Tennant 6550 Service Manual
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Tennant 6550 Service Manual

Tennant 6550 Service Manual

Gas/lp/diesel
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See also: Operator's Manual
6500/6550
Gas/LP/Diesel
Service Manual
330275
Rev. 02 (5- -02)
*330275*
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Summary of Contents for Tennant 6550

  • Page 1 6500/6550 Gas/LP/Diesel Service Manual 330275 Rev. 02 (5- -02) *330275* Home Find... Go To..
  • Page 2 This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT Model 6500/6550. The set is organized into seven major groups: General Information, Chassis, Sweeping, Electrical, Hydraulics, Engine--G/LPG, and Engine--D. General Information: Machine transport, machine jacking, machine storage, machine specifications, and machine maintenance chart.

  • Page 3: Table Of Contents

    ... . 1-21 THREAD SEALANT AND LOCKING COMPOUNDS ....1-21 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 4: Safety Precautions

    - - If it is not in proper operating condition. - - In flammable or explosive areas unless designed for use in those areas. - - In areas with possible falling objects unless equipped with overhead guard. 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 5 Keep area well ventilated. - - Use cardboard to locate leaking hydraulic fluid under pressure. - - Use TENNANT supplied or approved replacement parts. 7. When loading/unloading machine onto/off truck or trailer: - - Turn off machine.
  • Page 6 COMPARTMENT. 07748 HOPPER SUPPORT BAR LABEL - - LOCATED HOPPER LIFT ARMS LABEL - - LOCATED ON THE HOPPER SUPPORT BAR AND ON ON BOTH HOPPER LIFT ARMS. BOTH HOPPER LIFT ARMS. 6500/6550 330275 (6- -01) Home Find... Go To..
  • Page 7 OPERATOR COMPARTMENT. 07522 HOPPER SUPPORT BAR LABEL - - HOPPER LIFT ARMS LABEL - - LOCATED ON THE HOPPER SUPPORT LOCATED ON BOTH HOPPER BAR AND ON BOTH HOPPER LIFT LIFT ARMS. ARMS. 6500/6550 330275 (6- -01) Home Find... Go To..

  • Page 8: Specifications

    Minimum aisle turn width, left 2870 mm (113 in) Minimum aisle turn width, right 4725 mm (186 in) Maximum rated climb and descent angle (6500) Maximum rated climb and descent angle (6550) 6500/6550 330275 (3- -99) Home Find... Go To..

  • Page 9: Power Type

    950 + 50 rpm 2000 + 50 rpm 2400 + 50 rpm Engine lubricating oil without filter 6 L (6.35 qt) diesel rated engine oil above CD grade only 6500/6550 330275 (5- -01) Home Find... Go To..

  • Page 10: Steering

    HYDRAULIC SYSTEM System Capacity Fluid Type Hydraulic reservoir 24.6 L (6.5 gal) TENNANT part no. 65869 -- above 7_ C (45_ F) Hydraulic total N/A L (N/A gal) TENNANT part no. 65870 -- below 7_ C (45_ F) BRAKING SYSTEM Type...

  • Page 11: Machine Dimensions

    2360 mm (93 in) 1590 mm (62.5 in) TOP VIEW 2080 mm (82 in) 1475 mm (58 in) 1135 mm (44.75 in) 1560 mm (61.5 in) SIDE VIEW FRONT VIEW 350662 MACHINE DIMENSIONS 6500/6550 330275 (5- -98) Home Find... Go To..

  • Page 12: Maintenance

    Check for damage and wear Main brush Check for damage, wear, and adjustment Check brush pattern Side brush Check for damage, wear, and adjustment Check brush pattern 50 Hours Main brush Rotate end-for-end 1-10 6500/6550 330275 (5- -98) Home Find... Go To..
  • Page 13 Tennant Company or approved hydraulic fluid . . . Water and permanent-type ethylene glycol anti-freeze, --34_ C (--30_ F) . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) NOTE: Also check procedures indicted (*) after the first 50-hours of operation. 1-11...

  • Page 14: Maintenance Chart--Diesel

    Hopper side skirt Check for damage and wear Main brush Check for damage, wear, and adjustment Check brush pattern Side brush Check for damage, wear, and adjustment Check brush pattern 1-12 6500/6550 330275 (5- -98) Home Find... Go To..
  • Page 15 Tennant Company or approved hydraulic fluid . . . Water and permanent-type ethylene glycol anti-freeze, --34_ C (--30_ F) . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) NOTE: Also check procedures indicted (*) after the first 50-hours of operation. 1-13...

  • Page 16: Pushing, Towing, And Transporting The Machine

    1. Position the rear of the machine at the loading edge of the truck or trailer. FOR SAFETY: Use truck or trailer that will support the weight of the machine. NOTE: Empty the hopper before transporting the machine. 1-14 6500/6550 330275 (5- -01) Home Find... Go To..
  • Page 17 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. 1-15 6500/6550 330275 (5- -01) Home Find... Go To..
  • Page 18 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. 1-16 6500/6550 330275 (3- -00) Home Find... Go To..

  • Page 19: Machine Jacking

    FOR SAFETY: When servicing machine, block machine tires before jacking machine up. FOR SAFETY: When servicing machine, jack machine up at designated locations only. Block machine up with jack stands. 08030 1-17 6500/6550 330275 (5- -01) Home Find... Go To..

  • Page 20: Storing Machine

    Oil adheres to cold metal surfaces much better than hot surfaces. 5. Replace the high tension coil wire and spark plugs. 6. Drain the gasoline from the carburetor. 1-18 6500/6550 330275 (8- -94) Home Find... Go To..

  • Page 21: To Store Machine For More

    6. Seal the air cleaner inlet and the exhaust outlet with weatherproof masking tape. 7. Tighten the engine oil filler cap, the fuel tank cap, and the radiator cap to make certain they are securely in place. 1-19 6500/6550 330275 (8- -94) Home Find... Go To..

  • Page 22: Hardware Information

    47 (64) 58 (79) 83 (112) 94 (127) 133 (180) 144 (195) 196 (265) 260 (352) 336 (455) 470 (637) 664 (900) NOTE: Decrease torque by 20% when using a thread lubricant. 1-20 6500/6550 330275 (10- -93) Home Find... Go To..

  • Page 23: Bolt Identification

    Thread sealants and locking compounds may be used on this machine. They include the following: Locktite 515 sealant -- gasket forming material. TENNANT Part No. 75567,15 oz (440 ml) cartridge. Locktite 242 blue -- medium strength thread locking compound. TENNANT Part No.
  • Page 24 GENERAL INFORMATION 1-22 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 25 ......2--9 TO REPLACE REAR WHEEL HOUSING PIVOT BEARINGS ..2--9 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 26: Chassis

    CHASSIS 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 27: Seat

    SEAT The seat assembly is removable on both the 6500 and 6550. The seat can also be adjusted on both models, however you need tools to adjust it on the 6500. TO REMOVE SEAT ASSEMBLY FOR SAFETY: Before Leaving Or Servicing Machine;...

  • Page 28: To Adjust Seat Position (6500 Only)

    Reinstall the hair pin clip in the tapered pin and the prop rod back in the slot. TO ADJUST SEAT POSITION (6550 ONLY) FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key.

  • Page 29: Brakes And Tires

    Block machine up with jack stands. 9. Remove the hub cap in the center of front wheel. 10. Remove the cotter pin, slotted nut, flat washer, and bearing cone. 11. Slide the wheel off the axle. 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 30 25. Tighten the brake clevis jam nuts. 26. Reinstall the operators compartment floor plate. 27. Reinstall the battery and cables. 28. Reinstall the seat assembly. 29. Adjust the parking brake. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 31: To Adjust Brakes

    ADJUST BRAKES. Adjust the parking brake so it will hold the Machine on a smooth 8 degree incline. The brake pedal should not travel more than 25 mm (1 in) to fully engage the brakes. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 32: Front Tires And Wheels

    Inspect the front wheel bearings for seal damage. Repack and adjust the front wheel bearings after every 400 hours of operation. Use Lubriplate EMB grease (TENNANT part no. 01433--1). TO REPACK FRONT WHEEL BEARINGS FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key.

  • Page 33: Rear Tire And Wheel, And Wheel Support

    The rear wheel support bearings must be lubricated every 200 hours of operation. Use Lubriplate EMB grease (TENNANT part no. 01433--1). Check the rear tire pressure every 100 hours of operation. The proper tire air pressure is 790 + 35 kPa (115 + 5 psi).
  • Page 34 34 -- 40 Nm (25 -- 30 ft lb). Rotate casting to set bearings. Check for any play. If the pin is not seated, tap with rubber mallet and re--torque castle nut. 2-10 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 35 28. Mount the hub to the tapered motor shaft. 6500- -Tighten the slotted nut to 270 Nm (200 ft lb). Install the cotter pin. 6550- -Tighten the slotted nut to 508 Nm (375 ft lb). Install the cotter pin. 29. Install the rear tire and wheel assembly.
  • Page 36 CHASSIS 2-12 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 37 ....3-45 TO REPLACE BRUSH SHAFT BEARINGS MACHINE TROUBLESHOOTING . . . 3-47 (For all 6550 and 6500 model machines below serial number 20000) 3-25 TO REPLACE BRUSH SHAFT BEARINGS (For 6500 model machines serial number 20000 and above) 3-27...
  • Page 38 SWEEPING 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 39: Introduction

    The side brush sweeps debris into the path of the main brush. The main brush sweeps debris from the floor into the hopper. The vacuum system pulls dust and air through the hopper and the hopper dust filter. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 40: Debris Hopper

    For 6500 model machines below serial number 20000 and ALL 6550 model machines have metal hoppers. The 6500 models with serial number 20000 and above have plastic hoppers. TO REMOVE HOPPER FROM MACHINE FOR SAFETY: Before Leaving Or Servicing Machine;...
  • Page 41 9. Loosen the M8 hex screws holding the side brush lift cable to the hopper. Remove the cable from the pulleys. 10. The hopper can now be removed from the machine. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 42: To Install Hopper

