Tennant 6400E Service Manual
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Tennant 6400E Service Manual

Tennant 6400E Service Manual

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6400E
Service Manual
MM434
Rev. 02 (11- -01)

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Summary of Contents for Tennant 6400E

  • Page 1 6400E Service Manual MM434 Rev. 02 (11- -01)
  • Page 2 Electrical: Battery maintenance and replacement, instrument panel replacement, and electrical troubleshooting. Hydraulics: Valve replacement/repair, motor replacement/repair, cylinder replacement/repair, pump replacement/repair, filter replacement, and hydraulics troubleshooting. Manual Number -- MM434 Revision: 02 Published: 11--01 Copyright E 1999, 2001 TENNANT, Printed in U.S.A.

  • Page 3: Table Of Contents

    ... 1--14 HYDRAULIC O--RING FITTING TORQUE CHART ....1--14 MACHINE TROUBLESHOOTING ..1--15 6400E MM434 (11- -01)
  • Page 4 GENERAL INFORMATION 6400E MM434 (11- -01)

  • Page 5: Safety Precautions

    - - Avoid contact with battery acid. - - Use cardboard to locate leaking FOR SAFETY: hydraulic fluid under pressure. - - Use Tennant supplied or equivalent 1. Do not operate machine: replacement parts. - - Unless trained and authorized.
  • Page 6 FAN AND BELT LABEL - - LOCATED ON THE VACUUM FAN HOUSING AND BELT SHROUD. 350158 HOPPER SUPPORT LABEL - - LOCATED ON HOPPER LIFT ARMS LABEL - - LOCATED ON BOTH LIFT ARMS AND THE HOPPER BOTH LIFT ARMS. SUPPORT BAR. 6400E MM434 (7- -99)

  • Page 7: Specifications

    (93 in) Minimum turning radius, right 1490 mm (58.7 in) Minimum turning radius, left 1135 mm (44.7 in) Maximum rated incline with empty hopper 10_ / 17.6% Maximum rated incline with full hopper 8_ / 14.1% 6400E MM434 (11- -01)

  • Page 8: Power Type

    Utilizes service brakes, cable actuated TIRES Location Type Size Front (2) Solid 406 x 89 x 308 (16 x 3 1/2 x 12 1/8) Rear (1) Solid 406 x 102 x 308 (16 x 4 x 12 1/8) 6400E MM434 (7- -99)

  • Page 9: Machine Dimensions

    1230 mm 1395 mm (48.4 in) (55 in) 2260 mm (89 in) TOP VIEW 2085 mm (82 in) 1435 mm (56.5) 1135 mm 1135 mm (44.7 in) (44.7 in) SIDE VIEW FRONT VIEW 350158--- 350165 MACHINE DIMENSIONS 6400E MM434 (11- -01)

  • Page 10: Maintenance

    Main brush Check for damage or wear Check brush pattern Side brush Check for damage or wear Check brush pattern Hopper dust filter Shake 50 Hours Main brush Rotate end-for-end Batteries Check electrolyte level 6 (2) 6400E MM434 (7- -99)
  • Page 11 Tennant or approved hydraulic fluid . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) NOTE: Also check procedures indicated (H) after the first 50 hours of operation. NOTE: More frequent intervals may be required in extremely dusty conditions.

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

    FOR SAFETY: When loading machine onto truck or trailer, use winch. 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 6400E MM434 (11- -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. 6400E MM434 (11- -01) 1-11...

  • Page 14: Machine Jacking

    STORING MACHINE Before storing the machine for an extended period of time, the machine needs to be prepped to lessen the chance of rust, sludge, and other undesirable deposits from forming. Contact TENNANT service personnel. 1-12 6400E MM434 (11- -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

    (81 Nm) (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 6400E MM434 (7- -99)

  • Page 17: Machine Troubleshooting

    Hopper full Empty hopper 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 Recirculation flap damaged Replace flap 6400E MM434 (7- -99) 1-15...
  • Page 18 GENERAL INFORMATION 1-16 6400E MM434 (7- -99)
  • Page 19 ....2--17 TO INSTALL PROPELLING GEARBOX ....2--20 HURTH GEARBOX REPAIR MANUAL 2--23 6400E MM434 (7- -99)
  • Page 20 CHASSIS 6400E MM434 (7- -99)

  • Page 21: Introduction

    CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat, steering, brakes and tires. 6400E MM434 (7- -99)

  • Page 22: To Replace Operator Seat

    Machine And Remove Key. 1. Tilt the seat shroud back against the support cable. 2. Remove the four hex nuts holding the seat brackets to the seat shroud. 3. Remove the seat assembly from the seat shroud. 6400E MM434 (7- -99)
  • Page 23 Line up the holes and install the hardware. Tighten the hex screws to 18.5 -- 24Nm (15 -- 20 ft lb). 7. Close the seat shroud and adjust the seat to a comfortable position. 6400E MM434 (7- -99)

  • Page 24: To Adjust Seat Position

    The static drag chain prevents build up of static electricity in the machine. The chain is attached near the rear of the brush compartment skirts. The chain should be in contact with the floor at all times. 6400E MM434 (7- -99)

  • Page 25: Front Tires And Wheels

    2. Jack up one front corner of the machine. Place jack stands under machine frame. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 6400E MM434 (7- -99)
  • Page 26 8. Slide the flat washer and nut on the shaft. 9. Tighten the nut with a hand wrench until the wheel binds, then back the nut off to nearest cotter pin hole. 10. Insert a new cotter pin through nut and hole. 6400E MM434 (7- -99)
  • Page 27 CHASSIS 11. After making sure the wheel spins freely, carefully reinstall the hub cap. 12. Remove the jackstands and lower the machine. 13. Repeat the procedure on the other wheel. 6400E MM434 (7- -99)

  • Page 28: Brakes And Tires

    2. Jack up one front corner of the machine. Place jack stands under machine frame. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 2-10 6400E MM434 (7- -99)
  • Page 29 Remove the old brake shoes. 7. Replace the old brake shoes with new brake shoes. 8. Reinstall the one large ”C” shaped brake tension spring on the new brake shoes. 9. Slide the wheel back on the axle. 2-11 6400E MM434 (7- -99)
  • Page 30 12. Insert a new cotter pin through nut and hole. 13. After making sure the wheel spins freely, carefully reinstall the hub cap. 14. Remove the jackstands and lower the machine. 15. Repeat the procedure on the other wheel. 2-12 6400E MM434 (7- -99)

  • Page 31: Parking Brake

    See TO ADJUST BRAKES instructions. Adjust the parking brake so it will hold the Machine on a smooth 8 degree incline. The brake pedal should not travel more than 2 inches to fully engage the brakes. 2-13 6400E MM434 (7- -99)

  • Page 32: To Adjust Brakes

    Jack machine up at designated locations only. Block machine up with jack stands. 3. Remove the cotter pin and the clevis pin holding the brake rod clevis to the brake assembly lever. 2-14 6400E MM434 (7- -99)
  • Page 33 6. Reinstall the cotter pin and the clevis pin in the brake rod clevis and the brake assembly lever. 7. Repeat the procedure on both sides. 8. Drive the machine and operate the brakes. Check for equal engagement of the brakes on both wheels. 2-15 6400E MM434 (7- -99)

  • Page 34: Propelling Gearbox

    The bearing cavity is full when grease comes out of the top seal. Lubricate with Lubriplate EMB grease (Tennant part number 01433--1) after every 200 hours of machine operation, or after steam cleaning the gearbox area.

