chain from the small steering sprocket. 2-- 30 6100 G/LP 330235 (9- -00)
  • Page 47 11. Use an arbor press to press the short steering shaft and two bearings out of the housing. Discard the bearings. Retain the short shaft. Note the orientation of the shaft in the housing. 2-- 31 6100 G/LP 330235 (9- -00)
  • Page 48 Tighten the set screws tight. 15. Reinstall the U--joint and square key on the top of the steering housing. Tighten the set screws tight. 2-- 32 6100 G/LP 330235 (9- -00)
  • Page 49 Reinstall the master link. 19. Turn the steering wheel all the way to the left and then to the right. Find the point in the rotation where the steering chain is the most tight. 2-- 33 6100 G/LP 330235 (9- -00)
  • Page 50 37 -- 48 Nm (26 -- 34 ft lb). 21. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering chain for proper operation. 2-- 34 6100 G/LP 330235 (9- -00)

  • Page 51: To Replace Steering U--Joint

    U--joint. Loosen the two set screws on the top of the steering U--joint. 3. Pull the steering wheel and long steering shaft up and out of the top of the steering U--joint. 2-- 35 6100 G/LP 330235 (9- -00)
  • Page 52 6. Position the long steering shaft and steering wheel into the top of the steering U--joint. Tighten the set screws tight. 7. Operate the machine and check the steering U--joint for proper operation. 2-- 36 6100 G/LP 330235 (9- -00)

  • Page 53: To Replace Small Steering Sprocket

    3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. This will loosen the steering chain. 2-- 37 6100 G/LP 330235 (9- -00)
  • Page 54 7. Install the new small sprocket and woodruff key onto the steering shaft. The teeth of the new sprocket face down. Position the sprocket in the same location as the old one. Tighten the two set screws tight. 2-- 38 6100 G/LP 330235 (9- -00)
  • Page 55 37 -- 48 Nm (26 -- 34 ft lb). 11. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering for proper operation. 2-- 39 6100 G/LP 330235 (9- -00)

  • Page 56: To Replace Large Steering Sprocket

    3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. This will loosen the steering chain. 2-- 40 6100 G/LP 330235 (9- -00)
  • Page 57 7. Remove the four hex screws holding the wheel support and large sprocket to the pivot bearing assembly. Drop the wheel support and large sprocket out of the machine. 2-- 41 6100 G/LP 330235 (9- -00)
  • Page 58 Reinstall the four screws and tighten to 64 -- 83 Nm (47 -- 61 ft lb). 11. Reconnect the short brake rod to the brake lever. 2-- 42 6100 G/LP 330235 (9- -00)
  • Page 59 37 -- 48 Nm (26 -- 34 ft lb). 16. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering for proper operation. 2-- 43 6100 G/LP 330235 (9- -00)

  • Page 60: To Replace Front Wheel Housing Needle Bearing/Thrust Washers

    3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. This will loosen the steering chain. 2-- 44 6100 G/LP 330235 (9- -00)
  • Page 61 7. Pull the brake pedal up and disconnect the clevis end of the short brake rod where it attaches to the brake pedal assembly. 2-- 45 6100 G/LP 330235 (9- -00)
  • Page 62 Remove the castle nut and flat washer. 10. Pull the cone bearing out of the swivel plate. 11. Pull the swivel plate off the swivel plate weldment. Make sure to retain the rubber seal ring. 2-- 46 6100 G/LP 330235 (9- -00)
  • Page 63 17. Reinstall the large flat washer and castle nut. Tighten to 37 -- 48 Nm (26 -- 34 ft. lb). Reinstall the small thread roller into the cross hole. Back off the castle nut if needed to align cross hole. 2-- 47 6100 G/LP 330235 (9- -00)
  • Page 64 21. Go back to the operators compartment. Push the steering housing forward in the slots. This will remove any slack in the steering chain. Tighten the two hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 2-- 48 6100 G/LP 330235 (9- -00)
  • Page 65 23. Reconnect the short brake rod to the brake pedal. 24. Reinstall the brake pedal and clevis pin. 25. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering for proper operation. 2-- 49 6100 G/LP 330235 (9- -00)

  • Page 66: To Replace Front Wheel Housing Cone Bearing

    3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. This will loosen the steering chain. 2-- 50 6100 G/LP 330235 (9- -00)
  • Page 67 7. Pull the brake pedal up and disconnect the clevis end of the short brake rod where it attaches to the brake pedal assembly. 2-- 51 6100 G/LP 330235 (9- -00)
  • Page 68 12. Reinstall the large flat washer and castle nut. Tighten to 37 -- 48 Nm (26 -- 34 ft. lb). Reinstall the small thread roller into the cross hole. Back off the castle nut if needed to align cross hole. 2-- 52 6100 G/LP 330235 (9- -00)
  • Page 69 16. Go back to the operators compartment. Push the steering housing forward in the slots. This will remove any slack in the steering chain. Tighten the two hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 2-- 53 6100 G/LP 330235 (9- -00)
  • Page 70 18. Reconnect the short brake rod to the brake pedal. 19. Reinstall the brake pedal and clevis pin. 20. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering for proper operation. 2-- 54 6100 G/LP 330235 (9- -00)

  • Page 71: Propel Assembly

    7--3/8 in. 4. Lengthen the rod to increase the forward 7- -3/8 inch speed, shorten the rod to decrease the forward speed. 2-- 55 6100 G/LP 330235 (9- -00)
  • Page 72 CHASSIS 2-- 56 6100 G/LP 330235 (9- -00)
  • Page 73 ....3--51 TO REPLACE SIDE BRUSH LIFT CABLE ......3--52 3-- 1 6100 G/LP 330235 (9- -00)
  • Page 74 SWEEPING 3-- 2 6100 G/LP 330235 (9- -00)

  • Page 75: Introduction

    6100G/LP. The side brush sweeps debris in front of the machine and the main brush sweeps the debris into the hopper. The vacuum fan pulls air from the hopper and through the dust filter. 3-- 3 6100 G/LP 330235 (9- -00)

