Page 1 6100E Service Manual 330255 Rev. 02 (6- -01)
Page 2 Chassis: Tire/wheel replacement, brake adjustment and replacement, steering adjustment and replacement. Sweeping: Hopper repair/replacement, brush repair/replacement, skirt/seal repair/replacement, and sweeping troubleshooting. Electrical: Battery maintenance and replacement, motor replacement, electrical schematics, and electrical troubleshooting. Manual Number -- 330255 Revision: 02 Published: 6--01 Copyright E 2000, 2001 TENNANT, Printed in U.S.A.
Page 3: Table Of Contents
... 1--14 THREAD SEALANT AND LOCKING COMPOUNDS ....1--14 1-- 1 6100E 330255 (6- -01)
Page 4 GENERAL INFORMATION 1-- 2 6100E 330255 (6- -01)
Page 5: Safety Precautions
- - Avoid contact with battery acid. - - Use cardboard to locate leaking The following information signals potentially hydraulic fluid under pressure. dangerous conditions to the operator or - - Use Tennant supplied or equivalent equipment: replacement parts. FOR SAFETY: 7. When loading/unloading machine onto/off truck or trailer: 1.
Page 6 FOR SAFETY LABEL - - LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT. FLYING DEBRIS LABEL - - LOCATED ABOVE HOPPER BATTERY CHARGING LABEL - - LOCATED IN BATTERY COMPARTMENT. 352182 1-- 4 6100E 330255 (9- -00)
Page 7: Specifications
Maximum forward speed 8.5 km/h (5 .5 mph) Maximum reverse speed 4.8 km/h (3 mph) Minimum turning radius 1725 mm (68 in) Maximum rated incline with empty hopper Maximum rated incline with full hopper 1-- 5 6100E 330255 (9- -00)
Page 8: Power Type
Utilizes service brakes, cable actuated TIRES Location Type Size Front (1) Solid 90 x 305 mm (3.5 in x12 in OD) Rear (2) Solid 76 x 305 mm (3 in x 12 in OD) 1-- 6 6100E 330255 (9- -00)
Page 9: Machine Dimensions
GENERAL INFORMATION 1520 mm (60 in) 805 mm (32 in) TOP VIEW SIDE VIEW 1180 mm (46 in) 352185 MACHINE DIMENSIONS 1-- 7 6100E 330255 (9- -00)
Page 10: Maintenance
Check brush pattern Batteries Check electrolyte level 6 (3) Vacuum wand bag (Option) Check or change vacuum bag Vacuum wand fan(s) Check for damage or wear (Option) QuickMoptbroom (Option) Rotate or wash sweep heads 1-- 8 6100E 330255 (6- -01)
Page 11 ..Distilled water ..SAE 30 Engine oil . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) NOTE: More frequent intervals may be required in extremely dusty conditions. 1-- 9 6100E 330255 (6- -01)
Page 12: Pushing, Towing, And Transporting The Machine
380 mm (15 in) from the ground, use a winch to load machine. If the loading surface is horizontal AND is 380 mm (15 in) or less from the ground, the machine may be driven onto the truck or trailer. 1-- 10 6100E 330255 (6- -01)
Page 13 5. Position the machine onto the truck or trailer as far as possible. If the machine starts to veer off the centerline of the truck or trailer, stop and turn the steering wheel to center the machine. 1-- 11 6100E 330255 (6- -01)
Page 14 FOR SAFETY: When unloading machine off truck or trailer, use winch. Do not drive the machine off the truck or trailer unless the loading surface is horizontal AND 380 mm (15 in) or less from the ground. 1-- 12 6100E 330255 (6- -01)
Page 15: Machine Jacking
Block machine up with jack stands. STORING MACHINE Before storing the machine for an extended time, the machine needs to be serviced to lessen the chance of rust, sludge, and other undesirable deposits from forming. 1-- 13 6100E 330255 (6- -01)
Page 16: Hardware Information
Thread sealants and locking compounds may be (121--157) used on this machine. They include the following: 0.62 in 130--170 117--265 (176--231) (159--359) Locktite 515 sealant -- gasket forming material. TENNANT Part No. 75567,15 oz 0.75 in 215--280 313--407 (291--380) (424--552) (440 ml) cartridge. 1.00 in 500--650...