  • Page 35: To Remove Propelling Gearbox

    2. Remove the rear tire and wheel assembly. 3. Remove the drain plug from the bottom of the gear box to drain the gear lube. Reinstall the plug after all the lube has been drained. 2-17 6400E MM434 (7- -99)
  • Page 36 7. Mark the location of the steering cylinder mount ring in relation to the gearbox. Remove the seven hex screws holding the steering cylinder mount ring to the top of the propelling gearbox. 2-18 6400E MM434 (7- -99)
  • Page 37 11. Drop the gearbox down and out of the machine. NOTE: Make sure to support the top of the propelling gear box when removing it from the machine to keep it from tipping over. 2-19 6400E MM434 (7- -99)

  • Page 38: To Install Propelling Gearbox

    242 blue loctite and tighten to 64 -- 83 Nm (50 -- 60 ft lb). NOTE: Make sure the gearbox is installed in the machine frame in the same orientation as it was removed. 2-20 6400E MM434 (7- -99)
  • Page 39 7. Go under the rear of the machine in back and reinstall the three hex screws that hold the drive motor to the gearbox. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 2-21 6400E MM434 (7- -99)
  • Page 40 Tighten the wheel nuts to 122 -- 150 Nm (90 -- 110 ft lb). 9. Remove the jack stands and lower the machine. 10. Reconnect the batteries. Start the machine and operate the propel circuit. Check for proper operation. 2-22 6400E MM434 (7- -99)
  • Page 63 BRUSH GUARD ....3--48 SIDE BRUSH PIVOT ....3--49 6400E MM434 (7- -99)
  • Page 64 SWEEPING 6400E MM434 (7- -99)

  • Page 65: 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. 6400E MM434 (7- -99)

  • Page 66: Debris Hopper

    Engage the support bar. 2. Remove the hopper level adjustment bolt, nut, and washers. 3. Cut the plastic ties holding the hopper harness to the main harness. 4. Unplug the hopper harness connectors from the main harness. 6400E MM434 (7- -99)
  • Page 67 NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 7. Disconnect the side brush lift cable at the hydraulic motor. 8. Remove the four hex screws holding the hopper bumper to the sides of the hopper. 6400E MM434 (7- -99)
  • Page 68 12. The hopper can now be pulled away from the machine. 13. Disconnect and plug the hydraulic hoses leading to the hopper dump door cylinder. 14. The hopper can now be removed from the machine. 6400E MM434 (7- -99)

  • Page 69: To Install Hopper

    3. Line up the holes in the hopper pivot bearing flanges with the holes in the hopper lift arms. Install the four hex screws and nyloc nuts. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 6400E MM434 (7- -99)
  • Page 70 7. Reconnect the side brush lift cable at the side brush assembly. 8. Reconnect the hopper harness to the main harness. 9. See the schematic in the ELECTRICAL section of this manual for proper harness connections. 6400E MM434 (7- -99)
  • Page 71 10. Reinstall the lip height adjustment bolt on the back of the hopper. 11. Start the machine and check for proper operation of hopper vacuum fan, dump door, side brush rotation and side brush up and down. 6400E MM434 (7- -99)

  • Page 72: To Adjust Hopper Lip Height

    2. Loosen the three hex screws holding the hopper bumper to the front of the hopper. 3. Adjust the hopper bumper so it is level with the machine frame. 4. Firmly tighten all of the hardware. 3-10 6400E MM434 (7- -99)

  • Page 73: Hopper Lift Arm

    Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Remove the debris hopper. See TO REMOVE HOPPER FROM MACHINE instructions. 4. Remove the cotter pins from the upper, hopper lift cylinder pin. 3-11 6400E MM434 (7- -99)
  • Page 74 Remove the pins and washers and remove the lift arm from the machine. 8. If the large self aligning bearing needs to be changed, remove retaining rings and press the old bearing out of the lift arm. 3-12 6400E MM434 (7- -99)

  • Page 75: To Install Hopper Lift Arm

    5. Align the hole in lift arm pin with the hole in the pin boss on the tower. Install the hex screws and tighten to 18 -- 24 Nm (13 -- 18 ft lb). 3-13 6400E MM434 (7- -99)
  • Page 76 6. Align the small fiberglide bearing in the lift arm cylinder lug with the hole in the clevis on the hopper lift cylinder. Reinstall the cylinder pin and cotter pins. 7. Reinstall the hopper assembly. See TO INSTALL HOPPER instructions. 3-14 6400E MM434 (7- -99)

  • Page 77: Hopper Dump Door

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 4. Disconnect the rod end of dump door cylinder from the bracket on the center of the dump door. 3-15 6400E MM434 (7- -99)
  • Page 78 7. Use a razer knife to remove the RTV from the two dump door pivot bolts on each side of the hopper. Remove the two hex screws. 8. Drop the dump door down and out of the hopper. 3-16 6400E MM434 (7- -99)

  • Page 79: To Install Hopper Dump Door

    4. Install the two hex screws and nuts. Hand tighten tight. 5. Put a small amount of RTV around the two hex screws. 6. Reinstall the seal on the front of the dump door. Hand tighten the five hex screws tight. 3-17 6400E MM434 (7- -99)
  • Page 80 9. Start the machine and open and close hopper door a few times. Check for proper operation. NOTE: Make sure the seals on the dump door are adjusted so they contact the inside wall of the hopper. 3-18 6400E MM434 (7- -99)

  • Page 81: Hopper Dust Filter

    Rinse the dust filter until it is clean. Air dry the wet dust filter; do not use compressed air. NOTE: Be sure the dust filter is completely dry before reinstalling it in the machine. 3-19 6400E MM434 (7- -99)

  • Page 82: To Replace Hopper Dust Filter

    Put the cleaned or new dust filter in the hopper insert with the arrows pointing up. 6. Lower the hopper cover support and close the hopper cover. Latch the hopper cover. 3-20 6400E MM434 (7- -99)

  • Page 83: Main Brush

    1. Stop the machine and set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Raise the main brush. 3. Open the right side main brush access door. 3-21 6400E MM434 (7- -99)
  • Page 84 8. Slide the main brush idler plate plug in the main brush. 9. Reinstall the attachment bolt. 10. Close the right side main brush access door. Check the main brush pattern. 3-22 6400E MM434 (7- -99)

  • Page 85: To Check And Adjust 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 and stop the main brush. 5. Drive the machine off the test area. 3-23 6400E MM434 (7- -99)
  • Page 86 A. Move the brush shaft bearing bracket up or down in the slots. B. Re- -check the main brush pattern and readjust as necessary. Then adjust the width of the main brush pattern. 3-24 6400E MM434 (7- -99)