  • Page 76: Debris Hopper

    The hopper is held in operating position with a retaining clip. NOTE: Check that the hopper retaining clip is securely in place each time before operating machine. 3-- 4 6100 G/LP 330235 (9- -00)

  • Page 77: To Remove Hopper

    2. Grasp the hopper retainer clip. Turn the retainer clip out of the way of the hopper lip. 3. Grasp the hopper handle. Pull up slightly then pull out on the hopper. 4. Remove the hopper from the machine. 3-- 5 6100 G/LP 330235 (9- -00)

  • Page 78: To Install Hopper

    1. Position the hopper into the back of the machine. 2. Push the hopper in until it is flush with the back of the machine frame. 3. Rotate the retainer clip down to lock the hopper in the machine. 3-- 6 6100 G/LP 330235 (9- -00)

  • Page 79: Hopper Dust Filter

    Air dry the wet dust filter; do not use compressed air to dry a wet filter. NOTE: Be sure the dust filter is completely dry before reinstalling it in the machine. 3-- 7 6100 G/LP 330235 (9- -00)

  • Page 80: To Replace Hopper Dust Filter

    Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Remove the debris hopper from the machine. 2. Un--latch the two filter pivot latches at the rear of the machine. 3. Let the hooper filter pivot down. 3-- 8 6100 G/LP 330235 (9- -00)
  • Page 81 7. Remove the filter shaker assembly from the filter. 8. Install the filter shaker assembly onto the new filter. Make sure the pin on the shaker assembly is inserted in the hole in the filter shaker comb. 3-- 9 6100 G/LP 330235 (9- -00)
  • Page 82 10. Reinstall the filter assembly into the filter tray. 11. Reconnect the wires to the filter shaker. 12. Pivot the filter tray up and re--latch the latches. 13. Reinstall the debris hopper and lock the retainer bracket. 3-- 10 6100 G/LP 330235 (9- -00)

  • Page 83: Main Brush

    FOR SAFETY: Before leaving or servicing machine, stop on level surface, set parking brake, turn off machine, and remove key. 2. Open the left side main brush access door. 3-- 11 6100 G/LP 330235 (9- -00)
  • Page 84 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. 3-- 12 6100 G/LP 330235 (9- -00)
  • Page 85 8. Slide the main brush idler arm plug onto the main brush. 9. Secure the idler arm on the bolts. Hand tighten the mounting knobs. 10. Close the main brush access door. 3-- 13 6100 G/LP 330235 (9- -00)

  • Page 86: Checking And Adjusting Main Brush Pattern

    NOTE: If chalk or other material is not available, allow the brushes to spin on the floor for two minutes. A polish mark will remain on the floor. 4. Raise the main brush. 5. Drive the machine off the test area. 3-- 14 6100 G/LP 330235 (9- -00)
  • Page 87 2. Allow the brush to operate and float into position for approximately 30 seconds. 3. Tighten the adjustment bolt and idler arm securing knob. 4. Check the main brush pattern and readjust as necessary. 3-- 15 6100 G/LP 330235 (9- -00)

  • Page 88: Main Brush Belts

    Surface, Set Parking Brake. 1. Remove the right hand machine panel. 2. Remove the four screws holding the right hand brush door to the machine frame. Remove the right hand side brush door. 3-- 16 6100 G/LP 330235 (9- -00)
  • Page 89 V--belt. 5. Remove the vacuum fan V--belt from the two groove jackshaft sheave. 6. Locate the main brush drive belt idler pulley between the jackshaft drive pulley and the larger brush pulley. 3-- 17 6100 G/LP 330235 (9- -00)
  • Page 90 11. Move the idler pulley forward in the slot until the belt is tight. Tighten the hex nut to 18 -- 24 Nm (15 -- 20 ft lb). 12. Install the vacuum fan V--belt over both pulleys. 3-- 18 6100 G/LP 330235 (9- -00)
  • Page 91 .95 lb) at belt midpoint. Tighten the screws hand tight. 14. Reinstall the right hand machine cover. 15. Reinstall the right hand side brush door. 16. Operate the machine and check the main brush for proper operation. 3-- 19 6100 G/LP 330235 (9- -00)

  • Page 92: To Replace Main Brush Jackshaft Belt

    1. Open the seat support and engage the prop rod. 2. Remove the main brush. See TO REPLACE MAIN BRUSH instructions in this section. 3. Locate the main brush jackshaft belt tension idler pulley mount plate beside the machine battery. 3-- 20 6100 G/LP 330235 (9- -00)
  • Page 93 6. Remove the V--belt from the engine sheave, idler sheaves, and main jack shaft sheave. Remove the V--belt from the machine. 7. Install the new V--belt onto the engine sheave, idler sheaves, and jack shaft sheave. 3-- 21 6100 G/LP 330235 (9- -00)
  • Page 94 9. Reinstall the main brush. See TO REPLACE MAIN BRUSH instructions in this section. 10. Disengage the seat rod and close the seat assembly. 11. Operate the machine and check the main brush for proper operation. 3-- 22 6100 G/LP 330235 (9- -00)

  • Page 95: To Replace Main Brush Jackshaft Inner Bearing

    4. Use the V--belt tension bolt to lower the idler pulley mount plate down. This will loosen the tension on the jack shaft center V--belt. 3-- 23 6100 G/LP 330235 (9- -00)
  • Page 96 Loosen the two set screws. Remove the sheave from the jackshaft. Retain the square key. 8. Loosen the set screws on the bearing lock collar. Use a hammer and punch to knock the collar loose from the bearing race. 3-- 24 6100 G/LP 330235 (9- -00)
  • Page 97 12. Install the new bearing onto the main brush jackshaft. Make sure the lock collar is installed on the shaft first. 13. Position the outer bearing flange onto the mount bracket. Reinstall the hardware. Leave loose for now. 3-- 25 6100 G/LP 330235 (9- -00)
  • Page 98 Hand tighten the two sheave set screws tight. 17. Position the V--belt over the jack shaft sheave, idler sheaves, and engine sheave. 3-- 26 6100 G/LP 330235 (9- -00)
  • Page 99 18 -- 24 Nm (15 -- 20 ft lb). 19. Reinstall the main brush. See TO REPLACE MAIN BRUSH instructions in this section. 20. Start the machine and operate the main brush. Check for proper operation. 3-- 27 6100 G/LP 330235 (9- -00)