    8. Install six M12 hex screws, nyloc nuts and Belleville washers along with the hopper plates. Tighten to 90 -- 117 Nm (65 -- 85 ft lb). 9. Install the hydraulic hose clamps to the hopper arm. 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 43 14. Reconnect wires to the filter shaker and Thermo Sentryt. 15. Start engine and check for proper operation of hopper vacuum fan, dump door, side brush rotation and side brush up and down. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 44: To Adjust And Level Hopper Height

    Reconnect the wires to filter shaker and Thermo Sentryt. 7. Start the engine and raise the hopper high enough to remove two 4” tall blocks. Lower hopper and check hopper to floor clearance. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 45: To Replace Thermo Sentryt

    3. Remove the two bolts holding Thermo Sentryt to the filter cover. 4. Mount the new Thermo Sentryt to bracket with existing hardware. 5. Reconnect the wires to the Thermo Sentryt. 6. Close the hopper cover. 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 46: Hopper Dust Filter

    NOTE: Be sure the dust filter is dry before reinstalling it in the machine. 3-10 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 47: To Replace Hopper Dust Filter

    4. Disconnect the filter shaker wire. For machines with the metal hopper, lift the dust filter cover for access to the wire. 5. Lift the dust filter element assembly out from the hopper. 3-11 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 48 10. Place the filter shaker plate onto the new or cleaned dust filter element. Make sure the lip on the filter shaker plate is fastened over the lip on the dust filter element. 3-12 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 49 15. For machines with the metal hopper, fasten the dust filter cover onto the element with the retainer brackets, washers, and knobs. 16. Close the hopper cover. 3-13 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 50: Hopper Dump Door

    Engage the parking brake. 2. Open the dump door and hopper cover. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3-14 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 51 Remove both hubs. 10. Slide the dump door all the way in either direction. Drop one side down and remove the dump door from the machine. 3-15 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 52: To Install Hopper Dump Door

    11. Reconnect the rod end of dump door cylinder and the dust door pivot link to the dump door pivot yoke. 12. Start the machine and open and close hopper door a few times. Check for proper operation. 3-16 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 53: Brushes

    50 to 65 mm (2.0 to 2.5 in) wide with the main brush in the Down position. (For 6500 Model machines below serial number 20000 and for ALL 6550 Models) Adjust the main brush pattern by turning the main brush pressure knob located next to the brush position lever.

  • Page 54: To Replace Main Brush

    SWEEPING TO REPLACE MAIN BRUSH (For 6500 Model machines below serial number 20000 and for ALL 6550 Models) 1. Stop the engine and set the machine parking brake. FOR SAFETY: Before leaving or servicing machine; stop on level surface, set parking brake, turn off machine and remove key.
  • Page 55 8. Replace the brush idler plate, and secure with the mounting knob. 9. Close the right side main brush access door. 3-19 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 56: To Check And Adjust Main Brush Pattern

    SWEEPING TO CHECK AND ADJUST MAIN BRUSH PATTERN (For 6500 Model machines below serial number 20000 and for ALL 6550 Models) 1. Apply chalk, or some other material that will not blow away easily, to a smooth, level floor. 2. Raise the side brush and main brush and position the main brush over the chalked area.
  • Page 57 Tighten the mounting bolts. C. Check the main brush pattern and readjust as necessary. Then adjust the width of the main brush pattern. 08215 3-21 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 58: To Check And Adjust Main Brush Pattern

    00582 9. To increase the width of the main brush pattern, loosen the main brush adjustment knob and slide the main brush adjustment plate forward 7 to 14 mm (0.25--0.50 in). 3-22 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 59 C. Check the main brush pattern and readjust as necessary. Set the main brush adjustment knob to match the same color band as the brush idler plate. 3-23 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 60: Plug Bearings

    NOTE: If you replace idler arm latch, use blue locktite on hardware to hold in place. 13. Reinstall the idler arm on the machine. 14. Operate the machine and check for proper operation. 3-24 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 61: To Replace Brush Shaft Bearings

    SWEEPING TO REPLACE BRUSH SHAFT BEARINGS (For 6500 Model machines below serial number 20000 and for ALL 6550 Models) FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Remove the main brush and idler arm from the machine.
  • Page 62 18. Reconnect the main brush lift cable to the brush shaft arm with the clevis and cotter pin. 19. Check main brush pattern for taper and width. Adjust as necessary. See TO CHECK AND ADJUST MAIN BRUSH PATTERN. 3-26 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 63 3. Remove the brush lift cable clevis from brush shaft arm. 4. Remove the two bolts holding the brush shaft to the bearings and set aside. 5. Pull the brush shaft out of the machine. 3-27 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 64 10. Reconnect the brush motor arm assembly. 11. Replace the main brush and idler arm. 12. Check main brush pattern for taper and width. Adjust as necessary. See TO CHECK AND ADJUST MAIN BRUSH PATTERN. 3-28 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 65: Side Brush

    50 mm (2 in) in length. You may change the side brush sooner if you are sweeping light litter, or wear the bristles shorter if you are sweeping heavy debris. 07799 3-29 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 66: To Replace Side Brush

    8. Secure the pin by clipping the pin keeper over the end of the pin. 9. Disengage the hopper support bar and lower the hopper. 10. Adjust the side brush pattern with the side brush down pressure knob. 3-30 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 67: Side Brush Guard

    3. Rotate or replace the side brush guard. 4. Reinstall the four bolts in the side brush motor and tighten to 22--27 Nm (16--20 ft lb). 3-31 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 68: Skirts And Seals

    7. Tighten the mounting hardware to 8--14 Nm (6--10 ft lb). 8. Start the engine and lower the hopper. 3-32 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 69: Brush Door Skirts

    NOTE: The brush door skirts have slotted holes to allow for a ground clearance adjustment. The door must be closed for proper adjustment. 3-33 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 70 6--8 ft lb (8--10 Nm). 5 mm (0.25 in) 3 mm to 5 mm 11. Repeat for the other brush door. (0.12 to 0.25 in) 3-34 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 71: Rear Skirt And Deflector Blade

    9. Tighten the rear floor skirt mounting bolts to 8--14 Nm (6--10 ft lb). 10. Remove the brush contact blade retaining strip and the brush contact blade. Discard the old blade. 3-35 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 72: Brush Door Seals

    They seal the main brush compartment. tighten the seal hardware to 4--5 Nm (3--4 ft lb). Inspect the seals for wear or damage every 100 hours of operation. 08023 3-36 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 73: To Replace Hopper Seals

    9. Pull the skirt toward the brush door. Secure in place with the C-shaped retainer and bolts. Tighten to 8--10 Nm (6--8 ft lb). 10. Repeat on the other side of the main frame. 3-37 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 74: Hopper Inspection Door Seal

    4. Remove the six M6 hex screws and nyloc nuts holding dump door seal, retainer, and sponge cord to dump door. Discard seal. 5. Use black RTV to hold sponge cord to new dump door seal. 3-38 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 75 (30 -- 39 In lb). Make sure seals are lined up with edge of hopper when tightening. 9. Start machine and lower hopper. 10. Operate the machine and check the dump door for proper operation. 3-39 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 76: Hopper Cover Seal

    Check the seals for wear or damage after every 100 hours of operation. You can reach the seals by lifting the dust filter cover and removing the filter element. 3-40 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 77: Hopper Lift Arm

    Remove the pins and washers and remove the lift arm from the machine. 9. If the large self aligning bearing needs to be changed, remove retaining rings and press out. 3-41 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 78: To Install Hopper Lift Arm

    7. Reconnect the speed limiter rod to the lift arm. Tighten the M10 nyloc to 37 -- 48 Nm (26 -- 34 ft lb). 8. Reinstall the hopper assembly. See TO INSTALL HOPPER instructions. 3-42 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 79: Vacuum Fan

    5. Disconnect and plug the three hydraulic hoses leading to the vacuum fan motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 6. Disconnect the wire harness from the vacuum fan motor solenoid. 3-43 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 80: To Install Vacuum Fan Assembly

    5. Install the three M10 hex screws, washers and nyloc nuts with holes on the underside of the fan transition mount bracket. Tighten to 18 -- 24 Nm (13 -- 18 ft lb). 3-44 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 81: To Replace Vacuum Fan Impeller

    4. Place the vacuum fan assembly in a vice. 5. Remove the four 0.25 in. hex screws and fender washers holding inlet plate to the fan housing. Remove the inlet plate. 3-45 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 82 Tighten to 11 -- 14 Nm (7 -- 10 ft lb). 11. Reinstall the vacuum fan assembly back in the machine. See TO INSTALL VACUUM FAN instructions. 3-46 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 83: Machine Troubleshooting

    Hopper lip skirts worn or damaged Replace lip skirts Hopper door partially or Open the hopper door completely closed Wrong sweeping brush Contact TENNANT representative for recommendations Main brush in Down position Put main brush in Float position 3-47 6500/6550 330275 (6- -01) Home Find... Go To..
  • Page 84 SWEEPING 3-48 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 85 INSTRUMENT PANEL TEST PLUG IN below serial number 20000 and for POWER UP TEST--3 ... 4-64 ALL 6550 G/LP Models) 4-16 SHAKER MOTOR CIRCUIT ..4-66...
  • Page 86 LOW L.P. FUEL CIRCUIT ..4-96 LOW LP FUEL LIGHT ... . . 4-97 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 87: Electrical System

    Never add acid to the batteries, only distilled water. Keep the battery caps on the batteries always except when adding water or taking hydrometer readings. FOR SAFETY: When Servicing Machine, Avoid Contact With Battery Acid. 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 88 (80_ F), the reading must be temperature corrected. Add or subtract to the specific gravity reading 0.004, 4 points, for each 6_ C (10_ F) above or below 27_ C (80_ F). 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 89: To Replace Battery

    Position the new battery in the machine. 6. Reinstall the battery hold down strap. 7. Reconnect the positive, then the negative battery cables. 8. Lower the seat assembly and start the machine to test the new battery. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 90: Instrument Touch Panel

    10. Position the dash panel back on the machine frame and reinstall the two M6 hex screws and two M8 hex screws. Hand tighten. 11. Reconnect the battery cables. 12. Start the machine and check for proper operation. 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 91: To Disassemble Instrument Touch Panel

    8. Any burned-out lamps can now be changed by turning them 1/4 turn counterclockwise and lifting out. 9. To replace the hour meter, unplug the two wires from the hour meter and remove the two pan head screws. 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 92: To Reassemble Instrument Touch Panel

    6. Reinstall the twelve pan head screws and hand tighten lightly. 7. The instrument touch panel is now ready to be reinstalled on the machine. See TO REPLACE INSTRUMENT TOUCH PANEL instructions. 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 93: To Replace Electrical Relay

    ELECTRICAL TO REPLACE ELECTRICAL RELAY (For 6500 Model machines below serial number 20000 and for ALL 6550 Models) FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Disconnect the battery cables from the battery.