  • Page 87: Main Brush Belts

    2. Stop the machine and set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Open the seat shroud. 4. Remove the belt guard. 3-25 6400E MM434 (7- -99)
  • Page 88 6. Open the LH brush door. 7. Remove the tension spring from the lower idler plate. 8. Remove the hex screw holding the lower idler plate to the brush shaft. 9. Remove the lower idler plate from the machine. 3-26 6400E MM434 (7- -99)
  • Page 89 Tighten the hex screw to 18 -- 24 Nm (15 -- 20 ft lb). 15. Position the new belt on the hydraulic pump sheave. 16. Reinstall the tension spring on the lower idler plate. 3-27 6400E MM434 (7- -99)
  • Page 90 8 mm (0.3 in) from a force of 2.3 kg (5 lb) at belt midpoint. Tighten the hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 18. Reinstall the belt guard. 19. Start the machine and check the main brush for proper operation. 3-28 6400E MM434 (7- -99)

  • Page 91: To Replace Main Brush Secondary Belt

    5. Loosen the hex screws holding the upper idler plate to the machine frame. Pull the idler plate back to remove tension on the primary belt. Remove the primary belt from the pump sheave groove. 3-29 6400E MM434 (7- -99)
  • Page 92 8. Remove the hex screw holding the lower idler plate to the brush shaft. 9. Remove the lower idler plate from the machine. 10. Remove the primary belt from the lower sheave groove. 3-30 6400E MM434 (7- -99)
  • Page 93 14. Reinstall the (hopper up) brush lift cable bracket to the brush arm. Tighten the two hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 15. Position the primary belt on the lower idler shaft sheave. 3-31 6400E MM434 (7- -99)
  • Page 94 2.3 kg (5 lb) at belt midpoint. Tighten the hex screw to 18 -- 24 Nm (15 -- 20 ft lb). 19. Reinstall the belt guard. 20. Start the machine and check the main brush for proper operation. 3-32 6400E MM434 (7- -99)

  • Page 95: To Adjust Main Brush Hopper Up Shut--Off Cable

    3. Check to see if the V--belt leading to the main brush drive pulley is disengaged. If the V--belt is loose the cable is adjusted properly. If the V--belt is tight the cable needs to be adjusted. 3-33 6400E MM434 (7- -99)
  • Page 96 7. Turn the cable clevis clockwise a few turns. 8. Reconnect the lift cable to the bracket. Check to see if the V--belt is now disengaged (loose). NOTE: Repeat steps 5 thru 7 if necessary. 3-34 6400E MM434 (7- -99)

  • Page 97: To Adjust Main Brush Raised Position Shut Off Bolt

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Shut off the machine and lower the main brush. 3. Open the left hand brush door. 3-35 6400E MM434 (7- -99)
  • Page 98 NOTE: If the main brush stops turning in the raised position- -- -the adjustment procedure is complete. If the main brush still turns after the lift lever is placed in the raised position- -- -repeat steps 5 and 6. 3-36 6400E MM434 (7- -99)

  • Page 99: To Replace Main Brush Idler Plug Bearing

    2. Remove the plastic cap from the idler plug. 3. Clean the area around where the cap was mounted in the idler plug. 4. Remove the M12 flat screw, nyloc hex nut, and washer holding the idler plug to the idler arm. 3-37 6400E MM434 (7- -99)
  • Page 100 9. Install the idler shaft in the new bearing. Tighten the four hex screws to 8--10 Nm (6--8 ft lb). 10. Position the idler plug on the idler arm shaft. Reinstall the long flat screw. Tighten to 68--81 Nm (50--60 ft lb). 3-38 6400E MM434 (7- -99)
  • Page 101 11. Put a small amount of RTV on the lip of the plastic cap and install in the end of the idler plug. 12. Reinstall the idler arm on the machine. 13. Operate the machine and check for proper operation. 3-39 6400E MM434 (7- -99)

  • Page 102: To Replace Main Brush Shaft Bearings

    3. Remove the large hex screw and nyloc nut holding the brush arm to the pivot bearings. 4. Let the brush arm drop down and out of the way. 3-40 6400E MM434 (7- -99)
  • Page 103 (15 -- 20 ft lb). 9. Reinstall the main brush motor plate and idler plate. 10. Check main brush pattern for taper and width. Adjust as necessary. See “TO CHECK AND ADJUST MAIN BRUSH PATTERN”. 3-41 6400E MM434 (7- -99)

  • Page 104: Side Brush

    1. Empty the debris hopper. 2. Set the machine parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Raise the side brush. 3-42 6400E MM434 (7- -99)
  • Page 105 6. Slide the new side brush on the side brush motor shaft. 7. Reinstall the side brush retaining pin through the side brush hub and shaft. 8. Secure the pin by clipping the pin keeper over the end of the pin. 3-43 6400E MM434 (7- -99)
  • Page 106 SWEEPING 9. Disengage the hopper support bar and lower the hopper. 10. Adjust the side brush pattern with the side brush down pressure lever. 3-44 6400E MM434 (7- -99)

  • Page 107: To Adjust Side Brush Pattern

    2. Turn the side brush lever clockwise to decrease side brush pattern. Turn the side brush lever counter--clockwise to increase side brush pattern. NOTE: One-half of the bristles should normally contact the floor. 3. Raise the side brush. 3-45 6400E MM434 (7- -99)

  • Page 108: To Adjust Side Brush Tilt Pattern

    2. Raise the hopper slightly and shut off the machine. 3. Loosen the two hex screws on the back of the hopper bumper near the side brush assembly. 4. Tilt the side brush in either direction. 3-46 6400E MM434 (7- -99)
  • Page 109 SWEEPING 5. Tighten the hardware firmly. 6. Lower the hopper. 7. Start the machine and turn on the side brush. Check the side brush pattern. 8. Raise the side brush. 3-47 6400E MM434 (7- -99)

  • Page 110: Side Brush Guard

    2. Remove the four bolts holding the side brush guard to the side brush motor. 3. Rotate or replace the side brush guard. 4. Reinstall the four bolts in the side brush motor and tighten to 22--27 Nm (16--20 ft lb). 3-48 6400E MM434 (7- -99)

  • Page 111: Side Brush Pivot

    Torque the front and rear compression springs to reduce excessive movement. The side brush tilt is adjusted with the side brush cable. Turn the clevis on the cable to get the desired side brush pattern. 3-49 6400E MM434 (7- -99)

  • Page 112: Skirts And Seals

    WARNING: Raised Hopper May Fall. Engage Hopper Support Bar. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 4. Remove the hopper lip retaining strip mounting hardware. 3-50 6400E MM434 (7- -99)
  • Page 113 6. Thread the retaining strip mounting bolts through the retaining strip, the new hopper lip, and the back-up strip. 7. Tighten the mounting hardware to 8--14 Nm (6--10 ft lb). 8. Start the machine and lower the hopper. 3-51 6400E MM434 (7- -99)