  • Page 100: To Replace Main Brush Jackshaft Outer Bearing

    Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Remove the right hand machine panel. 3. Remove the right hand brush door. 3-- 28 6100 G/LP 330235 (9- -00)
  • Page 101 7. Remove the V--belt from the engine sheave, idler sheaves, and main brush jackshaft sheave. 8. Open the left hand brush door and remove the main brush. See TO REPLACE MAIN BRUSH instructions in this section. 3-- 29 6100 G/LP 330235 (9- -00)
  • Page 102 11. Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V--belt. 12. Remove the vacuum fan V--belt from the two groove jackshaft sheave. 3-- 30 6100 G/LP 330235 (9- -00)
  • Page 103 Remove the main brush V--belt from the jackshaft sheave. 16. Loosen the two set screws holding the 2--groove sheave to the outside end of the main brush jackshaft. Pull the sheave off the shaft. Retain the shaft key. 3-- 31 6100 G/LP 330235 (9- -00)
  • Page 104 Make sure the bearing locking collar is in place on the jackshaft. 22. Push the jackshaft through the new bearing until the end is showing out the right hand side of the brush wrap. 3-- 32 6100 G/LP 330235 (9- -00)
  • Page 105 25. Use a hammer and punch to tighten the bearing locking collars onto the bearing race of both jackshaft bearings. Hand tighten the collar set screw tight. 26. Position the V--belt over the jack shaft sheave, idler sheaves, and engine sheave. 3-- 33 6100 G/LP 330235 (9- -00)
  • Page 106 (small sheave to the inside) onto the outer end of the jackshaft. Hand tighten the two set screws tight. 30. Position the main brush drive belt onto the jackshaft and brush drive pulleys. 3-- 34 6100 G/LP 330235 (9- -00)
  • Page 107 The correct tension is when the belt deflects 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. Tighten the screws hand tight. 34. Reinstall the right hand machine cover. 3-- 35 6100 G/LP 330235 (9- -00)
  • Page 108 SWEEPING 35. Reinstall the right hand side brush door. 36. Operate the machine and check the main brush for proper operation. 3-- 36 6100 G/LP 330235 (9- -00)

  • Page 109: To Replace Main Brush Idler Plug Bearing

    2. Remove the main brush idler mount plate. See TO REPLACE MAIN BRUSH instructions in this sections. 3. Remove the hex screw, nut, and washer holding the idler plug assembly to the brush lift plate. 3-- 37 6100 G/LP 330235 (9- -00)
  • Page 110 7. Position the new ball bearing into the idler plug. 8. Reinstall the bearing retainer plate on the idler plug. Reinstall the four screws and tighten to 8 -- 10 Nm (6 -- 7 ft lb). 3-- 38 6100 G/LP 330235 (9- -00)
  • Page 111 10. Reinstall the main brush idler mount plate. See TO REPLACE MAIN BRUSH instructions in this sections. 11. Close the left hand side brush door. 12. Operate the machine and check the main brush for proper operation. 3-- 39 6100 G/LP 330235 (9- -00)

  • Page 112: To Replace Main Brush Drive Plug Bearings

    2. Open the left hand side brush door. 3. Remove the main brush idler mount plate and main brush. See TO REPLACE MAIN BRUSH instructions in this sections. 4. Remove the right hand brush door. 3-- 40 6100 G/LP 330235 (9- -00)
  • Page 113 8. Hold the main brush drive plug from turning. Remove the large nut from the center of the drive plug. NOTE: THIS IS A LEFT HAND THREAD NUT. 9. Remove the main brush idler plug assembly from the main brush shaft 3-- 41 6100 G/LP 330235 (9- -00)
  • Page 114 18. Reinstall the main brush drive plug onto the main brush shaft on the inside. Reinstall the left hand nut. Hand tighten tight. Make sure the large washer is in place behind the brush plug. 3-- 42 6100 G/LP 330235 (9- -00)
  • Page 115 REPLACE MAIN BRUSH DRIVE BELT instructions in this section. 21. Reinstall the main brush. See TO REPLACE MAIN BRUSH instructions in this sections. 22. Reinstall the right hand brush door and close the left hand brush door. 3-- 43 6100 G/LP 330235 (9- -00)
  • Page 116 SWEEPING 23. Remove the jack stands and lower the machine. 24. Operate the machine and check the main brush for proper operation. 3-- 44 6100 G/LP 330235 (9- -00)

  • Page 117: To Replace Main Brush Drive Belt Idler Pulley

    Remove the right hand side brush door. 2. Locate the main brush drive belt idler pulley between the small jackshaft pulley and the larger brush pulley. 3. Loosen the hex nut in the center of the idler pulley. 3-- 45 6100 G/LP 330235 (9- -00)
  • Page 118 6. Remove the hex nut in the center of the idler pulley. Remove and discard the pulley. 7. Install the new idler pulley onto the hex bolt. Reinstall the hex nut. Leave loose for now. 3-- 46 6100 G/LP 330235 (9- -00)
  • Page 119 Tighten the pulley nut to 18 -- 24 Nm (15 -- 20 ft lb). 10. Reinstall the right hand side brush door. 11. Operate the machine and check the main brush for proper operation. 3-- 47 6100 G/LP 330235 (9- -00)

  • Page 120: Side Brush

    50 mm (2 in) in length. You may need to replace the side brush sooner if you are sweeping light litter or use a brush with shorter bristles if you are sweeping heavy debris. 3-- 48 6100 G/LP 330235 (9- -00)

  • Page 121: To Replace Side Brush

    3. Slide the side brush off the side brush drive shaft. 4. Slide the new side brush onto the side brush drive shaft. 3-- 49 6100 G/LP 330235 (9- -00)
  • Page 122 8. Move the pulley mount bracket up or down to achieve the proper side brush pattern. Retighten the hex screw. 3-- 50 6100 G/LP 330235 (9- -00)