  • Page 94: Circuit Breakers

    For all 6550 and 6500 models below serial number 20000, the circuit breakers are located in the operator compartment. CB--10 is located in the cab control panel.
  • Page 95 15 A Cab heater, defrost, dome light, wiper motor (options) CB-9 15 A Cab pressurizer fan (option) CB-10 Open CB-11 30 A Cab AC condenser CB-12 30 A Cab AC fan 4-11 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 96: To Replace Circuit Breaker

    ELECTRICAL TO REPLACE CIRCUIT BREAKER (For 6500 Model machines below serial number 20000 and for ALL 6550 Models) FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Disconnect the battery cables from the battery.

  • Page 97: To Replace Circuit Breaker (For 6500 Models With Serial Number 20000 And Above)

    Never substitute higher valve fuses than specified. The fuse is located in the operator compartment under the steering column. FUSE RATING CIRCUIT PROTECTED FU- -1 40 AMP GLOW PLUGS 4-13 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 98: To Replace Governor Control Box

    7. Connect the new control box to the main harness. See electrical schematic. 8. Start the machine and check the new control box for proper operation. 9. Disengage the safety arm and lower the hopper. 4-14 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 99: To Replace Filter Shaker Motor

    16. Position the two retainer plates on the ends of the filter cover. Reinstall the four knobs and tighten. 17. Reconnect the battery and operate the shaker system. Check the new shaker for proper operation. Close the hopper cover. 4-15 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 100: Electrical Schematic (Gas/Lp) (1 Of 4)

    ELECTRICAL ELECTRICAL SCHEMATIC (Gas/LP) (1 of 4) (For all 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 351772 - - G, LP 4-16 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 101 ELECTRICAL ELECTRICAL SCHEMATIC (Gas/LP) (2 of 4) (For all 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 351772 - - G, LP 4-17 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 102 ELECTRICAL ELECTRICAL SCHEMATIC (Gas/LP) (3 of 4) (For all 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 351772 - - G, LP 4-18 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 103 ELECTRICAL ELECTRICAL SCHEMATIC (Gas/LP) (4 of 4) (For all 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 351772 - - G, LP 4-19 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 104: Electrical Schematic (Diesel) (1 Of 4)

    ELECTRICAL ELECTRICAL SCHEMATIC (Diesel) (1 of 4) (For 6500D Model machines below serial number 20000 and for ALL 6550D Models) 351773 - - D 4-20 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 105 ELECTRICAL ELECTRICAL SCHEMATIC (Diesel) (2 of 4) (For 6500D Model machines below serial number 20000 and for ALL 6550D Models) 351773 - - D 4-21 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 106 ELECTRICAL ELECTRICAL SCHEMATIC (Diesel) (3 of 4) (For 6500D Model machines below serial number 20000 and for ALL 6550D Models) 351773 - - D 4-22 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 107 ELECTRICAL ELECTRICAL SCHEMATIC (Diesel) (4 of 4) (For 6500D Model machines below serial number 20000 and for ALL 6550D Models) 351773 - - D 4-23 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 108 ELECTRICAL ELECTRICAL SCHEMATIC (Gas/LP) (1 of 4) (For all 6500 G/LP Model machines serial number 20000 and above) 353657 - - 6500, G, LP 4-24 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 109 ELECTRICAL ELECTRICAL SCHEMATIC (Gas/LP) (2 of 4) (For all 6500 G/LP Model machines serial number 20000 and above) 353657 - - 6500, G, LP 4-25 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 110 ELECTRICAL ELECTRICAL SCHEMATIC (Gas/LP) (3 of 4) (For all 6500 G/LP Model machines serial number 20000 and above) 353657 - - 6500, G, LP 4-26 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 111 ELECTRICAL ELECTRICAL SCHEMATIC (Gas/LP) (4 of 4) (For all 6500 G/LP Model machines serial number 20000 and above) 353657 - - 6500, G, LP 4-27 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 112 ELECTRICAL ELECTRICAL SCHEMATIC (Diesel) (1 of 4) (For all 6500D Model machines serial number 20000 and above) 353658 - - 6500, D 4-28 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 113 ELECTRICAL ELECTRICAL SCHEMATIC (Diesel) (2 of 4) (For all 6500D Model machines serial number 20000 and above) 353658 - - 6500, D 4-29 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 114 ELECTRICAL ELECTRICAL SCHEMATIC (Diesel) (3 of 4) (For all 6500D Model machines serial number 20000 and above) 353658 - - 6500, D 4-30 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 115 ELECTRICAL ELECTRICAL SCHEMATIC (Diesel) (4 of 4) (For all 6500D Model machines serial number 20000 and above) 353658 - - 6500, D 4-31 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 116 ELECTRICAL WIRE HARNESSES GROUP (Gas/LP) (1 of 7) (For 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 16/GRN 44/GRY 1/RED 13B/BLK 13M/BLK 15B/BLU BATTERY 5/YEL 1F/RED 1F/RED 1A/RED 12/YEL 1D/RED HORN 1E/RED 17/BLU 17/BLU GOV.
  • Page 117 ELECTRICAL WIRE HARNESSES GROUP (Gas/LP) (2 of 7) (For 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) LIFT ARM SWITCH (6550 ONLY) 24/PUR 32/GRY JUMPER HARNESS (6500 ONLY) 13J/BLK 38/PUR 39A/GRY 13H/BLK HOPPER DOOR...
  • Page 118 ELECTRICAL WIRE HARNESSES GROUP (Gas/LP) (3 of 7) (For 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 13XX/BLK 13WW/BLK 13AAA/BLK 13EE/BLK 13CCC/BLK TO MAIN 111/ORA HARNESS 76A/ORA 76/ORA 13KK/BLK 13RR/BLK 93/ORA 13JJ/BLK REV/FLSH LIGHT...
  • Page 119 ELECTRICAL WIRE HARNESSES GROUP (Gas/LP) (4 of 7) (For 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) AUX SIDE BRUSH HARNESS CAB HARNESS TURN SIGNAL HARNESS 81/YEL 81A/YEL 80/BLU 108B/GRY 79/YEL 108C/GRY 81/YEL TURN LIGHT...
  • Page 120 ELECTRICAL WIRE HARNESSES GROUP (Gas/LP) (5 of 7) (For 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 4-36 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 121 ELECTRICAL WIRE HARNESSES GROUP (Gas/LP) (6 of 7) (For 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 4-37 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 122 ELECTRICAL WIRE HARNESSES GROUP (Gas/LP) (7 of 7) (For 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) CB- -10 PRESSURIZER HEATER DOME LIGHT WIPER 120/GRY 118/YEL 113/YEL 111U/ORA 111C/ORA 111B/ORA 115/GRN 119/BRN 116/BLU 112/PUR...
  • Page 123 ELECTRICAL ENGINE WIRE HARNESS GROUP (Gas/LP) (For 6500 G/LP Model machines below serial number 20000 and for ALL 6550 G/LP Models) 4-39 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 124 62C/YEL BROWN BATTERY GAS AND DIESEL FUEL LOCATION SENDER 1/RED 13LLL/BLK 42A/ORA FUEL HARNESS SOCKET WIRE COLOR SOCKET WIRE COLOR SOCKET WIRE COLOR SOCKET WIRE COLOR PLUG PLUG PLUG PLUG PLUG 4-40 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 125 ELECTRICAL WIRE HARNESS GROUP (Diesel) (2 of 7) (For 6500D Model machines below serial number 20000 and for ALL 6550 Models) LIFT ARM SWITCH (6550 ONLY) 24/PUR 32/GRY JUMPER HARNESS (6500 ONLY) 13J/BLK 38/PUR 39A/GRY 13H/BLK HOPPER DOOR HOPPER HARNESS...
  • Page 126 ELECTRICAL WIRE HARNESS GROUP (Diesel) (3 of 7) (For 6500D Model machines below serial number 20000 and for ALL 6550 Models) 4-42 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 127 ELECTRICAL WIRE HARNESS GROUP (Diesel) (4 of 7) (For 6500D Model machines below serial number 20000 and for ALL 6550 Models) 4-43 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 128 ELECTRICAL WIRE HARNESS GROUP (Diesel) (5 of 7) (For 6500D Model machines below serial number 20000 and for ALL 6550 Models) 13XX/BLK 13WW/BLK 13AAA/BLK 13EE/BLK 13CCC/BLK TO MAIN 111/ORA HARNESS 76A/ORA 76/ORA 13KK/BLK 13RR/BLK 93/ORA 13JJ/BLK REV/FLSH LIGHT OHG/CAB 90/GRY...
  • Page 129 ELECTRICAL WIRE HARNESS GROUP (Diesel) (6 of 7) (For 6500D Model machines below serial number 20000 and for ALL 6550 Models) AUX SIDE BRUSH HARNESS CAB HARNESS TURN SIGNAL HARNESS 81/YEL 81A/YEL 80/BLU 108B/GRY 79/YEL 108C/GRY TURN LIGHT 81/YEL TO CIRCUIT...
  • Page 130 ELECTRICAL WIRE HARNESS GROUP (Diesel) (7 of 7) (For 6500D Model machines below serial number 20000 and for ALL 6550 Models) CB- -10 PRESSURIZER HEATER DOME LIGHT WIPER 113/YEL 118/YEL 120/GRY 111U/ORA 111C/ORA 111B/ORA 20F/BLU 119/BRN 115/GRN 112/PUR 116/BLU HARNESS...