  • Page 114: Brush Door Skirts

    2. Stop the machine and set the machine parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Open the right hand brush door. 3-52 6400E MM434 (7- -99)
  • Page 115 9. Slide the brush door skirt up or down so it will clear the floor by 3--5 mm (0.12 to 0.25 in). Hand tighten the hex screws firmly. 10. Operate the machine and check the new skirt for proper operation. 3-53 6400E MM434 (7- -99)

  • Page 116: To Replace And Adjust Left Hand Brush Door Skirt

    Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Open the left hand brush door. 4. Remove the four hex screws holding the skirt mount plate to the machine. 5. Remove the brush skirt retaining bolts. 3-54 6400E MM434 (7- -99)
  • Page 117 11. Slide the brush door skirt up or down so it will clear the floor by 3--5 mm (0.12 to 0.25 in). Hand tighten the hex screws firmly. 12. Operate the machine and check the new skirts for proper operation. 3-55 6400E MM434 (7- -99)

  • Page 118: Right Brush Door Seal

    5 mm (0.25 in) in dusty conditions, and touch the floor otherwise. The deflector blade is spring loaded. Check the skirt and blade for wear or damage and adjustment daily. NOTE: Rear tire pressure will affect skirt clearances. 3-56 6400E MM434 (7- -99)

  • Page 119: To Replace And Adjust The Rear Skirt And Deflector Blade

    Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Open the main brush doors. 4. Remove the main brush. 5. Remove the retaining strip and floor skirt. Discard the old skirt. 3-57 6400E MM434 (7- -99)
  • Page 120 9. Tighten the rear floor skirt mounting bolts to 8--14 Nm (6--10 ft lb). up to 5 mm (up to 0.25 in) 10. Remove the brush contact blade retaining strip and the brush contact blade. Discard the old blade. 3-58 6400E MM434 (7- -99)
  • Page 121 13. Tighten the brush contact blade mounting bolts to 8--14 Nm (6--10 ft lb). 14. Reinstall the main brush. 15. Close the main brush doors. 16. Operate the machine and check for proper operation. 3-59 6400E MM434 (7- -99)

  • Page 122: Hopper Side Seals

    Check the seal for wear or damage every 100 hours of operation. You can reach the seal by lifting the hopper and engaging the prop arm. 3-60 6400E MM434 (7- -99)

  • Page 123: To Replace Hopper Side Seals

    5. Position the new skirt and existing retainer on the front of the machine frame. Secure with plastic push--in hardware. 6. Repeat on the other side of the main frame. 3-61 6400E MM434 (7- -99)

  • Page 124: Hopper Inspection Door Seal

    The hopper door seals are located on the hopper door. They seal the hopper when the hopper door is closed. Tighten hardware to 3--4 Nm (2.5--3.5 ft lb). Check the seals for wear or damage every 100 hours of operation. 3-62 6400E MM434 (7- -99)

  • Page 125: To Replace Hopper Dump Door Seals

    4. Remove the six hex screws holding the dump door seal, retainer, and sponge cord to dump door. Discard the old seal. 5. Remove the three hex screws holding each side seal to the dump door. Discard the old seals. 3-63 6400E MM434 (7- -99)
  • Page 126 Tighten to 3.3 -- 4.4 Nm (30 -- 39 In lb). Make sure the seals are lined up with edge of hopper when tightening. 8. Start machine and lower hopper. 9. Operate the machine and check the dump door for proper operation. 3-64 6400E MM434 (7- -99)

  • Page 127: Vacuum Fan

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Open the seat shroud. 4. Remove the vacuum hose connected to the vacuum fan assembly. 3-65 6400E MM434 (7- -99)
  • Page 128 7. Remove the tension spring from the frame bracket. 8. Remove the two hex screws holding the vacuum fan assembly to the frame mount bracket. 9. Remove the vacuum fan assembly from the machine. 3-66 6400E MM434 (7- -99)

  • Page 129: To Install Vacuum Fan Assembly

    4. Position the vacuum fan assembly in the machine. 5. Align the holes in vacuum fan mount bracket with the bracket on the machine. Reinstall the two hex screws and nuts. Tighten to 37 -- 48 Nm (27 -- 35 ft lb). 3-67 6400E MM434 (7- -99)
  • Page 130 8. Reinstall the belt guard. Tighten the hardware to 18 -- 24 Nm (15 -- 20 ft lb). 9. Reconnect the hose to the vacuum fan housing. 10. Start the machine and operate the vacuum fan. Check for proper operation. 3-68 6400E MM434 (7- -99)

  • Page 131: Vacuum Fan Belt

    2. Stop the machine and set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Open the seat shroud. 4. Remove the vacuum fan belt guard. 3-69 6400E MM434 (7- -99)
  • Page 132 Allow the tension spring to pull the vacuum fan assembly back up and tension the V--belt. 9. Reinstall the belt guard. 10. Start the machine and check the vacuum fan for proper operation. 3-70 6400E MM434 (7- -99)

  • Page 133: To Replace Vacuum Fan Impeller

    5. Hold the impeller from turning and remove the hex nut from the end of the fan impeller shaft. Pull the impeller straight off the shaft. NOTE: Make sure to retain the shaft key and spacer. 3-71 6400E MM434 (7- -99)
  • Page 134 9. Reinstall the fan housing on the fan assembly. 10. Reinstall the nine thread cutting screws in the fan housing. Hand tighten. 11. Reinstall the vacuum fan assembly in the machine. See TO INSTALL VACUUM FAN ASSEMBLY instructions in this section. 3-72 6400E MM434 (7- -99)

  • Page 135: To Replace Vacuum Fan Impeller Bearings

    5. Hold the impeller from turning and remove the hex nut from the end of the fan impeller shaft. Pull the impeller straight off the shaft. NOTE: Make sure to retain the shaft key and spacer. 3-73 6400E MM434 (7- -99)
  • Page 136 NOTE: Make sure to note the orientation of the bearings and impeller shaft in relation to the bearing housing. 9. Press two new bearings in the bearing housing. 3-74 6400E MM434 (7- -99)
  • Page 137 NOTE: Place a small amount of grease on the impeller shaft to ease installation. 13. Reinstall the fan impeller housing using the nine thread cutting screws. Tighten to 223 -- 290 Ncm (20 -- 25 in lb). 3-75 6400E MM434 (7- -99)
  • Page 138 Push the sheave all the way on and hand tighten the two set screws tight. 15. Reinstall the vacuum fan assembly in the machine. See TO INSTALL VACUUM FAN ASSEMBLY instructions in this section. 3-76 6400E MM434 (7- -99)

  • Page 139: To Tension Vacuum Fan Belt

    1.4 kg (3.0 lb). 2. Tighten or loosen the hex nut on the eye bolt that attaches the tension spring to the vacuum fan assembly. This will raise or lower the vacuum fan belt tension. 3-77 6400E MM434 (7- -99)