  • Page 123: Side Brush Guard

    SIDE BRUSH PIVOT The side brush pivot should be checked for excessive movement after every 200 hours of operation. Torque the front and rear compression springs to reduce excessive movement. 3-- 51 6100 G/LP 330235 (9- -00)

  • Page 124: To Replace Side Brush Lift Cable

    3. Go to the operators compartment. Remove the three cable pulleys, sleeves, and cable clips from the side brush lift assembly. Note the orientation of the cable clips for proper re--assembly. 3-- 52 6100 G/LP 330235 (9- -00)
  • Page 125 18 -- 24 Nm (15 -- 20 ft lb). 7. Connect the new side brush lift cable to the side brush pivot screw. Hand tighten the hex nut. Cable should pivot on the hardware. 8. Raise the side brush. 3-- 53 6100 G/LP 330235 (9- -00)

  • Page 126: Skirts And Seals

    Check the skirts for wear or damage and adjustment daily. Note: The recirculation skirt must be folded in between the brush and the machine frame before the brush door is mounted on for the machine to work properly. 3-- 54 6100 G/LP 330235 (9- -00)

  • Page 127: Side Skirts

    5 mm. TO ADJUST SIDE SKIRTS FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the LH brush door . 2. Remove the RH brush door. 3-- 55 6100 G/LP 330235 (9- -00)
  • Page 128 4. Place a flat washer under the bottom edge of the skirts. Make sure the skirt is touching the washer. Tighten the hardware to 560Ncm. 5. Close the LH brush door. 6. Reinstall the RH brush door. 3-- 56 6100 G/LP 330235 (9- -00)

  • Page 129: Large Debris Trap Skirt

    The lower lip of the hopper rests on this seal when the hopper is setting in proper sweeping position. Check the seal for wear or damage after every 100 hours of operation. 3-- 57 6100 G/LP 330235 (9- -00)

  • Page 130: To Adjust Recirculating Skirt Cam

    Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Pull the brush lift handle forward. 2. Lift the recirculation cam until it hits the frame. 3. Slowly lower the brush lift handle to the down position. 3-- 58 6100 G/LP 330235 (9- -00)
  • Page 131 4. If the cam follows the lever, do NOT adjust. 5. If the lever does not lower, Loosen the hardware and move the lever. NOTE: The lever must not move to the front of the cam. 3-- 59 6100 G/LP 330235 (9- -00)

  • Page 132: Vacuum Fan

    200 hours of operation. The correct tension is when the belt deflects 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. WARNING: Moving belt and fan. Keep away. 3-- 60 6100 G/LP 330235 (9- -00)

  • Page 133: To Replace Vacuum Fan Drive Belt

    2. Remove the four screws holding the right hand brush door to the machine frame. Remove the right hand side brush door. 3. Loosen the four hex screws holding the vacuum fan housing to the machine frame. 3-- 61 6100 G/LP 330235 (9- -00)
  • Page 134 V--belt pulley. Remove the cover. 6. Remove the vacuum fan V--belt from both pulleys. Remove the old V--belt from the machine. 7. Install the new vacuum fan V--belt over both pulleys. 3-- 62 6100 G/LP 330235 (9- -00)
  • Page 135 9. Reinstall the V--belt cover. Tighten the two screws hand tight. 10. Reinstall the right hand side brush door. 11. Reinstall the right hand machine cover. 12. Operate the machine. Check the vacuum fan for proper operation. 3-- 63 6100 G/LP 330235 (9- -00)

  • Page 136: To Tension Vacuum Fan Drive Belt

    V--belt. The correct tension is when the belt deflects 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. 3-- 64 6100 G/LP 330235 (9- -00)
  • Page 137 SWEEPING 4. Tighten the four mounts screws hand tight. 5. Reinstall the right hand machine cover. 6. Operate the machine. Check the vacuum fan for proper operation. 3-- 65 6100 G/LP 330235 (9- -00)

  • Page 138: To Replace Vacuum Fan Impeller

    2. Loosen the four hex screws holding the vacuum fan housing to the machine frame. 3. Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V--belt. 3-- 66 6100 G/LP 330235 (9- -00)
  • Page 139 Remove the assembly from the machine. Make sure to retain the two steel sleeves from the bottom two hex screws. 7. Place the assembly on a work bench with the vacuum fan inlet plate facing up. 3-- 67 6100 G/LP 330235 (9- -00)
  • Page 140 Make sure to reinstall the square key on the fan shaft. 11. Reinstall the nyloc nut onto the fan shaft. Tighten to 11 -- 14 Nm (7 -- 10 ft lb). 3-- 68 6100 G/LP 330235 (9- -00)
  • Page 141 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. 16. Tighten the four mounts screws hand tight. 3-- 69 6100 G/LP 330235 (9- -00)
  • Page 142 SWEEPING 17. Reinstall the V--belt cover. Tighten the two screws hand tight. 18. Reinstall the right hand machine cover. 19. Operate the machine. Check the vacuum fan for proper operation. 3-- 70 6100 G/LP 330235 (9- -00)

  • Page 143: To Replace Vacuum Fan Impeller Bearings

    2. Loosen the four hex screws holding the vacuum fan housing to the machine frame. 3. Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V--belt. 3-- 71 6100 G/LP 330235 (9- -00)
  • Page 144 Remove the assembly from the machine. Make sure to retain the two steel sleeves from the bottom two hex screws. 7. Place the assembly on a work bench with the vacuum fan inlet plate facing up. 3-- 72 6100 G/LP 330235 (9- -00)
  • Page 145 10. Loosen the two set screws holding the V--belt pulley to the fan shaft. Remove the pulley. 11. Remove the four hex screws holding the vacuum fan bearing assembly to the bearing plate. Remove the bearing assembly. 3-- 73 6100 G/LP 330235 (9- -00)
  • Page 146 The long end of the shaft is on the side with the sound foam. Reinstall the four hex screws and washers. Tighten to 8 -- 10 Nm (6 -- 8 ft lb). 3-- 74 6100 G/LP 330235 (9- -00)
  • Page 147 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). 3-- 75 6100 G/LP 330235 (9- -00)
  • Page 148 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. 22. Tighten the four mounts screws hand tight. 23. Reinstall the V--belt cover. Tighten the two screws hand tight. 3-- 76 6100 G/LP 330235 (9- -00)
  • Page 149 SWEEPING 24. Reinstall the right hand machine cover. 25. Operate the machine. Check the vacuum fan for proper operation. 3-- 77 6100 G/LP 330235 (9- -00)