  • Page 131: Main Wire Harnesses Group

    ELECTRICAL MAIN WIRE HARNESSES GROUP (Gas/LP) (1 of 2) (For 6500 G/LP Model machines serial number 20000 and above) 353645 - - 6500, G, LP 4-47 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 132 ELECTRICAL MAIN WIRE HARNESSES GROUP (Gas/LP) (2 of 2) (For 6500 G/LP Model machines serial number 20000 and above) 353645 - - 6500, G, LP 4-48 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 133: Main Wire Harnesses Group (Diesel) (1 Of 2)

    ELECTRICAL MAIN WIRE HARNESSES GROUP (Diesel) (1 of 2) (For 6500D Model machines serial number 20000 and above) 353648 - - 6500, D, NA 4-49 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 134 ELECTRICAL MAIN WIRE HARNESSES GROUP (Diesel) (2 of 2) (For 6500D Model machines serial number 20000 and above) 353648 - - 6500, D, NA 4-50 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 135: Hopper Wire Harness Group

    ELECTRICAL HOPPER WIRE HARNESS GROUP (For 6500 Gas/LP/D Model machines serial number 20000 and above) 353648 - - 6500, D, NA 4-51 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 136: Engine Wire Harness Group

    ELECTRICAL ENGINE WIRE HARNESS GROUP (For 6500 Gas/LP Model machines serial number 20000 and above) 353647 - - 6500, G, LP 4-52 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 137: Troubleshooting

    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. 4-53 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 138: Engine Run Circuit

    42/ORA SE- - 1 13L/BLK PANEL COOLANT TEMP CLOSES AT SENDER SE- - 2 43/BLU 225 F N.O.H.C. S- - 9 44/GRY 13M/BLK LOW L.P. FUEL 13T/BLK 13S/BLK 13R/BLK L.P. GND. 4-54 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 139: Alternator Fault

    SENSE 1D/RED BATT. C.B.- - 1 20/BLU IGNITION SWITCH S- - 3 18E/ P1- - 14 19/BLU CB- - 6 23A/GRY 2.5A P1- - 1 ELECTRONIC PANEL INSTRUMENT LAMP PANEL 13T/BLK 4-55 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 140: Alternator

    AFTER CHECKING THE BATTERY AND ITS CONNECTIONS TURN KEY ON LIGHT START ENGINE CHECK VOLTAGE > 1 VOLT 0 VOLTS REPLACE BULB ACROSS PLUG 1 P1 - - P14 REPLACE ALTERNATOR RETEST BATTERY 4-56 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 141: Fuel Sender Circuit

    CB- - 6 23A/GRY 2.5A P1- - 1 PANEL SE- - 1 LAMP FUEL SENDER 42/ORA P1- - 13 13L/BLK 0 TO 90 OHMS ELECTRONIC 90 OHMS FULL INSTRUMENT PANEL 13T/BLK 4-57 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 142: Fuel Light

    OR VARIATION (VARIABLE 90 TO 0 OHMS) CHECK CONNECTIONS REPLACE GAUGE & CONTINUITY OF 42 ORA AND 13L BLK TEST VOLTAGE BATTERY REPAIR AS NECESSARY P1 TO P13 VOLTAGE REPLACE BOARD 4-58 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 143: Oil Pressure

    N.C. = ENGINE OFF IGNITION SWITCH S- - 3 18E/ 16/GRN P1- - 2 19/BLU CB- - 6 23A/GRY P1- - 1 ELECTRONIC PANEL INSTRUMENT LAMP PANEL 13T/BLK SHOWN IN LIGHT ON POSITION 4-59 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 144: Thermal Sentryt

    19/BLU CB- - 6 ELECTRONIC INSTRUMENT 23B/GRY 23A/GRY PANEL HOPPER P1- - 1 THERMAL PANEL 24/PUR LAMP S- - 5 24A/PUR P1- - 6 13T/BLK THERMAL OPEN- -0 VOLTS, LIGHT ON 4-60 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 145: Power Up Circuit

    ELECTRICAL POWER UP CIRCUIT BATTERY 13/BLK 540 C.C.A. 1D/RED BATT. C.B.- - 1 20/BLU IGNITION SWITCH S- - 3 18E/ 19/BLU CB- - 6 2.5A 23A/GRY ELECTRONIC INSTRUMENT PANEL 13T/BLK 4-61 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 146: Power Up Testing

    23A GRAY / BATT. NEG. 19 BLUE (=BATTERY VOLTAGE) TEST 3 GROUND TEST ALL REPAIR OR REPLACE ACCESSORIES OFF 23A GRAY PLUG 1 P1 - - P23 REPLACE BOARD REPLACE 13T BLK 4-62 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 147: Power Up Test--1

    Volts Volts D.C. D.C. POWER UP TEST- -2 C.B. 6 C.B. 6 1E RED 22 YELLOW 1E RED 22 YELLOW battery battery voltage voltage Volts Volts D.C. D.C. 4-63 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 148: Instrument Panel Test Plug In Power Up Test--3

    1 2 3 4 5 6 19 20 21 22 23 24 19 20 21 22 23 24 < 100 > 1 meg Ohms Ohms D.C. D.C. Switch on Switch off 4-64 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 149 ELECTRICAL C.B. 6 1E RED 22 YELLOW Volts D.C. 4-65 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 150: Shaker Motor Circuit

    S- - 3 20A/BLU 18E/ 19/BLU RED CB- - 6 23A/GRY 2.5A ELECTRONIC INSTRUMENT PANEL SHAKER MOTOR RELAY 23C/GRY 29/GRN 13T/BLK 20A/ 26A/ CB- - 2 30/GRY 30A/GRY 13X/BLK 15 AMP SHAKER MOTOR 4-66 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 151 TEST 4 LET COOL 3 MIN. OUT OF SPEC CHECK CONTINUITY CHECK RESISTANCE OF 29 GREEN PLUG 1 P16 - - P23 (< 100 OHMS SWITCH ON) REPAIR OR REPLACE REPLACE BOARD 4-67 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 152: Shaker Test 1

    Ohms D.C. D.C. Switch held on Switch off SHAKER TEST 2 C.B. 2 C.B. 2 20A BLUE 26A ORANGE 20A BLUE 26A ORANGE battery battery voltage voltage Volts Volts D.C. D.C. 4-68 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 153: Instrument Panel Test Plug In Shaker Test--3

    SHAKER TEST- -4 1 2 3 4 5 6 1 2 3 4 5 6 192021 222324 192021 222324 < 100 > 1 meg Ohms Ohms D.C. D.C. Switch held on Switch off 4-69 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 154: Coolant Sender Circuit

    P1- - 1 PANEL COOLANT TEMP LAMP SENDER SE- - 2 CLOSES AT 43/BLU P1- - 5 225 F < 80 OHMS - - ON > 85 OHMS - - OFF 4-70 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 155: Coolant Temperature

    REMOVE WIRE REPLACE BULB FOR SENSOR INSERT TEST HARNESS GROUNDED REPLACE CHECK WIRE SENSOR 43 BLUE FOR GROUND TO FRAME SHORT CHECK VOLTAGE BATTERY REPAIR P1 TO P5 VOLTAGE REPLACE BOARD 4-71 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 156: Vacuum Fan Circuit

    FAN SOL. LIFT VALVE SW. 32/ ELECTRONIC S- - 5 N.O.H.C. INSTRUMENT S- - 6 24A/PUR HOPPER PANEL THERMAL SW. 13T/BLK 20A/ CB- - 2 27/YEL 13W/BLK 15 AMP FAN SOL. VALVE 4-72 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 157: Hopper Door Circuit

    P1- - 1 2.5A 39/GRY 13J/BLK P1- - 4 S- - 8 PANEL LAMP S- - 8 CLOSED = 1.) HOPPER DOOR CLOSED 2.) PANEL LAMP ON ELECTRONIC INSTRUMENT PANEL 13T/BLK 4-73 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 158 TURN KEY ON LIGHT INSERT TEST HARNESS CHECK VOLTAGE REPLACE SWITCH PLUG 1 P1 - - P4 CHECK CONNECTIONS AND CONTINUITY OF REPLACE BOARD 39 GRAY / 13J BLK REPAIR OR REPLACE 4-74 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 159: Down Force Circuit

    23A/GRY P1- - 1 2.5A DN. FORCE PANEL 40/YEL 13K/BLK LAMP S- - 9 P1- - 7 S- - 9 CLOSED = EXCESSIVE BRUSH DOWN FORCE EXISTS ELECTRONIC INSTRUMENT PANEL 13T/BLK 4-75 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 160: Down Force Circuit

    JUMP S- -8 REPLACE S- -8 INSERT TEST HARNESS CHECK VOLTAGE 0 VOLTS BATTERY P1- -1 TO P1- -7 VOLTAGE CHECK CONNECTIONS & CONTINUITY OF REPLACE BOARD 40 YEL & 13K BLK 4-76 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 161: Clogged Filter Switch Circuit

    CB- - 6 23A/GRY N.O. = VACUUM IN HOPPER 2.5A P1- - 1 FILTER CLOGGED PANEL LAMP ELECTRONIC INSTRUMENT PANEL 13T/BLK REMOVE WIRE 38 PURPLE, PLACE JUMPER TO GROUND, LIGHT WILL COME ON. 4-77 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 162: Vacuum Fan Circuit