  • Page 140: Machine Troubleshooting

    Contact TENNANT service personnel Hopper full Empty hopper 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 3-78 6400E MM434 (7- -99)
  • Page 141 ....4--46 MAIN POWER AND HYDRAULIC PUMP CONTACTORS WILL NOT PULL IN ....4--47 6400E MM434 (11- -01)
  • Page 142 ELECTRICAL 6400E MM434 (7- -99)

  • Page 143: Introduction

    ELECTRICAL INTRODUCTION The machines electrical system consists of the batteries, instrument panel, drive motor, actuators, switches, relays, and circuit breakers. 6400E MM434 (7- -99)

  • Page 144: Electrical System

    If needed, add just enough distilled water to cover the plates. Never add acid to the batteries. Do not overfill. Always keep the battery caps on, except when adding water or taking hydrometer readings. 6400E MM434 (11- -01)
  • Page 145 NOTE: If the readings are taken when the battery electrolyte is any temperature other than shown, the reading must be temperature corrected. Add or subtract to the specific gravity reading 0.004, 4 points, for each 6_ C (10_ F) above or below 25_C. 6400E MM434 (11- -01)

  • Page 146: Charging The Batteries

    DO NOT OVERFILL. The batteries can overflow during charging due to expansion. NOTE: Make sure the battery caps are in place while charging. FOR SAFETY: When maintaining or servicing machine, avoid contact with battery acid. 6400E MM434 (11- -01)
  • Page 147 TENNANT charger, this indicates that something is wrong with the battery. The charger can not charge the battery when this happens. 8. The Tennant charger will start automatically. When the batteries are fully charged, the Tennant charger will automatically turn off.

  • Page 148: Battery Discharge Indicator

    Operate the machine a few minutes before reading the charge level of the batteries. NOTE: The battery discharge indicator will not reset from the flashing indicator unless the batteries have been fully charged. 6400E MM434 (11- -01)

  • Page 149: Thermo Sentryt

    Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the hopper cover and engage prop rod. 2. Locate the Thermo Sentryton the back of the filter shaker motor bracket. Unplug the two wires leading to the Thermo Sentryt. 6400E MM434 (7- -99)
  • Page 150 3. Remove the hex screws holding the Thermo Sentryt to the bracket. Remove from the hopper. 4. Install the new Thermo Sentryt on the bracket. Reinstall the hardware and tighten, 5. Reconnect the wires and close the hopper cover. 4-10 6400E MM434 (7- -99)

  • Page 151: To Replace Thermo Sentry Shut Off Solenoid

    2. Cut the plastic wire tie holding the Thermo Sentryt solenoid wire to the machine. Disconnect the Thermo Sentryt solenoid wire harness from hopper harness. 3. Remove the pin connecting the rod of the Thermo Sentryt solenoid to the lever. 4-11 6400E MM434 (7- -99)
  • Page 152 Remove the Thermo Sentryt solenoid from the machine. 5. Mount the new Thermo Sentryt solenoid on the bracket with existing hardware. 6. Reconnect the wires to the Thermo Sentryt solenoid. 7. Close the seat support. 4-12 6400E MM434 (7- -99)

  • Page 153: Instrument Panel

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the hopper and engage the support bar. 2. Open the seat support and disconnect the battery. 4-13 6400E MM434 (7- -99)
  • Page 154 7. Install the new light in the mount plate. Snap in place. 8. Reconnect the wires to the new light. See schematic in this section. 9. Position the mount plate back on the instrument panel. Reinstall the two nyloc nuts and tighten. 4-14 6400E MM434 (7- -99)
  • Page 155 ELECTRICAL 10. Reconnect the battery cables. 11. Close the seat support. 12. Start the machine and lower the hopper. Check the indicator lights for proper operation. 4-15 6400E MM434 (7- -99)

  • Page 156: Circuit Breakers

    Never substitute higher value fuses than specified. The fuses are located in the control box. Fuse Rating Circuit Protected FU-1 100 A Hydraulic pump motor FU-2 80 A Propelling 4-16 6400E MM434 (7- -99)

  • Page 157: To Replace Machine Circuit Breaker

    3. Locate the circuit breakers below the indicator light panel. 4. Use the electrical schematic in this section to locate the circuit breaker that needs to be replaced. 5. Disconnect the wires leading to the faulty circuit breaker. 4-17 6400E MM434 (7- -99)
  • Page 158 NOTE: The circuit breaker will only fit in the hole in one direction. 9. Plug the main harness wires into the new circuit breaker. See the schematic in this section. 10. Reconnect the battery cables. 4-18 6400E MM434 (7- -99)
  • Page 159 ELECTRICAL 11. Close the seat support. 12. Start the machine and lower the hopper. Check the new circuit breaker for proper operation. 4-19 6400E MM434 (7- -99)

  • Page 160: To Replace Filter Shaker Motor

    1. Open the hopper cover and engage the prop rod. 2. Locate the filter shaker motor on the top side of the filter shaker assembly. 3. Unplug the filter shaker motor from the hopper harness. 4-20 6400E MM434 (7- -99)
  • Page 161 Position the weight flush with the guard plate. 8. Install the new shaker motor on the assembly mount plate. Tighten the two hex screws to 18 -- 24 Nm (15 -- 20 ft lb). 4-21 6400E MM434 (7- -99)
  • Page 162 18 -- 24 Nm (15 -- 20 ft lb). 10. Plug the shaker motor into the hopper harness. 11. Test the shaker motor for proper operation. 12. Disengage the hopper cover prop rod and lower the cover. 4-22 6400E MM434 (7- -99)

  • Page 163: Directional Pedal

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the seat support and disconnect the batteries. 2. Remove the floor plate in the operators compartment. 4-23 6400E MM434 (7- -99)
  • Page 164 6. Remove the two hex screws holding the directional controller to the two mount brackets. Remove the directional controller from the machine. NOTE: Mark the orientation of the arm to the controller for proper re- -assembly. 4-24 6400E MM434 (7- -99)
  • Page 165 9. Position the new controller on the left hand mount bracket. Reinstall the two hex screws and nuts. Tighten to 8 -- 10 Nm (5 -- 6 ft lb). 10. Position the pedal, clevis pin, and cotter pin back on the mount brackets. 4-25 6400E MM434 (7- -99)
  • Page 166 (5 -- 6 ft lb). 12. Feed the controller wire harness back down under the floor plate and reconnect to the main harness. 13. Reconnect the batteries and operate the machine. Check the controller for proper operation. 4-26 6400E MM434 (7- -99)

  • Page 167: Rear Drive Motor

    1. Raise the rear of the machine and place jack stands under the machine frame. FOR SAFETY: When servicing machine, jack up machine at designated locations only. Block machine up with jack stands. 2. Remove the rear tire and wheel assembly. 4-27 6400E MM434 (7- -99)
  • Page 168 5. Remove the four power cables leading to the rear drive motor. 6. Mark the location of the drive motor in relation to the gearbox. Lift the drive motor up and out of the gearbox. Remove the drive motor from the machine. 4-28 6400E MM434 (7- -99)
  • Page 169 11. Reinstall the three hex screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 12. Reinstall the rear tire and wheel assembly. Tighten the wheel nuts to 122 -- 150 Nm (90 -- 110 ft lb). 4-29 6400E MM434 (7- -99)
  • Page 170 13. Reconnect the four power cables to the drive motor. See Power Cable drawing in this section. 14. Reconnect the batteries and close the seat support. 15. Lower the machine to the floor and operate the propelling. Check for proper operation. 4-30 6400E MM434 (7- -99)