Page 17 ....2--51 TO REPLACE FRONT WHEEL HOUSING NEEDLE BEARING/ THRUST WASHERS ..2--55 TO REPLACE FRONT WHEEL HOUSING CONE BEARING ..2--61 6100E 330255 (9- -00) 2-- 1...
Page 18 CHASSIS 2-- 2 6100E 330255 (9- -00)
Page 19: Introduction
CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat, steering, brakes, and tires. 2-- 3 6100E 330255 (9- -00)
Page 20: Brakes And Tires
CHASSIS BRAKES AND TIRES SERVICE BRAKES The service brakes on the model 6100E consists of a single disc and caliper located on the front tire and wheel assembly. The parking brake uses the same disc and caliper. The service brake and parking brake are each actuated with a foot pedal.
Page 21: To Adjust Parking Brake
The lever pin can now be moved up to the next hole. Retighten the hardware. TO ADJUST PARKING BRAKE The parking brake adjustment is made at the same time as the service brake. See TO ADJUST SERVICE BRAKE instructions. 2-- 5 6100E 330255 (9- -00)
Page 22: To Replace Brake Pads
REMOVE FRONT TIRE AND WHEEL instructions in this section. 2. Remove the tension spring from the brake caliper lever and wheel housing. 3. Remove the nuts from the shoulder screws holding the brake caliper to the wheel housing. 2-- 6 6100E 330255 (9- -00)
Page 23 5. Remove the two shoulder screws from the caliper assembly. 6. Pull the two brake pads out of the caliper assembly. Note the orientation of the pads. 7. Install the new pads into the caliper assembly in the same orientation. 2-- 7 6100E 330255 (9- -00)
Page 24 11. Reinstall the front tire and wheel assembly. See TO INSTALL FRONT TIRE AND WHEEL instructions in this section. 12. Operate the machine and check the brakes for proper operation. 2-- 8 6100E 330255 (9- -00)
Page 25: Rear Tires And Wheels
Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Remove the debris hopper from the rear of the machine. 2. Jack up the machine at the rear jack point. Place a jack stand under the machine frame. 2-- 9 6100E 330255 (9- -00)
Page 26 4. Support the rear wheel and remove the axle shaft. 5. Remove the rear tire assembly from the machine. 6. Remove the three hex screws and nuts holding the wheel hub to the tire assembly. 2-- 10 6100E 330255 (9- -00)
Page 27 CHASSIS 7. Remove the hub assembly from the tire assembly. 2-- 11 6100E 330255 (9- -00)
Page 28: To Install Rear Tire Assembly
Note the “D” shape of the frame mount hole and the “ D” on the axle shaft. Line these two up and push the axle all the way into the mount hole. 2-- 12 6100E 330255 (9- -00)
Page 29 37 -- 48 Nm (26 -- 34 ft lb). 5. Spin the tire assembly to make sure it turns freely. 6. Remove the jack stand and lower the machine to the floor. 7. Operate the machine for proper operation. 2-- 13 6100E 330255 (9- -00)
Page 30: Front Drive Wheel, And Wheel Housing Support
O--ring chain that turns the front tire assembly. The steering on the model 6100E is controlled by a steering wheel which turns a chain that is connected to the front wheel housing. The front wheel housing turns on a large bearing and rubber seal.