    LIFT VALVE SW. 32/ ELECTRONIC S- - 5 N.O.H.C. INSTRUMENT S- - 6 24A/PUR 6 HOPPER PANEL THERMAL SW. 13T/BLK 20A/ CB- - 2 27/YEL 13W/BLK 15 AMP FAN SOL. VALVE 4-78 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 163: Vacuum Fan Failure

    REMOVE M5 RELAY CHECK VOLTAGE CHECK 32 YEL TO BATT. NEG. HYDRAULICS CHECK CONTINUITY 24 PUR TO 32 YEL REPAIR OR REPLACE REPAIR OR REPLACE 23B GRAY AS NEEDED CONT. NEXT PAGE 4-79 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 164 (< 100 OHMS SWITCH ON) TEST 4 LET COOL 3 MIN. OUT OF SPEC REPLACE BOARD CHECK RESISTANCE PLUG 1 P21 - - P23 (< 100 OHMS SWITCH ON) REPAIR AS NECESSARY REPLACE BOARD 4-80 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 165: Vacuum Fan Test--1

    D.C. D.C. Switch held on Switch off VACUUM FAN TEST- -2 C.B. 2 C.B. 2 20A BLUE 20A BLUE 26A ORANGE 26A ORANGE battery battery voltage voltage Volts Volts D.C. D.C. 4-81 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 166: Instrument Panel Test Plug In Vacuum Fan Test--3

    VACUUM FAN TEST- -4 1 2 3 4 5 6 1 2 3 4 5 6 192021 222324 192021 222324 < 100 > 1 meg Ohms Ohms D.C. D.C. Switch on Switch off 4-82 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 167: Rotating Light Circuit

    19/BLU CB- - 6 23A/GRY 2.5A ELECTRONIC INSTRUMENT PANEL 23B/ ROT. LIGHTS RELAY 75/BRN 13T/BLK 23E/GRY FLASHING LIGHT 76A/ORA 13KK/BLK 20C/ CB- - 4 ROTATING LIGHT 76/ORA 76B/GRN 13LL/BLK 15 AMP 4-83 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 168: Flashing And Rotating Light Failure

    AT CB 4 (BOTH SIDES) A OR B A ONLY BATTERY VOLTAGE REPAIR OR REPLACE A & B REPLACE CB4 20A / 20C BLUE REPAIR OR REPLACE 74 PURPLE CONT. NEXT PAGE 4-84 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 169 TEST 4 LET COOL 3 MIN. CHECK CONTINUITY OUT OF SPEC OF 75 BRN CHECK RESISTANCE PLUG 1 P19 - - P23 REPAIR OR REPLACE (< 100 OHMS SWITCH ON) REPLACE BOARD 4-85 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 170: Rotating Light Test--1

    D.C. D.C. Switch held on Switch off ROTATING LIGHT TEST- -2 C.B. 4 C.B. 4 20C BLUE 74 PURPLE 20C BLUE 74 PURPLE battery battery voltage voltage Volts Volts D.C. D.C. 4-86 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 171: Instrument Panel Test Plug In Rotating Light Test--3

    ROTATING LIGHT TEST- -4 1 2 3 4 5 6 1 2 3 4 5 6 192021 222324 192021 222324 < 100 > 1 meg Ohms Ohms D.C. D.C. Switch on Switch off 4-87 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 172: Hourmeter Circuit

    13B/BLK C.B.- - 1 S- - 4 20/BLU N.C. OIL SWITCH N.O. = ENGINE RUNNING IGNITION SWITCH S- - 3 18E/ 19/BLU CB- - 6 23A/GRY 2.5A ELECTRONIC INSTRUMENT PANEL 13T/BLK 4-88 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 173: Hourmeter Does Not Work

    THE HOURMETER RUNS WHEN THE ENGINE IS RUNNING ONLY, NOT WITH THE KEY ON. TEST 1 TEST OIL PRESSURE SWITCH CHECK CONTINUITY REPLACE OF WIRE 15A BLUE TEST 2 CHECK RUNS WON’T RUN REPLACE HOURMETER REPLACE REPLACE PC BOARD HOURMETER 4-89 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 174: Hourmeter Test--1

    OIL SWITCH N.O. N.O. N.C. N.C. battery 0 volts voltage Volts Volts D.C. D.C. Engine running Not running HOURMETER TEST- -2 UNPLUGGED HOUR METER P2 1 Battery Voltage Volts D.C. Engine Running 4-90 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 175: Headlight Circuit

    19/BLU CB- - 6 23A/GRY 2.5A ELECTRONIC INSTRUMENT PANEL 13T/BLK HEAD LIGHTS RELAY 23D/GRY 60/GRN HEADLIGHT R.H. 20B/ CB- - 3 62/YEL 62A/YEL 62E/YEL 13BB/BLK 15 AMP 62D/YEL 13CC/BLK HEADLIGHT L.H. 4-91 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 176: Headlight Failure

    A OR B A ONLY LIGHTS BATTERY VOLTAGE REPLACE 20A OR A & B REPLACE M6 REPLACE CB3 20B BLUE CHECK CONTINUITY 62 YEL / 62A YEL REPAIR OR REPLACE CONT. NEXT PAGE 4-92 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 177 P- -20 / P- -23 REMOVE M6 RELAY (SWITCH ON) TEST 4 LET COOL 3 MIN. OUT OF SPEC CHECK RESISTANCE PLUG 1 P20 - - P23 (< 50 OHMS SWITCH ON) REPLACE BOARD 4-93 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 178: Headlight Test--1

    Ohms D.C. D.C. Switch held on Switch off HEADLIGHT TEST- -2 C.B. 3 C.B. 3 20B BLUE 20B BLUE 59 ORANGE 59 ORANGE battery battery voltage voltage Volts Volts D.C. D.C. 4-94 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 179: Instrument Panel Test Plug In Headlights Test--3

    HEADLIGHTS TEST- -4 1 2 3 4 5 6 1 2 3 4 5 6 19 2021 222324 192021 222324 < 100 > 1 meg Ohms Ohms D.C. D.C. Switch on Switch off 4-95 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 180: Low L.p. Fuel Circuit

    S- - 3 18E/ ELECTRONIC INSTRUMENT PANEL 19/BLU CB- - 6 23A/GRY P1- - 1 2.5A PANEL LAMP LOW L.P. FUEL S- - 10 13M/BLK 44/GRY N.C.H.O. 13T/BLK 13S/BLK 13R/BLK L.P. GND. 4-96 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 181: Low Lp Fuel Light

    REPAIR OR REPLACE REPLACE LAMP 13M BLK 44 GRAY 0 VOLTS CHECK VOLTAGE REPLACE BATTERY VOLTAGE PLUG 1 P1 - - P23 FUEL GAUGE (BATTERY VOLTAGE) RECHECK WIRES REPLACE BOARD AND GAUGE 4-97 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 182 ELECTRICAL 4-98 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 183 DIRECTIONAL PEDAL ....5--10 TO ADJUST DIRECTIONAL CONTROL FOOT PEDAL -- 6550 ONLY ..5--10 TO ADJUST DIRECTIONAL CONTROL LINKAGE .

  • Page 184: Hydraulics

    HYDRAULICS 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 185: Hydraulic Fluid Reservoir

    Replace the filter element every 800 hours of operation. The reservoir has a built-in strainer outlet that filters hydraulic fluid before it enters the system. Replace the strainer every 800 hours of operation. 6500/6550 330275 (6- -01) Home Find... Go To..

  • Page 186: Hydraulic Fluid

    The quality and condition of the hydraulic fluid play 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 fluids provide a longer life for the hydraulic components. There are two fluids available for different temperature ranges: TENNANT part no.

  • Page 187: To Drain Hydraulic Fluid Reservoir And Replace Filter Element

    5. Apply a thin coat of hydraulic fluid to the seal of the new hydraulic fluid filter element. 6. Thread and hand tighten the new hydraulic fluid filter element on the filter head. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 188: To Fill Hydraulic Fluid Reservoir

    FOR SAFETY: When servicing machine, use cardboard to locate leaking hydraulic fluid under pressure. If you discover a fluid leak, contact your mechanic/supervisor. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 189: Hydraulic Pumps

    4. Pull the accessary pump straight out of the propel pump without disconnecting the hydraulic hoses. Make sure not to loose the rubber O--ring on the accessary pump. 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 190 Remove the arm. NOTE: The pump control arm is on a tapered shaft and will need to be pried off or removed with a puller. 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 191 20. Start the machine and check the propel circuit for proper operation. 21. Reinstall the front dust panel. Tighten the four M8 hex screws to 18 -- 24 Nm (15 -- 20 ft lb). Lower the hopper. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 192: To Replace Accessary Pump

    9. Start the machine and check the accessary circuit for proper operation. 10. Reinstall the front dust panel and tighten the four M8 hex screws to 18 -- 24 Nm (15 -- 20 ft lb). Lower the hopper. 5-10 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 193: Directional Pedal

    The pedal linkages should also be adjusted whenever the reverse is faster or slower than machine specification. TO ADJUST DIRECTIONAL CONTROL FOOT PEDAL - - 6550 ONLY 1. Remove the hair cotter pin holding the clevis pin in place. 2. Remove the clevis pin.
  • Page 194 1.5--3 mm (0.06 -- 0.12 in). 16. Adjust the balljoint on the end of the speed control rod to get the correct gap. Tighten all jam nuts. 5-12 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 195: To Replace Hopper Lift Cylinder

    ”C” clip. 11. Reconnect the hydraulic hoses to the new cylinder. See schematic in this section. 12. Start the machine and raise the hopper. Check for any leaks and proper operation. 5-13 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 196: To Replace Hopper Dump Door Cylinder

    11. Reconnect the hydraulic hoses to the dump door cylinder. See the schematic in this section. 12. Start the machine and open and close the hopper dump door. Check for any leaks and proper operation. 5-14 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 197: To Replace Steering Cylinder