  • Page 171: Main Accessories Motor

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the seat support and disconnect the batteries. 2. Remove the hose leading to the vacuum fan assembly. 4-31 6400E MM434 (7- -99)
  • Page 172 6. Loosen the two hex screws in the adjustment slots on the motor mount pivot. Let the pivot drop down and remove the V--belt from the motor sheave. 7. Disconnect the two electrical cables leading to the accessories motor. 4-32 6400E MM434 (7- -99)
  • Page 173 18 -- 24 Nm (15 -- 20 ft lb). 11. Use a straight edge to line up the sheave on the motor assembly with the sheave on the hydraulic pump. Tighten the two set screws firmly. 4-33 6400E MM434 (7- -99)
  • Page 174 Tighten the two hex screws to 18 -- 24 Nm (15 -- 20 ft lb). 16. Reinstall the vacuum fan V--belt tension spring to the vacuum fan and machine frame. 4-34 6400E MM434 (7- -99)
  • Page 175 See TO TENSION VACUUM FAN BELT in the sweeping section. 18. Reinstall the hose on the vacuum fan assembly. 19. Reconnect the batteries. Start the machine and check the new motor for proper operation. 4-35 6400E MM434 (7- -99)

  • Page 176: Electrical Schematic

    ELECTRICAL ELECTRICAL SCHEMATIC 4-36 6400E MM434 (11- -01)
  • Page 177 ELECTRICAL ELECTRICAL SCHEMATIC 4-37 6400E MM434 (11- -01)

  • Page 178: Wire Harness Group

    ELECTRICAL WIRE HARNESS GROUP 340 OR 425 AMP HOUR HEAVY DUTY BATTERIES---18 VOLTS (OPTION) ELECTRONIC CONTROL PANEL SEE DETAIL G MAIN HARNESS WIRE ASSY 340 OR 425 AMP HOUR HEAVY DUTY BATTERIES---18 VOLTS (OPTION) 4-38 6400E MM434 (11- -01)

  • Page 179: Control Panel Cable Group

    ELECTRICAL CONTROL PANEL CABLE GROUP 4-39 6400E MM434 (11- -01)

  • Page 180: Control Panel Wire Group

    ELECTRICAL CONTROL PANEL WIRE GROUP 4-40 6400E MM434 (11- -01)

  • Page 181: Wire Harness Group

    ELECTRICAL WIRE HARNESS GROUP 4-41 6400E MM434 (11- -01)
  • Page 182 ELECTRICAL WIRE HARNESS GROUP 4-42 6400E MM434 (11- -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. 6400E MM434 (7- -99) 4-43...

  • Page 184: 6400E Electrical Schematic

    ELECTRICAL 6400E ELECTRICAL SCHEMATIC (POWER- -ON / PROPEL CIRCUITS) 36 VOLT BATTERY PACKAGE 13/BLK 1/RED BATTERY BATTERY DISCONNECT DISCONNECT 100 AMP PUMP MOTOR 1C/RED PUMP MOTOR MTR 1 LOAD 70FLA DISCHARGE RESISTOR CB- -1 SOLENOID 15 AMP MAIN POWER CONTACTOR...

  • Page 185: Machine Will Not Propel

    MAKE SURE ANY OF THE TERMINALS VOLTAGE WHEN THE PEDAL IS IN THE ARE NOT SHORTED TO THE CASE NEUTRAL POSITION AND NEAR ZERO WHEN THE PEDAL IS FULLY FORWARD. REPLACE THE PROPEL MOTOR REPLACE THE PROPEL MOTOR CONTROLLER 6400E MM434 (7- -99) 4-45...

  • Page 186: 6400E Electrical Schematic

    ELECTRICAL 6400E ELECTRICAL SCHEMATIC (POWER- -ON / PROPEL CIRCUITS) 36 VOLT BATTERY PACKAGE 13/BLK 1/RED BATTERY BATTERY DISCONNECT DISCONNECT 100 AMP PUMP MOTOR 1C/RED PUMP MOTOR MTR 1 LOAD 70FLA DISCHARGE RESISTOR CB- -1 SOLENOID 15 AMP MAIN POWER CONTACTOR...

  • Page 187: Main Power And Hydraulic Pump Contactors Will Not Pull In

    SWITCH TO THE START POSITION, THEN DIRECTLY BACK TO THE RUN POSITION, IS THERE BATTERY VOLT- AGE BETWEEN 3/GRN AND ANY 13/BLK WIRE ? REPLACE DIODE D3 IF THE CONTACTORS STILL DO NOT PULL IN, REPLACE THE DEFECTIVE CONTACTOR 6400E MM434 (7- -99) 4-47...
  • Page 188 ELECTRICAL 4-48 6400E MM434 (7- -99)
  • Page 189 ....5--54 CHAR--LYNN HYDRAULIC MOTOR REPAIR INFORMATION ... 5--55 6400E MM434 (11- -01)

  • Page 190: Hydraulics

    HYDRAULICS 6400E MM434 (7- -99)
  • Page 191 HYDRAULICS INTRODUCTION The hydraulic system consists of the propel pump, accessory pump, control valve, drive motors, and vacuum fan motor. 6400E MM434 (7- -99)

  • Page 192: Hydraulic Fluid Reservoir

    The reservoir has a built-in strainer outlet that filters hydraulic fluid before it enters the system. Replace the strainer after every 800 hours of operation. 6400E MM434 (7- -99)

  • Page 193: 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 is one recommended fluid.

  • Page 194: To Fill Hydraulic Fluid Reservoir

    Always allow for expansion when filling the reservoir. 6. Put the reservoir breather-filler cap on the reservoir. 7. Start machine and operate all the hydraulic components. 8. Recheck the hydraulic fluid level. 9. Check for any leaks. 6400E MM434 (7- -99)

  • Page 195: To Replace Hydraulic Pump

    1. Open the seat support and disconnect the batteries. 2. Remove the pump/vacuum fan belt guard. 3. Push down on the vacuum fan assembly to release tension on the belt. Remove the V--belt from the large diameter sheave on the accessories motor. 6400E MM434 (7- -99)
  • Page 196 Let the pivot drop down and remove the V--belt from the large diameter sheave on the hydraulic pump. 7. Remove the four allen screws from the sheave on the hydraulic pump. Remove the sheave. 6400E MM434 (7- -99)
  • Page 197 Hand tighten the set screws tight. NOTE: Make sure the key is installed on the shaft of the new motor before installing sheave. 6400E MM434 (7- -99)
  • Page 198 Pull up on the motor mount pivot until the V--belt is tight. The proper tension is when the belt deflects 4mm (.15in) from a force of 2.5 Kg (5.5 lb) at belt midpoint. Tighten the two hex screws tight. 5-10 6400E MM434 (7- -99)
  • Page 199 Tighten the hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 19. Reinstall the pump/vacuum fan belt guard. 20. Start the machine and check the new hydraulic pump for proper operation. 5-11 6400E MM434 (7- -99)