Page 31 6. Support the front drive wheel. Remove the axle from the front wheel. 7. Let the front wheel drop down and out of the brake caliper. Remove the front drive wheel from the machine. 2-- 15 6100E 330255 (9- -00)
Page 32 Make sure to retain the four steel sleeves. Pull the brake disc off the hub. 9. Remove the three wheel nuts holding the tire to the front hub. Remove the tire assembly from the hub. 2-- 16 6100E 330255 (9- -00)
Page 33: To Install Front Tire And Wheel
The brake disc is positioned on the left side of the wheel support. NOTE: Use a screw driver to spread the brake pads apart to ease the installation of the assembly into the wheel support. 2-- 17 6100E 330255 (9- -00)
Page 34 9. Push the motor gearbox up until the drive chain is tight (+/- - 1/8 inch at mid- -point). Tighten nuts to 18 -- 24 Nm (15 -- 20 ft lb). 2-- 18 6100E 330255 (9- -00)
Page 35 10. Reinstall the drive chain guard and tighten the two nuts to 18 -- 24 Nm (15 -- 20 ft lb). 11. Remove the jack stands and lower the machine to the floor. Operate the machine and check for proper operation. 2-- 19 6100E 330255 (9- -00)
Page 36: To Replace Front Wheel Drive Chain
Remove the chain guard. 3. Loosen the three nuts holding the drive motor gearbox to the wheel support. Let the gearbox drop down so the drive chain has some slack. 2-- 20 6100E 330255 (9- -00)
Page 37 7. Push the gearbox assembly up until the chain is tight (+/- - 1/8 inch at mid- -point). Tighten nuts to 18 -- 24 Nm (15 -- 20 ft lb). 2-- 21 6100E 330255 (9- -00)
Page 38 18 -- 24 Nm (15 -- 20 ft lb). 9. Remove the jack stands and lower the machine to the floor. Operate the machine and check the new drive chain for proper operation. 2-- 22 6100E 330255 (9- -00)
Page 39: To Replace Front Wheel Hub Bearings
Push the bearings down until they are seated flush against the housing. 4. Reinstall the front wheel assembly. See TO INSTALL FRONT TIRE AND WHEEL instructions in this section. 2-- 23 6100E 330255 (9- -00)
Page 40: To Remove Gearbox Assembly
Remove the chain guard. 3. Loosen the three nuts holding the gearbox assembly to the wheel support. Let the gearbox drop down so the drive chain has some slack. 2-- 24 6100E 330255 (9- -00)
Page 41 6. Disconnect the drive motor from the main electrical harness. 7. Finish removing the three nuts and washers holding the gearbox assembly to the wheel support. Remove the gearbox assembly from the machine. 2-- 25 6100E 330255 (9- -00)
Page 42: To Install Gearbox Assembly
3. Reinstall the drive chain around the drive sprocket on the drive motor and front wheel assembly. Reinstall the master link. Make sure the four small O- -rings are in place behind the master link clip. 2-- 26 6100E 330255 (9- -00)
Page 43 18 -- 24 Nm (15 -- 20 ft lb). 6. Reconnect the drive motor to the main electrical harness. 7. Remove the jack stands and lower the machine to the floor. Operate the machine and check the gearbox assembly for proper operation. 2-- 27 6100E 330255 (9- -00)
Page 44: To Replace Drive Wheel Cogged Belt
2. Disconnect the drive motor from the main electrical harness. Turn the steering wheel all the way to the right. 3. Remove the six hex screws holding the two black covers to the side of the gearbox. 2-- 28 6100E 330255 (9- -00)
Page 45 Let the motor slide toward the back of the machine. The cogged belt will now be loose on the pulleys. 7. Remove the old cogged belt from both drive pulleys. Discard the old belt. 2-- 29 6100E 330255 (9- -00)
Page 46 (15 -- 20 ft lb). Plug the drive motor into the main electrical harness. 12. Remove the jack stands and lower the machine to the floor. Operate the machine and check the gearbox assembly for proper operation. 2-- 30 6100E 330255 (9- -00)
Page 47: To Replace Gearbox Bearings
3. Go to the other side of the gearbox assembly. Remove the six hex screws holding the two black covers to the side of the gearbox. 2-- 31 6100E 330255 (9- -00)
Page 48 7. Pull the large pulley out of the gearbox. You may have to lightly tap on the shaft to dislodge the inner bearing from the bottom case of the gearbox assembly. Remove the three hex screws holding the hub to the sprocket. 2-- 32 6100E 330255 (9- -00)
Page 49 Make sure the inner bearing is seated properly in the lower case. 11. Position the cogged belt onto the large and small pulleys. 2-- 33 6100E 330255 (9- -00)