  • Page 150: Machine Troubleshooting

    Operator not in seat Sit in operator seat Machine will not start Engine oil level low Check and fill Fuel tank valve closed Open valve -- LPG tank valve or valve below gasoline tank 3-- 78 6100 G/LP 330235 (9- -00)
  • Page 151 WITH ENGINE RUNNING ..4--35 SHAKE SYSTEM NOT OPERATING 4--36 SIDE BRUSH IS NOT OPERATING 4--37 ENGINE WILL NOT START ..4--38 4-- 1 6100 G/LP 330235 (9- -01)
  • Page 152 ELECTRICAL 4-- 2 6100 G/LP 330235 (9- -00)

  • Page 153: Introduction

    ELECTRICAL INTRODUCTION The model 6100G/LP electrical system consists of the battery, instrument panel, side brush motor, switches, relays, and circuit breakers. 4-- 3 6100 G/LP 330235 (9- -00)

  • Page 154: Battery

    Surface, Set Parking Brake, turn off machine, and remove key. 1. Open the seat support and engage the prop rod. 2. Locate the battery at the center of the machine, in front of the hydraulic tank. 4-- 4 6100 G/LP 330235 (9- -00)
  • Page 155 6. Remove the charger after the voltage meter reads a full charge. 7. Reinstall the negative battery cable and start the machine. Check the battery for proper operation. 8. Disengage the prop rod and lower the seat support. 4-- 5 6100 G/LP 330235 (9- -00)

  • Page 156: To Replace Battery

    1. Open the seat support and engage the prop rod. 2. Locate the battery at the center of the machine, in front of the hydraulic tank. 3. Remove the battery hold down bracket. 4-- 6 6100 G/LP 330235 (9- -00)
  • Page 157 6. Install the new battery in the machine in the same orientation as the old one. 7. Reconnect the battery cables to the battery (red cable to positive post, black cable to negative post) 8. Reinstall the hold down bracket. 4-- 7 6100 G/LP 330235 (9- -00)
  • Page 158 ELECTRICAL 9. Disengage the prop rod and lower the seat support. 10. Check the new battery for proper operation. If battery needs charging, see TO CHARGE BATTERY instructions in this section. 4-- 8 6100 G/LP 330235 (9- -00)

  • Page 159: Instrument Panel

    TO ACCESS INSTRUMENT PANEL FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine battery. 4-- 9 6100 G/LP 330235 (9- -00)
  • Page 160 5. Remove the four hex screws and two pan screws holding the instrument panel to the front shroud. 6. Pull the instrument panel back away from the front shroud for better access to the circuit breakers. 4-- 10 6100 G/LP 330235 (9- -00)
  • Page 161 Reinstall the hardware and hand tighten tight. 8. Remove the tie holding the side brush in the up position. 9. Open the seat support and engage the prop rod. 10. Reconnect the battery. 4-- 11 6100 G/LP 330235 (9- -00)
  • Page 162 ELECTRICAL 11. Disengage the prop rod and lower the seat support. 12. Start the machine and check for proper operation. 4-- 12 6100 G/LP 330235 (9- -00)

  • Page 163: To Replace Instrument Panel Circuit Breaker

    Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine battery. 3. Disengage the prop rod and lower the seat support. 4-- 13 6100 G/LP 330235 (9- -00)
  • Page 164 6. Pull the instrument panel back away from the front shroud for better access to the circuit breakers. 7. Locate the circuit breaker that needs to be changed. 4-- 14 6100 G/LP 330235 (9- -00)
  • Page 165 12. Install the metal retainer ring onto the back of the new circuit breaker. Push the retainer all the way down the circuit breaker. 13. Install the rubber boot onto the out side of the new circuit breaker. 4-- 15 6100 G/LP 330235 (9- -00)
  • Page 166 15. Position the instrument panel back onto the front shroud. Reinstall the hardware and hand tighten tight. 16. Remove the tie holding the side brush in the up position. 17. Open the seat support and engage the prop rod. 4-- 16 6100 G/LP 330235 (9- -00)
  • Page 167 ELECTRICAL 18. Reconnect the battery. 19. Disengage the prop rod and lower the seat support. 20. Start the machine and check for proper operation. 4-- 17 6100 G/LP 330235 (9- -00)

  • Page 168: To Replace Side Brush Motor

    1. Jack up the front of the machine at the jack point. Install jack stands under the machine frame. 2. Lower the side brush. 3. Remove the side brush from the motor assembly. See TO REPLACE SIDE BRUSH instructions in the SWEEPING section. 4-- 18 6100 G/LP 330235 (9- -00)
  • Page 169 6. Drop the motor out of the mount bracket and past the brush guard. 7. Position the new side brush motor onto the motor mount bracket. The motor is positioned to the rear of the machine. 4-- 19 6100 G/LP 330235 (9- -00)
  • Page 170 10. Wire tie the motor wires to the motor housing. 11. Reinstall the side brush. See TO REPLACE SIDE BRUSH instructions in the SWEEPING section. 12. Operate the machine. Check the side brush for proper operation. 4-- 20 6100 G/LP 330235 (9- -00)

  • Page 171: To Replace Engine Starter

    Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Tilt the seat assembly forward and engage the prop rod. 2. Disconnect the battery cables from the battery. 3. Disconnect the wires from the starter motor. 4-- 21 6100 G/LP 330235 (9- -00)
  • Page 172 7. Reconnect the battery cables to the battery and check the starter for proper operation. 8. Disengage the seat prop rod and pivot the seat assembly down. Check the new starter for proper operation. 4-- 22 6100 G/LP 330235 (9- -00)

  • Page 173: Thermo Sentryt

    If the Thermo Sentryt will senses a fire in the filter area, the vacuum shut--off solenoid will close, shutting down the airflow. Access the Thermo Sentryt by dropping the dust filter down. 4-- 23 6100 G/LP 330235 (9- -00)