  • Page 200: Hydraulic Pump Belt

    1. Open the seat support and disconnect the batteries. Remove the pump/vacuum fan belt guard. 2. Push down on the vacuum fan assembly to release tension on the belt. Remove the V--belt from the large diameter sheave on the accessories motor. 5-12 6400E MM434 (7- -99)
  • Page 201 V--belt is tight. The correct tension is when the belt at midpoint deflects 4 mm (0.15 in) from a force of 2.5 kg (5.5 lb). Tighten the two hex screws tight. 5-13 6400E MM434 (7- -99)
  • Page 202 2.3 kg (5 lb) at belt midpoint. Tighten the hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 10. Reinstall the pump/vacuum fan belt guard. 11. Start the machine and check the new hydraulic pump V--belt for proper operation. 5-14 6400E MM434 (7- -99)

  • Page 203: To Replace Hopper Lift Cylinder

    NOTE: Always observe hydraulic cleanliness requirements when opening hydraulic lines. 5. Remove the inside cotter pin from the upper clevis pin on the upper end of the hopper lift cylinder. Remove the clevis pin. 5-15 6400E MM434 (7- -99)
  • Page 204 9. Position the new cylinder in the machine with the rod end pointing to the front of the machine. 10. Align the bottom of the lift cylinder with the hole in the frame mount lug. Reinstall the clevis pin and cotter pin. 5-16 6400E MM434 (7- -99)
  • Page 205 12. Reconnect the hydraulic hoses to the new cylinder. See schematic in this section. 13. Start the machine and operate the hopper. Check for any leaks and proper operation. 5-17 6400E MM434 (7- -99)

  • Page 206: To Replace Hopper Dump Door Cylinder

    4. Disconnect and plug the two hoses leading to the hopper dump door cylinder. 5. Remove the cotter pin and clevis pin from the top of the dump door cylinder were it attaches to the center/rear of the debris hopper. 5-18 6400E MM434 (7- -99)
  • Page 207 8. Remove the fittings from the old cylinder and install in the new cylinder in the same orientation. 9. Position the new cylinder in the machine with the rod end pointing to the center of the dump door. 5-19 6400E MM434 (7- -99)
  • Page 208 12. Reconnect the hydraulic hoses to the dump door cylinder. See the schematic in this section. 13. Start the machine and open and close the hopper dump door. Check for any leaks and proper operation. 5-20 6400E MM434 (7- -99)

  • Page 209: To Replace Steering Cylinder

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 2. Open the seat support. 3. Turn the steering wheel all the way to the left. 5-21 6400E MM434 (7- -99)
  • Page 210 6. Disconnect and cap the two hydraulic hoses leading to the steering cylinder. NOTE: Always observe hydraulic cleanliness requirements when opening hydraulic lines. 7. Remove the steering cylinder from the machine. 5-22 6400E MM434 (7- -99)
  • Page 211 Install the drag link on the new cylinder in the same orientation. Tighten the jam nut. 11. Position the new steering cylinder assembly in the machine with the drag link pointing toward the rear of the machine. 5-23 6400E MM434 (7- -99)
  • Page 212 14. Reconnect the hydraulic hoses to the steering cylinder. See schematic in this section. NOTE: Always observe hydraulic cleanliness requirements when opening hydraulic lines. 15. Start machine and turn steering wheel in both directions. Observe the steering cylinder for any leaks. 5-24 6400E MM434 (7- -99)

  • Page 213: To Replace Steering Valve

    Machine And Remove Key. 2. Turn off the machine and engage the parking brake. Open the seat support. 3. Disconnect the battery. 4. Remove the rubber cap in the center of the steering wheel. Remove the large nut. 5-25 6400E MM434 (7- -99)
  • Page 214 NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 8. Remove the hex screws holding the hydraulic steering valve to the steering column. 9. The hydraulic steering valve can now be removed from machine. 5-26 6400E MM434 (7- -99)
  • Page 215 12. Reconnect the hydraulic hoses to hydraulic steering valve. See the schematic in this section. 13. Reinstall the steering wheel on the steering column. Tighten the wheel nut to 18 -- 24 Nm (15 -- 20 ft lb). 5-27 6400E MM434 (7- -99)
  • Page 216 HYDRAULICS 14. Reinstall the rubber steering wheel cover. 15. Reconnect the battery cables and start the machine. Turn the steering wheel and check for any leaks and proper operation. 5-28 6400E MM434 (7- -99)

  • Page 217: Hydraulic Control Valve

    Machine And Remove Key. 1. Open the seat support. 2. Remove the two valve handle boots. 3. Mark, disconnect, and plug the hydraulic hoses leading to the control valve. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-29 6400E MM434 (7- -99)
  • Page 218 6. Remove the fittings from the old valve and install in the new valve in the same orientation. 7. Remove the valve handles and C pins from the old valve and install on the new valve in the same orientation. 5-30 6400E MM434 (7- -99)
  • Page 219 9. Reconnect the hydraulic hoses. See schematic in this section. 10. Reconnect the tension spring to the left handle. 12. Reinstall the valve handle boots. 13. Start the machine and check the control valve for proper operation. 5-31 6400E MM434 (7- -99)

  • Page 220: Hydraulic Solenoid Valve

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the hopper and engage the support bar. 2. Open the seat support. 3. Disconnect the battery. 5-32 6400E MM434 (7- -99)
  • Page 221 Locate the two hex screws holding the solenoid valve to the machine frame. Remove the valve from the machine. 7. Remove the fittings from the old solenoid valve and install in the new valve in the same orientation. 5-33 6400E MM434 (7- -99)
  • Page 222 9. Reconnect the hydraulic hoses. See schematic in this section. 10. Reconnect the two electrical coils to the main harness. 11. Reconnect the battery. 12. Start the machine and check the new valve for any leaks and proper operation. 5-34 6400E MM434 (7- -99)

  • Page 223: To Replace Side Brush Motor

    5. Remove the side brush from the side brush motor. 6. Remove and plug the hydraulic hoses leading to the side brush motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-35 6400E MM434 (7- -99)
  • Page 224 Tighten the four hex screws to (27 -- 35 ft lb). 10. Reconnect the hydraulic hoses to the side brush motor. See schematic in this section. 11. Reinstall the side brush on the side brush motor. 5-36 6400E MM434 (7- -99)
  • Page 225 13. Secure the pin by clipping the pin keeper over the end of the pin. 14. Disengage the hopper support bar and lower the hopper. 15. Adjust the side brush pattern with the side brush down pressure lever. 5-37 6400E MM434 (7- -99)