Page 50 See TO INSTALL GEARBOX ASSEMBLY instructions in this section. 16. Remove the jack stands and lower the machine to the floor. Operate the machine and check the gearbox assembly for proper operation. 2-- 34 6100E 330255 (9- -00)
Page 51: To Adjust Steering Chain
Loosen the two screws. 3. Turn the steering wheel all the way to the left and then to the right. Find the point in the rotation where the steering chain is the most tight. 2-- 35 6100E 330255 (9- -00)
Page 52 37 -- 48 Nm (26 -- 34 ft lb). 5. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering chain for proper operation. 2-- 36 6100E 330255 (9- -00)
Page 53: To Replace Steering Chain
3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. 2-- 37 6100E 330255 (9- -00)
Page 54 Install a new master link in the new chain. 7. Turn the steering wheel all the way to the left and then to the right. Find the point in the rotation where the steering chain is the most tight. 2-- 38 6100E 330255 (9- -00)
Page 55 37 -- 48 Nm (26 -- 34 ft lb). 9. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering chain for proper operation. 2-- 39 6100E 330255 (9- -00)
Page 56: To Replace Steering Housing Bearings
2. Turn the steering wheel all the way to the left. 3. Go to the operators compartment and locate the steering U--joint. Loosen the two set screws on the top of the steering U--joint. 2-- 40 6100E 330255 (9- -00)
Page 57 6. Go under the machine and locate the small steering chain sprocket. 7. Locate the master link on the steering chain. Remove the master link and steering chain from the small steering sprocket. 2-- 41 6100E 330255 (9- -00)
Page 58 11. Use an arbor press to press the short steering shaft and two bearings out of the housing. Discard the bearings. Retain the short shaft. Note the orientation of the shaft in the housing. 2-- 42 6100E 330255 (9- -00)
Page 59 14. Reinstall the small steering sprocket and woodruff key on the bottom of the steering housing. Tighten the set screws tight. 15. Reinstall the U--joint and square key on the top of the steering housing. Tighten the set screws tight. 2-- 43 6100E 330255 (9- -00)
Page 60 Reinstall the master link. 19. Turn the steering wheel all the way to the left and then to the right. Find the point in the rotation where the steering chain is the most tight. 2-- 44 6100E 330255 (9- -00)
Page 61 37 -- 48 Nm (26 -- 34 ft lb). 21. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering chain for proper operation. 2-- 45 6100E 330255 (9- -00)
Page 62: To Replace Steering U--Joint
U--joint. Loosen the two set screws on the top of the steering U--joint. 3. Pull the steering wheel and long steering shaft up and out of the top of the steering U--joint. 2-- 46 6100E 330255 (9- -00)
Page 63 6. Position the long steering shaft and steering wheel into the top of the steering U--joint. Tighten the set screws tight. 7. Operate the machine and check the steering U--joint for proper operation. 2-- 47 6100E 330255 (9- -00)
Page 64: To Replace Small Steering Sprocket
3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. This will loosen the steering chain. 2-- 48 6100E 330255 (9- -00)
Page 65 7. Install the new small sprocket and woodruff key onto the steering shaft. The teeth of the new sprocket face down. Position the sprocket in the same location as the old one. Tighten the two set screws tight. 2-- 49 6100E 330255 (9- -00)
Page 66 Tighten the two hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 11. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering for proper operation. 2-- 50 6100E 330255 (9- -00)
Page 67: To Replace Large Steering Sprocket
3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. This will loosen the steering chain. 2-- 51 6100E 330255 (9- -00)
Page 68 7. Remove the four hex screws holding the wheel support and large sprocket to the pivot bearing assembly. Drop the wheel support and large sprocket out of the machine. 2-- 52 6100E 330255 (9- -00)
Page 69 Reinstall the four screws and tighten to 64 -- 83 Nm (47 -- 61 ft lb). 11. Reconnect the short brake rod to the brake lever. 2-- 53 6100E 330255 (9- -00)
Page 70 Tighten the two hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 16. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering for proper operation. 2-- 54 6100E 330255 (9- -00)
Page 71: To Replace Front Wheel Housing Needle Bearing/Thrust Washers
3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. This will loosen the steering chain. 2-- 55 6100E 330255 (9- -00)