    7. Turn the steering wheel to the left so the rear drive casting can be accessed from the fuel tank area of the machine. 8. Disconnect the directional control pedal from the control rod balljoint. 5-15 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 198 15. Remove the steering cylinder from the machine. 16. Remove the fittings from old cylinder. Install the fittings in the new cylinder in the same orientation. 5-16 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 199 29. Remove jack stands from machine and lower. 30. With the seat in the up position, start machine and turn steering wheel in both directions. Observe the steering cylinder for any leaks. 5-17 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 200: To Replace Steering Valve

    U--bolt from the bracket. 11. The hydraulic steering valve can now be removed from machine. 12. Remove hydraulic fittings from old control motor. Install the fittings in the new valve in the same orientation. 5-18 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 201 18 -- 24 Nm (15 -- 20 ft lb). 18. Reinstall the rubber steering wheel cover. 19. Reconnect the battery cables and start engine. Move the steering wheel, checking for any leaks and proper operation. 5-19 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 202: Hydraulic Control Valve

    9. Thread the three valve knobs on the valve handles. Use a small amount of blue locktite. 10. Check the hydraulic fluid level. 11. Start the machine and check the control valve for proper operation. 5-20 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 203: To Replace Main Brush Motor

    Install a new cotter pin. 13. Reinstall the main brush. Operate the machine and check for proper operation. 5-21 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 204: To Replace Side Brush Motor

    13. Secure the pin by clipping the pin keeper over the end of the pin. 14. Disengage the hopper support bar and lower the hopper. 15. Adjust the side brush pattern with the side brush down pressure knob. 5-22 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 205: To Replace Vacuum Fan Motor

    12. Install the new fan motor on the motor mount plate using the four M8 flat head screws and nyloc nuts. Tighten to 18 -- 24 Nm (13 -- 18 ft lb). 5-23 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 206 Tighten to 11 -- 14 Nm (7 -- 10 ft lb). 17. Reinstall the vacuum fan assembly back in the machine. See TO INSTALL VACUUM FAN instructions. 5-24 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 207: To Replace Rear Drive Motor

    10. Slide the new motor back in the wheel housing. Note the hydraulic fitting orientation. 11. Reinstall the four hex head screws and tighten to 88--115 Nm (65--85 ft lb). 5-25 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 208 (200 ft lb) and put new 0.125 x 2.50 cotter pin through slotted nut. 14. Install the rear tire. Tighten the nuts to 122--150 Nm (90--110 ft lb). 15. Lower the machine. 5-26 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 209 HYDRAULICS 5-27 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 210: 6500 Hydraulic Schematic

    HYDRAULICS 6500 HYDRAULIC SCHEMATIC (METAL HOPPER) 3 4 5 5-28 6500/6550 330275 (6- -01) Home Find... Go To..
  • Page 211 HYDRAULICS 6500 HYDRAULIC SCHEMATIC (METAL HOPPER) 3 4 5 351757 - - 6500, NA 5-29 6500/6550 330275 (6- -01) Home Find... Go To..

  • Page 212: 6500 Hydraulic Schematic (Plastic Hopper)

    HYDRAULICS 6500 HYDRAULIC SCHEMATIC (PLASTIC HOPPER) 3 4 5 5-30 6500/6550 330275 (6- -01) Home Find... Go To..
  • Page 213 HYDRAULICS 6500 HYDRAULIC SCHEMATIC (PLASTIC HOPPER) 3 4 5 351757 - - 6500, NA 5-31 6500/6550 330275 (6- -01) Home Find... Go To..

  • Page 214: 6550 Hydraulic Schematic

    HYDRAULICS 6550 HYDRAULIC SCHEMATIC 4 5 6 351758 - - 6550 5-32 6500/6550 330275 (6- -01) Home Find... Go To..
  • Page 215 HYDRAULICS 6550 HYDRAULIC SCHEMATIC 4 5 6 351758 - - 6550 5-33 6500/6550 330275 (6- -01) Home Find... Go To..

  • Page 216: 6500 Hydrulic Hose Group (Metal Hopper)

    HYDRAULICS 6500 HYDRULIC HOSE GROUP (METAL HOPPER) 5-34 6500/6550 330275 (6- -01) Home Find... Go To..

  • Page 217: 6500 Hydrulic Hose Group (Plastic Hopper)

    HYDRAULICS 6500 HYDRULIC HOSE GROUP (PLASTIC HOPPER) 5-35 6500/6550 330275 (6- -01) Home Find... Go To..

  • Page 218: 6550 Hydrulic Hose Group

    HYDRAULICS 6550 HYDRULIC HOSE GROUP 351758 5-36 6500/6550 330275 (6- -01) Home Find... Go To..

  • Page 219: Troubleshooting

    The troubleshooting charts that follow are organized so they lead you through the hydraulic circuits. They include flow charts and instructions for you as to where to insert your test instruments. 5-37 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 220: 6500 Main Brush / Vac Fan

    1600 PSI RV 5 1000 2500 PSI 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER 25 PSI HEAT EXCHANGER 3 PSI FILTER RESERVOIR 5-38 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 221 MAIN BROOM 600 PSI RV 5 2500 PSI 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP 25 PSI STRAINER HEAT EXCHANGER 3 PSI FILTER RESERVOIR 5-39 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 222: 6500 Side Brush/Main & Vac Fan

    1800 PSI 1000 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 7 HEAT 25 PSI RV 4 EXCHANGER 3 PSI FILTER RESERVOIR 5-40 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 223: 6550 Main & Side Brush

    HYDRAULICS 6550 MAIN & SIDE BRUSH BROOMS 800 PSI CV1A RV 5 SIDE BROOM MAIN BROOM 2500 PSI 600 PSI 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP RV 7 STRAINER 25 PSI...

  • Page 224: 6500 Side Brush/Main & Vac Fan

    1800 PSI 1000 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 7 HEAT RV 4 25 PSI EXCHANGER 3 PSI FILTER RESERVOIR 5-42 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 225: 6500 Main Brush / Vac Fan

    1600 PSI RV 5 2500 PSI 1000 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER 25 PSI HEAT EXCHANGER 3 PSI FILTER RESERVOIR 5-43 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 226 CV 2 RV 8 1800 PSI 1000 PSI 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER 25 PSI HEAT EXCHANGER 3 PSI FILTER RESERVOIR 5-44 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 227: 6500/6550 Lower Hopper

    LIFT CV1C CYLINDER RESTRICTOR LIFT 5.1 GPM @ 2000 6.2 GPM @ 2400 PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 7 HEAT 25 PSI RV 4 EXCHANGER 3 PSI FILTER RESERVOIR 5-45 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 228: 6500/6550 Raise Hopper

    HYDRAULICS 6500/6550 RAISE HOPPER LIFT LIFT CYLINDER CV1C RESTRICTOR 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI RESERVOIR 5-46 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 229: 6500/6550 Open Door

    HYDRAULICS 6500/6550 OPEN DOOR CYLINDERS DOOR OPEN CV1B OPEN PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 7 HEAT RV 4 25 PSI EXCHANGER 3 PSI FILTER RESERVOIR 5-47 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 230: 6500/6550 Close Door

    RV 5 2500 PSI 5.1 GPM @ 2000 RPM 6.2 GPM @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 7 25 PSI HEAT RV 4 EXCHANGER 3 PSI FILTER RESERVOIR 5-48 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 231: 6500/6550 Right Turn

    550 PSI CYLINDER 3.9 GPM @ 2000 RPM 4.7 GPM @ PRESSURE 2400 RPM RETURN SUCTION ACCESSORY PUMP STRAINER RV 7 HEAT 25 PSI RV 4 EXCHANGER 3 PSI FILTER RESERVOIR 5-49 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 232: 6500/6550 Left Turn

    550 PSI CYLINDER 3.9 GPM @ 2000 RPM 4.7 GPM @ PRESSURE 2400 RPM RETURN SUCTION ACCESSORY PUMP STRAINER RV 7 HEAT 25 PSI RV 4 EXCHANGER 3 PSI FILTER RESERVOIR 5-50 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 233: Information