  • Page 226: Hydraulic Schematic, Electric

    HYDRAULICS HYDRAULIC SCHEMATIC, ELECTRIC 5-38 6400E MM434 (11- -01)

  • Page 227: Hydraulic Hose Group, Electric

    HYDRAULICS HYDRAULIC HOSE GROUP, ELECTRIC 5-39 6400E MM434 (11- -01)

  • Page 228: Troubleshooting

    HYDRAULICS 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. 5-40 6400E MM434 (7- -99)

  • Page 229: Side Brush On Circuit

    ON CIRCUIT 225 PSI SV 1 SIDE BRUSH 90 RPM RV 2 1300 3.1 GPM TOTAL (1.3 GPM @ UNLOAD) RV 1 1000 RPM STRAINER PRESSURE SUCTION RETURN CASE DRAIN PRESSURE READINGS BASED ON 150 F 5-41 6400E MM434 (7- -99)

  • Page 230: Side Brush Does Not Turn On

    REPLACE SV1 FLOW OK? STEM CARTRIDGE REPAIR OR PLUMBING OK? REPLACE MOTOR PUMP OUTLET REPAIR OR FLOW & REPLACE PRESSURE OK? PLUMBING REPAIR OR RV1 RELIEF REPLACE CARTRIDGE OK? PUMP REPAIR OR REPLACE RV RELIEF CARTRIDGE 5-42 6400E MM434 (7- -99)

  • Page 231: Side Brush Does Not Turn Off

    HYDRAULICS SIDE BRUSH DOES NOT TURN OFF SV1 STEM MAGNETIZED? SV1 STEM CHECK CARTRIDGE ELECTRICAL SYSTEM SHIFTING OK? REPLACE SV1 STEM CARTRIDGE REPAIR OR SEALS REPLACE SV1 STEM CARTRIDGE 5-43 6400E MM434 (7- -99)

  • Page 232: Steering Circuit Right Turn

    HYDRAULICS STEERING CIRCUIT RIGHT TURN STRG CYL. FILTER 50 PSI (STATIONARY) 175 PSI (TURNING - - CONCRETE) 550 PSI (HELD AT STOP) PRESSURE SUCTION RETURN CASE DRAIN PUMP PRESSURE READINGS BASED ON 150 F STRAINER 5-44 6400E MM434 (7- -99)

  • Page 233: Steering Circuit Left Turn

    HYDRAULICS STEERING CIRCUIT LEFT TURN STRG CYL. FILTER 50 PSI (STATIONARY) 175 PSI (TURNING - - CONCRETE) 550 PSI (HELD AT STOP) PRESSURE SUCTION RETURN CASE DRAIN PUMP PRESSURE READINGS BASED ON 150 F STRAINER 5-45 6400E MM434 (7- -99)

  • Page 234: Power Steering Is Not Normal

    ROD ENDS & SEALS OK? REPAIR OR PLUMBING OK? REPLACE STEER CYLINDER ENDS PUMP OUTLET REPAIR OR FLOW & REPLACE PLUMBING PRESSURE OK? STEERING INLET REPAIR OR PRESSURE OK? REPLACE PUMP REPAIR OR REPLACE STEERING CONTROL 5-46 6400E MM434 (7- -99)

  • Page 235: Hopper Door Circuit Closed

    HYDRAULICS HOPPER DOOR CIRCUIT CLOSED LIFT LIFT DOOR CLOSE 1300 PSI (DOOR HELD CLOSED) RV2 (IN SIDE BRUSH CIRCUIT) 1300 PRESSURE SUCTION RETURN CASE DRAIN PUMP PRESSURE READINGS BASED ON 150 F STRAINER 5-47 6400E MM434 (7- -99)

  • Page 236: Hopper Door Does Not Open

    SEALS OK? REPLACE DOOR MANUAL CONTROL CYLINDER OR CLEVIS VALVE SPOOL PINS SHIFTING OK? REPAIR OR PLUMBING OK? REPLACE MANUAL CONTROL VALVE PUMP OUTLET REPAIR OR FLOW & REPLACE PLUMBING PRESSURE OK? REPAIR OR REPLACE PUMP 5-48 6400E MM434 (7- -99)

  • Page 237: Hopper Door Does Not Close

    PINS SHIFTING OK? REPAIR OR PLUMBING OK? REPLACE MANUAL CONTROL VALVE PUMP OUTLET REPAIR OR FLOW & REPLACE PLUMBING PRESSURE OK? REPAIR OR RV1 RELIEF REPLACE PUMP PRESSURE OK? REPAIR OR REPLACE RELIEF VALVE CARTRIDGE 5-49 6400E MM434 (7- -99)

  • Page 238: Hopper Door Does Not Stay Closed

    HOPPER DOOR DOES NOT STAY CLOSED DOOR CYLINDER CLEVIS PINS & SEALS OK? REPLACE DOOR MANUAL CONTROL CYLINDER OR CLEVIS VALVE SPOOL PINS SHIFTING OK? REPAIR OR PLUMBING OK? REPLACE MANUAL CONTROL VALVE REPAIR OR REPLACE PLUMBING 5-50 6400E MM434 (7- -99)

  • Page 239: Hopper Lift Circuit

    HYDRAULICS HOPPER LIFT CIRCUIT LIFT LIFT DOOR CLOSE 1300 PSI (HOPPER UP FULL) RV2 (IN SIDE BRUSH CIRCUIT) 1300 PRESSURE SUCTION RETURN CASE DRAIN PUMP PRESSURE READINGS BASED ON 150 F STRAINER 5-51 6400E MM434 (7- -99)

  • Page 240: Hopper Does Not Raise

    REPAIR OR & PLUMBING OK? REPLACE MANUAL CONTROL VALVE PUMP OUTLET REPAIR OR FLOW & REPLACE CYLINDER PRESSURE OK? ORIFICE OR PLUMBING REPAIR OR RV1 RELIEF REPLACE PUMP PRESSURE OK? REPAIR OR REPLACE RELIEF VALVE CARTRIDGE 5-52 6400E MM434 (7- -99)

  • Page 241: Hopper Does Not Lower

    CLEVIS PINS & SEALS OK? REPAIR OR MANUAL CONTROL REPLACE LIFT VALVE SPOOL CYLINDER OR CLEVIS SHIFTING OK? PINS CYLINDER ORIFICE REPAIR OR & PLUMBING OK? REPLACE MANUAL CONTROL VALVE REPAIR OR REPLACE CYLINDER ORIFICE OR PLUMBING 5-53 6400E MM434 (7- -99)

  • Page 242: Hopper Does Not Hold Up Position

    HOPPER DOES NOT HOLD UP POSITION CAN SAFETY LEG BE PUT IN PLACE? LIFT CYLINDER SYSTEM OK SEALS OK? MANUAL CONTROL REPAIR OR VALVE SPOOL REPLACE LIFT SHIFTING OK? CYLINDER REPAIR OR REPLACE MANUAL CONTROL VALVE 5-54 6400E MM434 (7- -99)
  • Page 291 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 293 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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