  • Page 174: Vacuum Fan Shutoff Solenoid

    If the Thermo Sentry will senses a fire in the filter area, the vacuum shut--off solenoid will close, shutting down the airflow. Access the shutoff solenoid by dropping the dust filter down. 4-- 24 6100 G/LP 330235 (9- -00)
  • Page 175 ELECTRICAL 4-- 25 6100 G/LP 330235 (9- -01)

  • Page 176: Electrical Schematic Gas

    ELECTRICAL ELECTRICAL SCHEMATIC GAS 4-- 26 6100 G/LP 330235 (9- -01)
  • Page 177 ELECTRICAL ELECTRICAL SCHEMATIC GAS 4-- 27 6100 G/LP 330235 (9- -01)

  • Page 178: Electrical Schematic Lp

    ELECTRICAL ELECTRICAL SCHEMATIC LP 4-- 28 6100 G/LP 330235 (9- -01)
  • Page 179 ELECTRICAL ELECTRICAL SCHEMATIC LP 4-- 29 6100 G/LP 330235 (9- -01)

  • Page 180: Wire Diagram Gas/Lp

    ELECTRICAL WIRE DIAGRAM GAS/LP 4-- 30 6100 G/LP 330235 (9- -01)
  • Page 181 ELECTRICAL WIRE DIAGRAM GAS/LP 4-- 31 6100 G/LP 330235 (9- -01)
  • Page 182 ELECTRICAL 4-- 32 6100 G/LP 330235 (9- -01)

  • Page 183: Troubleshooting

    ELECTRICAL 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. 4-- 33 6100 G/LP 330235 (9- -00)

  • Page 184: Battery Not Charging (Alternator Light Is On)

    REPLACE VOLTAGE REGULATOR, IT SYSTEM IS NOW WORKING. REPLACE D1 AND D2 MAY BE PULLING AC STATOR OUTPUT SO HOUR METER OPERATES PROPERLY. VOLTAGE DOWN. STILL LESS THAN 18VAC REPLACE AC STATOR ON ENGINE 4-- 34 6100 G/LP 330235 (9- -00)

  • Page 185: Hour Meter Is Not Operating With Engine Running

    CHECK CONTINUITY OF WIRES 2/BRN AND 11/ORA FROM DIODE CONNECTIONS TO STATOR OUT- PUT. IF THEY ARE GOOD, GO TO ALTERNATOR TESTING FLOW CHART. IF THEY ARE OPEN, RE- PAIR THEM AND RETEST. 4-- 35 6100 G/LP 330235 (9- -00)

  • Page 186: Shake System Not Operating

    THE SOLENOID ASSEMBLY IS PHYSI- CALLY JAMMED OR THE SOLENOID IS DEFECTIVE. NOTE: IF THE SHAKER SYSTEM WORKS FOR A SHORT DURATION, THEN STOPS OR SLOWS, THE SHAKER COIL IS DRAWING EXCESSIVE CURRENT. REPLACE THE SHAKER COIL. 4-- 36 6100 G/LP 330235 (9- -00)

  • Page 187: Side Brush Is Not Operating

    11A/PUR AND 13B/BLK AT THE CON- NECTOR. B+ VOLTAGE 0 VOLTS WIRE 11A/PUR 13B/BLK, OR SIDE BRUSH MOTOR CON- SIDE BRUSH MOTOR OR NECTOR ON MACHINE HAR- OR CONNECTOR IS BAD. NESS IS OPEN. 4-- 37 6100 G/LP 330235 (9- -00)

  • Page 188: Engine Will Not Start

    FROM SENSOR ARE IS OPEN WHEN HELD IN SHORTED TO GROUND. START POSITION 9/ORA IS TIED TO GROUND THROUGH KEYSWITCH IF TURNED OFF. REPLACE STARTER MOTOR SOLENOID REPLACE STARTER MOTOR. CONTINUED ON NEXT PAGE 4-- 38 6100 G/LP 330235 (9- -00)
  • Page 189 17/BLU AND 18/GRN DISCONNECTED FROM CIRCUIT. TEST DIODES INSIDE D- -3 WITH MULTIMETER DIODE TESTER. TESTS GOOD TESTS BAD REPLACE ANY OPEN REPLACE THE WIRES 17/BLU OR START MODULE 18/GRN OR BAD D- -3 DIODE ASSEMBLIES. 4-- 39 6100 G/LP 330235 (9- -00)
  • Page 190 ELECTRICAL 4-- 40 6100 G/LP 330235 (9- -00)
  • Page 191 ....5--22 TROUBLESHOOTING ....5--29 5-- 1 6100 G/LP 330235 (9- -00)
  • Page 192 HYDRAULICS 5-- 2 6100 G/LP 330235 (9- -00)

  • Page 193: Introduction

    HYDRAULICS INTRODUCTION The hydraulic system on the model 6100G/LP consists of the hydraulic pump, directional control valve, and drive motor. 5-- 3 6100 G/LP 330235 (9- -00)

  • Page 194: Hydraulic Fluid Reservoir

    The hydraulic fluid filter is located in front of the hydraulic reservoir near the rear of the engine compartment. Replace the filter element every 800 hours of operation. 5-- 4 6100 G/LP 330235 (9- -00)

  • Page 195: Hydraulic Fluid

    The quality and condition of the hydraulic fluid plays a very important role in how well the machine operates. TENNANT’s hydraulic fluid is specially selected to meet the needs of TENNANT machines. TENNANT’s hydraulic fluid provides a longer life for the hydraulic components.