    Char-Lynn ® No. 7-118 May, 1999 Disc Valve Motor Repair Information 4000 Series ® Geroler Motors -004 -006 Std., Whl. and Brgl. Std. and Whl. Home Find... Go To..
  • Page 234 4000 Series Char-Lynn Motors Shuttle (Two Way) Balance Check Plug Assembly Spring Plug Ring Valve Assembly Plug Poppet Outer Valve Assembly Spring Spring Plug Assembly Face Seal Spring Seal Valve Sleeve, Dash Pot Plate Plug Ball Piston Shuttle Seal Sleeve, Dash Pot Housing, Bearing Drive Plug...
  • Page 235 4000 Series Char-Lynn Motors Tools Wheel motor and bearingless motor repair information on page 9 and 10. Shuttle valve and seal guard repair information on page 10. Seal guard reference on page 10. Tools required for disassembly and reassembly — Torque wrench (68 Nm [600 lb-in] capacity) —...
  • Page 236 4000 Series Char-Lynn Motors Disassembly Cleanliness is extremely important when repairing a hydraulic motor. 3 Lift valve housing straight up. If done carefully, the springs and Work in a clean area. Before disconnecting the lines, clean port area of balance ring subassembly will remain on valve for easy removal. motor thoroughly.
  • Page 237 4000 Series Char-Lynn Motors Disassembly Valve Drive Valve Seal Plate Seal Figure 7 Figure 5 16 Use a stud remover or vise grips to remove studs (earlier models only). Clamp bearing housing in vise as shown in Figure 7. Loosen 8 9 Remove valve plate.
  • Page 238 4000 Series Char-Lynn Motors Disassembly 18 Remove shaft and bearing assembly. You may need a press to Shaft Face Seal Shaft and remove shaft and bearing assembly (see Figure 10). Bearing Assembly 19 Remove shaft face seal from bore of bearing housing (see Figure 10).
  • Page 239 4000 Series Char-Lynn Motors Reassembly 23 Apply petroleum jelly to 88,6 [3.49] ID seal. Install seal in seal 29 Pour a small amount of light oil inside the output shaft. groove of bearing housing (see Figure 13). 30 Apply a light film of petroleum jelly on 88,6 mm [3.49 inch] I.D. 24 Use a small press, if available, to install dust seal in retainer.
  • Page 240 4000 Series Char-Lynn Motors Reassembly 41 Apply a light film of petroleum jelly on 82,3 mm [3.24 inch] I.D. 36 Apply a light film of petroleum jelly on 88,6 mm [3.49 inch] I.D. seal. Install seal in outside seal groove of valve housing. seal.
  • Page 241 4000 Series Char-Lynn Motors Reassembly 44 Insert your finger through port of housing. Apply pressure to side 45 Install and finger tighten 2 bolts (or studs for earlier models) of balance ring assembly. Hold ring in position until valve housing is opposite alignment studs.
  • Page 242 4000 Series Char-Lynn Motors Reassembly Important: This motor requires Loctite in threaded holes of mounting flange. Follow these procedures: Attention: Adequate Loctite penetration and sealing depend highly on cleanliness Do not use and dryness of threads. Use a non-petroleum base solvent to clean more than excess oil from threads of flange after disassembly.
  • Page 243 4000 Series Char-Lynn Motors How to Order Replacement Parts Date Code Char-Lynn ® 00 0 Each Order Must Include the Following: Product number 1. Product Number 4. Part Number 2. Date Code 5. Quantity of Parts Week of Last 3. Part Name Year 01 Number Eaton Corp.
  • Page 244 Disc Valve Motors 4000 Series Motors Eaton Corporation Eaton Ltd. Eaton B.V. Sumitomo Eaton Hydraulic Co. Hydraulics Division Hydraulics Division Boeing Avenue 11 8 Temasek Blvd. 15151 Hwy. 5 Glenrothes, Fife 1119 PC Schiphol-Rijk 42-01 Suntec Tower Three Eden Prairie, MN 55344 Scotland, KY7 4NW The Netherlands Singapore 03988...
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  • Page 273 No. 7-623 Eaton ® July,1995 Medium Duty Piston Pump Repair Information Model 70142 / 70144, 20.3 cm /r [1.24 in /r] Displacement and 70145, 23.6 cm /r [1.44 in /r] Displacement Variable Displacement Piston Pump 01 02 design code Valve Plate with Home Find...
  • Page 274 Model 70142 / 70144 and 70145 Introduction Table of Contents Introduction ....................... Identification ...................... Required Tools ....................Exploded View Drawing ..................4 & 5 Parts List ......................6 & 7 Disassembly and Inspection ................Reassembly ....................... Appendix A: ....................... Appendix B: ....................... Fault-Logic Trouble Shooting ................

  • Page 275: Identification

    Model 70142 / 70144 and 70145 Identification and Tools Required Identification Numbers Stamped on each unit. B - Rotation, A - Product Number Discription R = Righthand, 70142 = Piston Pump with Gerotor (20.3 cm /r [1.24 in /r]) L = Lefthand 70144 = Piston Pump without Gerotor (20.3 cm...
  • Page 276 Model 70142 / 70144 and 70145 Parts Drawing - Figure 1-1 51-1 Date Code and Assembly Number Location 50-1 Left Side Right Side Shaft assembly for single pump or front pump of tandem. Shaft assembly for rear pump of tandem. Home Find...
  • Page 277 Model 70142 / 70144 and 70145 49-1 49-2 K2-4 49-3 49-4 49-5 K2-3 K1-1 19-1 (K2-2) K2-3 design code K2-2 (K2-1) 19-1 K4-3 (K3-3) K4-2 (K4-4) (K4-1) design code Groove (K3-2) 34-1 (K3-1) 49-1 49-2 49-3 49-4 49-5 19-1 design code 19-1 Home Find...

  • Page 278: Parts List

    Model 70142 / 70144 and 70145 Parts List Item Qty. Description Drive Shaft Backplate Assembly Housing Assembly Rotating Kit Assembly Camplate Washer Retaining Ring Retaining Ring Thrust Bearing Bearing Race + 11 Shaft Seal, Drive + 12 Housing Gasket Needle Bearing + 14 O-ring, 3.175 mm Dia.
  • Page 279 Model 70142 / 70144 and 70145 Parts List Item Qty. Description Dump Valve sub-assembly + 49-1 Retaining Ring 49-2 Separator Plug 49-3 Separator + 49-4 O-ring, 1.59 mm Dia. x 9.53 mm I.D. [.0625 in. Dia. x .375 in. I.D.] + 49-5 O-ring, 2.46 mm Dia.
  • Page 280 Model 70142 / 70144 and 70145 Disassembly Disassembly Remove housing gasket from housing or backplate. The following instructions apply to a variable displacement piston pump with or without a gerotor charge pump. A tandem To remove rotating kit assembly from housing, first pump assembly should be separated into individual pumps remove pump from vise holding the rotating kit assembly in before disassembly.

  • Page 281: Reassembly

    Model 70142 / 70144 and 70145 Reassembly Reassembly 13 Apply a small amount of petroleum jelly to the steel side of All parts should be cleaned and critical moving parts valve plate to hold in place for installation. Aligning the index lubricated before reassembly.
  • Page 282 Model 70142 and 70145 Appendix A - Charge Pump Adapter Assembly Configuration for 13.8 to 17.2 bar [200 to 250 lbf/in ] or 36-4a 17.2 to 20.7 bar [250 to 300 lbf/in Charge Relief Valve 36-3a or 3b 36-2a Pressure Check Port or Remote Charge Port 36-4 36-3...
  • Page 283 Model 70142 / 70144 and 70145 Appendix B - Rotating Kit Assembly Item Qty. Description Piston assemblies Spider Spider Pivot Retainer Piston Block Pins Washer Spring Retaining Ring The following parts are required to disassemble the piston block: 2 ea. 5/16 in.

  • Page 284: Fault-Logic Trouble Shooting

    Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Explanatory Diagram This fault - logic trouble shooting guide is a diagnostic aid in Symptom: locating transmission problems. Action Match the transmission symptoms with the problem statements Step and follow the action steps shown in the box diagrams. This will give expedient aid in correcting minor problems eliminating Comment Inspect...
  • Page 285 Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Symptom: Neutral Difficult or Impossible to Find Inspect Inspect External Control Servo Control Linkage (If used) Defective Defective Repair Repair Replace Replace Symptom: System Operating Hot Inspect Heat Check Inspect Check Exchanger...
  • Page 286 Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Symptom: Operates in One Diection Only Inspect Inspect Inspect External Control Servo Control System Relief Linkage (If used) Valves Defective Defective Defective Repair Repair Repair Replace Replace Replace Symptom: System Response Sluggish Check Inspect Inspect...
  • Page 287 Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Symptom: System Will Not Operate In Either Direction Inspect Check Check External Check Dump Valve Oil Level in Control Charge Reservoir Linkage (If used) Pressure Below Level Defective Defective Fill to Repair Repair...
  • Page 288 Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Diagram Action Step Comments Inspect External Control Linkage for: 11 Inspect Charge Relief Valve for: a. misadjusted or disconnected a. improper charge relief pressure setting * b. binding, bent, or broken b.

  • Page 289: Start-Up Procedure

    Model 70142 / 70144 and 70145 Start-up Procedure When initially starting a new or a rebuilt transmission system, it After the system starts to show signs of fill, slowly move is extremely important that the start-up procedure be followed. pump camplate to a slight cam angle. Continue to operate It prevents the chance of damaging the unit which might occur system slowly with no load on motors until system responds if the system was not properly purged of air before start-up.
  • Page 290 Model 70142 / 70144 and 70145 Notes Home Find... Go To..
  • Page 291 Model 70142 / 70144 and 70145 Notes Home Find... Go To..
  • Page 292 Order parts from number 6-632 Parts Information booklet. Each order must include the following information. 1. Product and/or Part Number 2. Serial Code Number 3. Part Name 4. Quantity Eaton Corporation Eaton Ltd. Hydraulics Division Hydraulics Division 15151 Hwy. 5 Glenrothes, Fife Eden Prairie, MN 55344 Scotland, KY7 4NW...
  • Page 293 ..6-33 TO REMOVE ENGINE ..6-34 TO INSTALL ENGINE ... 6-36 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 294 ENGINE - - G/LPG 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 295: Lubrication

    Use 10W30 SAE--SG/SH rated engine oil. Fill the engine with oil to the level indicated on the oil dipstick. The engine oil capacity is 4.7 L (5.0 qt) including the oil filter. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 296: Cooling System

    FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. Flush the radiator and the cooling system every 800 hours of operation, using a dependable cleaning compound. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 297: Engine Fan Belt

    Machines with the heavy duty air filter option have a safety element. It is inside the standard element. Replace this element, do not clean it, after the regular element has been damaged or cleaned three times. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 298: To Replace Air Filter Element

    11. Install the dust cap with the arrows pointing up. Tighten the clamp ring to hold it in place. Check all intake hose connections for leaks or abrasions. 12. Reset the air filter restriction indicator. 13. Close the access doors. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 299: Fuel System -- Gasoline

    Increase the engine speed by turning the screw clockwise. Decrease the engine speed by turning the screw counter--clockwise. Idle speed is 1350 + 250 rpm with no power to the electronic governor. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 300: Fuel System -- Lpg

    Never operate an LPG powered machine if the LPG fuel system is leaking, or if any component in the fuel system is malfunctioning. Operating the machine under either of these conditions may cause a fire or explosion. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 301: Lp Fuel Tanks