  • Page 196: Hydraulic Fluid Filter

    Servicing Machine; Stop On Level Surface, Set Parking Brake, turn off machine, and remove key. 1. Open the seat support and engage the prop rod. 2. Locate the hydraulic fluid filter in front of the hydraulic tank. 5-- 6 6100 G/LP 330235 (9- -00)
  • Page 197 6. Screw the new filter onto the filter head. Tighten until snug then 1/4 turn. 7. Remove the drain pan or rag. 8. Start the machine and check the new hydraulic fluid filter for any leaks. 5-- 7 6100 G/LP 330235 (9- -00)
  • Page 198 HYDRAULICS 9. Disengage the prop rod and close the seat support. 5-- 8 6100 G/LP 330235 (9- -00)

  • Page 199: Hydraulic Pump

    1. Tilt the seat assembly forward and engage the prop rod. Disconnect the battery cables from the battery. 2. Mark, disconnect, and plug the two hoses leading to the hydraulic pump. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-- 9 6100 G/LP 330235 (9- -00)
  • Page 200 6. Install the V--belt sheave onto the shaft of the new hydraulic pump in the same orientation that it was removed. Leave the set screws loose for now. 5-- 10 6100 G/LP 330235 (9- -00)
  • Page 201 10. Pull the hydraulic pump back to tension the V--belt. Tighten the pump mounting hardware. 11. Use a straight edge to align the hydraulic pump sheave with the sheave on the engine. Tighten the two set screws. 5-- 11 6100 G/LP 330235 (9- -00)
  • Page 202 13. Reconnect the battery cables. 14. Start the machine and check the new pump for proper operation and for leaks. 15. Disengage the prop rod and lower the seat support. 5-- 12 6100 G/LP 330235 (9- -00)

  • Page 203: To Replace Hydraulic Pump V--Belt

    2. Locate the main brush jackshaft belt tension idler pulley mount plate beside the machine battery. 3. Loosen the nuts holding the idler mount plate to the main engine pulley plate. 5-- 13 6100 G/LP 330235 (9- -00)
  • Page 204 V--belt is tight. Tighten the two nuts to 18 -- 24 Nm (15 -- 20 ft lb). 9. Operate the machine and check the hydraulic pump for proper operation. 5-- 14 6100 G/LP 330235 (9- -00)
  • Page 205 HYDRAULICS 10. Disengage the seat rod and close the seat assembly. 5-- 15 6100 G/LP 330235 (9- -00)

  • Page 206: Hydraulic Drive Motor

    Machine And Remove Key. 1. Tilt the seat assembly forward and engage the prop rod. Disconnect the battery cables from the battery. 2. Raise the front of the machine and install jackstands under the machine frame. 5-- 16 6100 G/LP 330235 (9- -00)
  • Page 207 6. Turn the front tire until the master link is visible at the bottom of the drive sprocket. Remove the master link from the drive chain. Make sure to retain the four small O- -rings from behind the master link clip. 5-- 17 6100 G/LP 330235 (9- -00)
  • Page 208 Note the orientation of the motor to the mount plate. 10. Remove the three hydraulic fittings from the old motor and install into the new hydraulic motor in the same orientation. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-- 18 6100 G/LP 330235 (9- -00)
  • Page 209 14. Spread the drive chain and install around the large sprocket on the front wheel assembly. Reinstall the master link. Make sure the four small O- -rings are in place behind the master link clip. 5-- 19 6100 G/LP 330235 (9- -00)
  • Page 210 17. Connect the hydraulic hoses to the new drive motor. See schematic in this section. NOTE: Observe hydraulic cleanliness requirements when reconnecting hydraulic lines. 18. Remove the jack stands and lower the machine to the floor. 5-- 20 6100 G/LP 330235 (9- -00)
  • Page 211 HYDRAULICS 19. Reconnect the battery cables. 20. Start the machine and check the new drive motor for proper operation and for leaks. 21. Disengage the prop rod and lower the seat support. 5-- 21 6100 G/LP 330235 (9- -00)

  • Page 212: Directional Control Valve

    Machine And Remove Key. 1. Tilt the seat assembly forward and engage the prop rod. Disconnect the battery cables from the battery. 2. Raise the front of the machine and install jackstands under the machine frame. 5-- 22 6100 G/LP 330235 (9- -00)
  • Page 213 6. Remove the two screws holding the control valve and mount plate assembly to the bottom of the machine frame. Remove the assembly from the machine. 5-- 23 6100 G/LP 330235 (9- -00)
  • Page 214 10. Position the new valve onto the mount plate and reinstall the hardware. Tighten to 11 -- 14 Nm (7 -- 10 ft lb). NOTE: Position hex nuts on the valve side. 5-- 24 6100 G/LP 330235 (9- -00)
  • Page 215 The distance between the center line of the two ball joints should be 7--3/8 in. See TO ADJUST DIRECTIONAL PEDAL LINKAGE instructions in the CHASSIS section. 7- -3/8 inch 5-- 25 6100 G/LP 330235 (9- -00)
  • Page 216 16. Reconnect the battery cables. 17. Start the machine and check the new directional valve for proper operation and for leaks. 18. Disengage the prop rod and lower the seat support. 5-- 26 6100 G/LP 330235 (9- -00)
  • Page 217 HYDRAULICS HYDRAULIC SCHEMATIC 5-- 27 6100 G/LP 330235 (9- -00)
  • Page 218 HYDRAULICS HYDRAULIC HOSE DIAGRAM 5-- 28 6100 G/LP 330235 (9- -00)

  • Page 219: Troubleshooting

    PROPEL MOTOR WILL NOT PROPEL CIRCUIT FLOW REPAIR OR REPLACE PROPEL PUMP REPAIR / REPLACE RELIEF PRESSURE RELIEF VALVE OR CONTROL VALVE MOTOR INLET REPAIR / REPLACE FLOW OK? PROPEL MOTOR REPAIR / REPLACE PLUMBING OK? PLUMBING 5-- 29 6100 G/LP 330235 (9- -00)
  • Page 220 HYDRAULICS 5-- 30 6100 G/LP 330235 (9- -00)
  • Page 251 ....6--15 TO INSTALL ENGINE ....6--19 6-- 1 6100 G/LP 330235 (9- -01)
  • Page 252 ENGINE- -GAS/LP 6-- 2 6100 G/LP 330235 (9- -00)

  • Page 253: Introduction

    This section includes repair information on the engine and related systems, such as fuel, electrical, and drive belts. Also, engine removal and installation. This section includes information on the gas and LP engines. 6-- 3 6100 G/LP 330235 (9- -00)

  • Page 254: Lubrication

    100 hours of machine operation. Use 10W30 SAE--CD/SE rated engine oil. ENGINE OIL DRAIN The engine oil drain hose is located at the front of the engine. Access the drain hose by opening the left hand brush door. 6-- 4 6100 G/LP 330235 (9- -00)

  • Page 255: Cooling System

    GOVERNOR The governor on the model 6100G/LP is an internal mechanical style using a centrifugal flyweight system. It requires no regular maintenance or adjustment. 6-- 5 6100 G/LP 330235 (9- -00)

  • Page 256: Air Intake System

    After cleaning the air filter element, inspect it for damage by placing a bright light inside. The slightest rupture requires replacement of the element. Inspect the seals on the ends of the element, they should be flexible and undamaged. 6-- 6 6100 G/LP 330235 (9- -00)

  • Page 257: Fuel System -- Gasoline

    The engine on the model 6100G/LP does not have an in--line fuel filter. This engine is equipped with a sediment bolt at the fuel tank shut--off valve. Clean the sediment bowl every 100 to 200 hours. 6-- 7 6100 G/LP 330235 (9- -00)

  • Page 258: To Clean Fuel Tank Sediment Bowl

    4. Remove the sediment bowl from the bottom of the fuel tank shut--off valve. 5. Clean any dirt or residue out of the sediment bowl. 6-- 8 6100 G/LP 330235 (9- -00)

  • Page 259: Gas Carburetor

    The gas carburetor is a horizontal draft, float type. Use an automobile grade of gasoline for best performance. This carburetor should not need to be adjusted. Remove, disassemble, and clean the carburetor every 500 to 600 hours. 6-- 9 6100 G/LP 330235 (9- -00)

  • Page 260: Fuel System -- Lpg

    LP fuel vaporizer. The carburetor is similar to the one used on the gas machine except for a few internal modifications. LP FUEL TANK The standard LP tank is a 20lb Vapor withdrawal type. 6-- 10 6100 G/LP 330235 (9- -00)

  • Page 261: To Change Lpg Fuel Tank

    2. Run the engine until all of the LP gas has been used up in the fuel lines. 3. Disconnect the coupler at the tank outlet. 4. Lift up on the lock clamp on the tank strap. 6-- 11 6100 G/LP 330235 (9- -00)
  • Page 262 7. Position the tank strap over the tank and snap the lock clamp. 8. Re--connect the LP coupler on the tank valve. Turn on the valve. 9. Start the engine and check the coupler for leaks. 6-- 12 6100 G/LP 330235 (9- -00)

  • Page 263: Engine Choke Knob

    The outlet port on the regulator is connected by hose to the LP carburetor. The LP regulator senses engine vacuum and controls the amount of LP fuel that flows to the carburetor. The LP regulator is non--adjustable. 6-- 13 6100 G/LP 330235 (9- -00)

  • Page 264: Ignition System

    6. Reconnect the spark plug wire. 7. Disengage the prop rod and close the seat support. 8. Clean or replace the spark plug every 200 hours: GAS: Replace with NGK B--4ES LPG: Replace with NGK B--6VX 6-- 14 6100 G/LP 330235 (9- -00)

  • Page 265: To Remove Engine

    Servicing Machine; Stop On Level Surface, Set parking brake. 1. Pivot the seat support open and engage the prop rod. 2. LP MACHINE: Remove the LP tank and mounting brackets. 3. Remove the left hand side panel. 6-- 15 6100 G/LP 330235 (9- -00)
  • Page 266 5. Disconnect the battery cables. 6. Remove the air duct baffle assembly from the left side of the engine. 7. LP MACHINE: Disconnect the LP fuel line and vacuum line at the engine carb. 6-- 16 6100 G/LP 330235 (9- -00)
  • Page 267 9. Shut the fuel valve off at the gas tank. 10. Disconnect the fuel line at the carb. 11. Mark, disconnect, and plug the two hoses leading to the hydraulic pump. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 6-- 17 6100 G/LP 330235 (9- -00)
  • Page 268 15. Disconnect two alternator wires, two low oil pressure switch wires, one solenoid wire, one ground cable, and a positive battery cable from the back of the engine. 16. The engine can now be removed from the machine. 6-- 18 6100 G/LP 330235 (9- -00)

  • Page 269: To Install Engine

    See schematic in the ELECTRICAL section. 3. Line up the four mount holes on the engine block with the mount holes in the machine frame. 6-- 19 6100 G/LP 330235 (9- -00)
  • Page 270 5. Install the exhaust pipe onto the muffler at the engine. 6. LP MACHINE: Reconnect the vacuum line and LP fuel line to the carb. 7. Reconnect the choke cable at the carburetor. 6-- 20 6100 G/LP 330235 (9- -00)
  • Page 271 10. Reinstall the jackshaft V--belt onto the sheave on the engine and the two idler sheaves. Pull the idler tight and tighten the hardware. 11. Reinstall the air duct baffle assembly onto the left side of the engine. 6-- 21 6100 G/LP 330235 (9- -00)
  • Page 272 15. Check the engine for oil. If needed, fill the engine with oil. The capacity of this engine is 0.65 liters (0.17 U. S. gallon). Use an automobile grade SAE #20, #30, or 10W--30. 6-- 22 6100 G/LP 330235 (9- -00)
  • Page 273 16. Disengage the prop rod and close the seat support. 17. LP MACHINE: Install the LP tank mounting brackets and LP tank. Reconnect the LP hose to the tank. Open the valve. 18. Start the engine and check for proper operation. 6-- 23 6100 G/LP 330235 (9- -00)
  • Page 274 ENGINE- -GAS/LP 6-- 24 6100 G/LP 330235 (9- -00)
  • Page 275 We Need Your Help... As part of Tennant’s Zero Defects Program, we want to know about errors you have found or suggestions you may have regarding our machine manuals. If you find an error or have a suggestion, please complete this postage-paid form and mail it to us.
  • Page 277 We Need Your Help... As part of Tennant’s Zero Defects Program, we want to know about errors you have found or suggestions you may have regarding our machine manuals. If you find an error or have a suggestion, please complete this postage-paid form and mail it to us.

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