    The following specific checks must also be made: Filler Valve -- Check the valve for proper functioning and the presence of the handwheel. Valve must be closed except during filling. 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 302 Do not tamper with the relief valve setting. Magnetic Liquid Level Gauge -- Check the operation against the maximum filling point as determined by weight. 6-10 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 303 Changing the tank is a chance for the machine operator to carefully check over the tank, fittings, and the fuel lines and fittings. If abnormal wear is detected, report the findings to the appropriate personnel. 6-11 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 304: To Change An Lpg Fuel Tank

    Close the service valve immediately if an LPG leak is found, and tell the appropriate personnel. 14. If no leaks are found, the engine is ready to start. 6-12 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 305: Fuel Filter Lock

    The engine oil pressure switch requires no regular maintenance. Never bypass the oil pressure switch. The switch is a safety feature that prevents LPG fuel from flowing when the engine is not operating properly. 6-13 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 306: Lpg Fuel Troubleshooting

    400 hours there after. See Ford VSG 413 Engine Service Manual. CRANKCASE VENTILATION SYSTEM Clean the crankcase ventilation hoses, tubes, and fittings and replace the PCV valve every 400 hours of operation. 6-14 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 307: Governor Troubleshooting6-15

    They are the Yellow Wire #71 and the Yellow Wire #72. To test this, use the governor test harness (TENNANT Part No. 66137). Once the harness is in place, use a tach/dwell meter to test for the proper RPM’s and a flat ignition signal.
  • Page 308 RPM’s depending on where you have the speed control switch set After you have verified that the ignition system and the fuel system are not at fault, go to the next step. 6-16 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 309 Low = 0VDC Panel (85/BLU) (H) Speed ELECTRONIC GOVERNOR WIRING PICTORIAL TO: HARNESS TO: GOVERNOR TEST PLUG NOTE: The wire colors of the test harness do not necessarily match the machine harness. 6-17 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 310 IT IS RARE TO HAVE A FAULTY CONTROL BOX, so proceed with the following voltage checks BEFORE REPLACING IT. 6-18 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 311 Pin G -- < 1 VDC Pin H -- 7 to 9 VDC Throttle control switch in the Litter sweep position: Pin G -- < 1 VDC Pin H -- < 1 VDC 6-19 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 312 Throttle control switch in the litter sweep position: Pin C -- 1200 ¦ 25 RPM Pin D -- 1200 ¦ 25 RPM Pin E -- Battery Voltage ¦ .2 Pin F -- 7 to 7.5 VAC 6-20 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 313 Hunts at running speed with the accessories off. b. Responds very sluggishly to switch changes, an adjustment change in the control box may be necessary. 6-21 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 314 RTV to keep dust and moisture out of the box. FOR DIGITAL CONTROLLER: See TO ADJUST GOVERNOR CONTROL BOX section of this manual. 6-22 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 315: Governor

    Repeat until surges do not occur. Replace hole plug if removed for adjustment. 6. FOR DIGITALCONTROLLER: Follow the instructions on the Digital Controller SetUp diagram. 7. Remove the jack stands and lower the machine. 6-23 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 316: Digital Controller Set--Up

    ENGINE - - G/LPG DIGITAL CONTROLLER SET-- UP 6-24 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 317: Ignition System

    4. Clean the spark plug seat in the cylinder head. 5. Use a new seat gasket and screw the plug in by hand. 6. Tighten the spark plugs with a socket wrench of the correct size. 6-25 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 318: Ford Distributorless Ignition System

    Minimum --39_ C 38_ F Maximum 112_ C 232_ F When the engine is starting, at 250 RPM or less, the timing is set at 10_ before top dead center (BTDC). 6-26 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 319: Run Mode

    UESC and vacuum inlet. The diaphragm should hold the pressure. If it fails, replace UESC unit. To test the sensors and wiring harness, follow the direction on the next three pages. 6-27 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 320: Failure Mode Of Dis" Ignition Harness

    10,000 rpm. If the acc. are on when the lead becomes intermittent, the engine will not develop enough power to overspeed excessively. 6-28 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 321: Ford Dis Ignition

    (Phase 850A Distributorless Ohms Ignition Coil 852A (Phase 72 Gray Remove the coil connector and probe 12.6 the center female terminal Volts + D.C. --- To Pin #9 FORD DIS IGNITION 6-29 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 322 158,000 168,000 95,000 105,000 58,750 68,750 37,300 47,300 24,270 34,270 16,150 26,150 10,970 20,970 7,600 17,600 5,360 15,360 3,840 13,840 2,800 12,800 2,070 12,070 1,550 11,550 1,180 11,180 10,930 10,701 10,550 6-30 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 323: To Replace Alternator

    Reinstall the M8 hex bolt, ground cable, and nyloc nut. Leave it loose for now. 10. Place the V--belt back on the alternator pulley. 6-31 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 324 13. Reconnect the wires to the back of alternator. See the schematic in the ELECTRICAL section. 14. Reconnect the battery cables and start the engine. Check the new alternator for proper operation. 6-32 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 325: To Replace Starter

    7. Reconnect the wires to the back of the starter. See the schematic in the ELECTRICAL section. 8. Reconnect the battery cables and start the engine. Check the starter for proper operation. 6-33 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 326: To Remove Engine

    12. Disconnect the wire harness from the alternator, starter, oil sender, temp. sender, governor, mag. pick--up, ect. Move the wires out of the way for engine removal. 13. Disconnect the engine ground strap from the machine frame. 6-34 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 327 20. The engine can now be carefully lifted out. NOTE: Make sure the engine is clear of any wires or hoses before you lift it out of the frame. 6-35 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 328: To Install Engine

    (50 -- 60 ft lb). 9. Reconnect the ground cable from the bellhousing to the machine frame. 10. Reinstall exhaust pipe back on the engine manifold. Reinstall the muffler clamp and hand tighten tight. 6-36 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 329 FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 22. Start the engine and check for any leaks and proper operation. 6-37 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 330 ENGINE - - G/LPG 6-38 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 331 ..7-16 TO REMOVE ENGINE ..7-17 TO INSTALL ENGINE ... 7-19 6500/6550 330275 (5- -02) Home Find... Go To..
  • Page 332 ENGINE - - D 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 333: Lubrication

    The following recommended oil grades are for use in engines during changing seasonal temperatures: SINGLE AND MULTI- -VISCOSITY OILS Below 32_F 32_ to 77_ F Above 77_ F (Below 0_ C) (0_ to 25_ C) (Above 25_ C) 10W30 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 334: Cooling System

    10 kg (22 lb) applied at the mid-point of the longest span. Check and adjust the belt tension every 100 hours of operation. WARNING: Moving belt and fan. Keep away. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 335: Air Intake System

    Service the air filter element only when the air filter indicator shows restriction in the air intake system. Do not remove the air filter element unless it is restricting air flow. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 336: To Replace Air Filter Element

    The slightest rupture requires replacement of the filter. Clean and inspect the seals on the ends of the element. They should be unbroken and flexible. Remember to replace the element after cleaning it three times. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 337: Cylinder Head

    400 hours of operation. See Kubota Diesel Engine Workshop Manual for 78.4 mm Stroke Series. CRANKCASE VENTILATION SYSTEM See Kubota Diesel Engine Workshop Manual for 78.4 mm Stroke Series. 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 338: Governor

    Repeat until surges do not occur. Replace hole plug if removed for adjustment. 6. FOR DIGITAL CONTROLLER: Follow the instructions on the Digital Controller SetUp diagram. 7. Remove the jack stands and lower the machine. 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 339: Digital Controller Set--Up

    ENGINE - - D DIGITAL CONTROLLER SET-- UP 6500/6550 330275 (5- -02) Home Find... Go To..

  • Page 340: To Adjust Transducer

    4. Slowly turn the engine over to make sure the flywheel does not hit the transducer (mag pickup). 5. If it hits, turn the transducer (mag pickup) out 1/4 more and repeat step 4. 7-10 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 341: To Adjust Throttle Linkage

    2 turns (.071 in.) to provide fuel shut--off pre--load. 8. Reconnect the ball joint to the diesel throttle block rod and tighten the nut. 7-11 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 342: Fuel System -- Diesel

    3. Lubricate the o-ring of the new filter cartridge and spin it onto the filter head. 4. Bleed the fuel lines of air as described in TO PRIME FUEL SYSTEM instructions. 7-12 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 343: Fuel Lines

    4. Close the air vent and shut off the engine. 5. Clean up any fuel that was spilled during the bleeding process. 7-13 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 344: To Replace Alternator

    Reinstall the M8 hex bolt, ground cable, and nyloc nut. Leave it loose for now. 10. Place the V--belt back on the alternator pulley. 7-14 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 345 13. Reconnect the wires to the back of alternator. See the schematic in the ELECTRICAL section. 14. Reconnect the battery cables and start the engine. Check the new alternator for proper operation. 7-15 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 346: To Replace Starter

    7. Reconnect the wires to the back of the starter. See the schematic in the ELECTRICAL section. 8. Reconnect the battery cables and start the engine. Check the starter for proper operation. 7-16 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 347: To Remove Engine

    12. Disconnect the wire harness from the alternator, starter, oil sender, temp. sender, governor, mag. pick--up, ect. Move the wires out of the way for engine removal. 13. Disconnect the engine ground strap from the machine frame. 7-17 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 348 20. The engine can now be carefully lifted out. NOTE: Make sure the engine is clear of any wires or hoses before you lift it out of the frame. 7-18 6500/6550 330275 (6- -98) Home Find... Go To..

  • Page 349: To Install Engine

    (50 -- 60 ft lb). 9. Reconnect the ground cable from the bellhousing to the machine frame. 10. Reinstall exhaust pipe back on the engine manifold. Reinstall the muffler clamp and hand tighten tight. 7-19 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 350 FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 21. Start the engine and check for any leaks and proper operation. 7-20 6500/6550 330275 (6- -98) Home Find... Go To..
  • Page 351 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 352 Home Find... Go To..
  • Page 353 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 354 Home Find... Go To..

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