Page 72 Remove the clevis pin and tension spring from the brake pedal. 7. Pull the brake pedal up and disconnect the clevis end of the short brake rod where it attaches to the brake pedal assembly. 2-- 56 6100E 330255 (9- -00)
Page 73 Remove the castle nut and flat washer. 10. Pull the cone bearing out of the swivel plate. 11. Pull the swivel plate off the swivel plate weldment. Make sure to retain the rubber seal ring. 2-- 57 6100E 330255 (9- -00)
Page 74 17. Reinstall the large flat washer and castle nut. Tighten to 37 -- 48 Nm (26 -- 34 ft. lb). Reinstall the small thread roller into the cross hole. Back off the castle nut if needed to align cross hole. 2-- 58 6100E 330255 (9- -00)
Page 75 21. Go back to the operators compartment. Push the steering housing forward in the slots. This will remove any slack in the steering chain. Tighten the two hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 2-- 59 6100E 330255 (9- -00)
Page 76 23. Reconnect the short brake rod to the brake pedal. 24. Reinstall the brake pedal and clevis pin. 25. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering for proper operation. 2-- 60 6100E 330255 (9- -00)
Page 77: To Replace Front Wheel Housing Cone Bearing
3. Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame. Loosen the two screws and push the bearing housing back in the slots. This will loosen the steering chain. 2-- 61 6100E 330255 (9- -00)
Page 78 Remove the clevis pin and tension spring from the brake pedal. 7. Pull the brake pedal up and disconnect the clevis end of the short brake rod where it attaches to the brake pedal assembly. 2-- 62 6100E 330255 (9- -00)
Page 79 12. Reinstall the large flat washer and castle nut. Tighten to 37 -- 48 Nm (26 -- 34 ft. lb). Reinstall the small thread roller into the cross hole. Back off the castle nut if needed to align cross hole. 2-- 63 6100E 330255 (9- -00)
Page 80 16. Go back to the operators compartment. Push the steering housing forward in the slots. This will remove any slack in the steering chain. Tighten the two hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 2-- 64 6100E 330255 (9- -00)
Page 81 18. Reconnect the short brake rod to the brake pedal. 19. Reinstall the brake pedal and clevis pin. 20. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering for proper operation. 2-- 65 6100E 330255 (9- -00)
Page 82 CHASSIS 2-- 66 6100E 330255 (9- -00)
Page 83 ....3--48 TO REPLACE VACUUM FAN IMPELLER BEARINGS ..3--53 MACHINE TROUBLESHOOTING ..3--60 3-- 1 6100E 330255 (6- -01)
Page 84: Introduction
SWEEPING INTRODUCTION This section includes information on the sweeping operation of the model 6100E. The side brush sweeps debris in front of the machine and the main brush sweeps the debris into the hopper. The vacuum fan pulls air from the hopper and through the dust filter.
Page 85: Debris Hopper
The hopper is held in operating position with a retaining clip. NOTE: Check that the hopper retaining clip is securely in place each time before operating machine. 3-- 3 6100E 330255 (9- -00)
Page 86: To Remove Hopper
2. Grasp the hopper retainer clip. Turn the retainer clip out of the way of the hopper lip. 3. Grasp the hopper handle. Pull up slightly then pull out on the hopper. 4. Remove the hopper from the machine. 3-- 4 6100E 330255 (9- -00)
Page 87: To Install Hopper
1. Position the hopper into the back of the machine. 2. Push the hopper in until it is flush with the back of the machine frame. 3. Rotate the retainer clip down to lock the hopper in the machine. 3-- 5 6100E 330255 (9- -00)
Page 88: Hopper Dust Filter
Air dry the wet dust filter; do not use compressed air to dry a wet filter. NOTE: Be sure the dust filter is completely dry before reinstalling it in the machine. 3-- 6 6100E 330255 (9- -00)
Page 89: To Replace Hopper Dust Filter
Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Remove the debris hopper from the machine. 2. Un--latch the two filter pivot latches at the rear of the machine. 3. Let the hooper filter pivot down. 3-- 7 6100E 330255 (9- -00)
Page 90 7. Remove the filter shaker assembly from the filter. 8. Install the filter shaker assembly onto the new filter. Make sure the pin on the shaker assembly is inserted in the hole in the filter shaker comb. 3-- 8 6100E 330255 (9- -00)
Page 91 10. Reinstall the filter assembly into the filter tray. 11. Reconnect the wires to the filter shaker. 12. Pivot the filter tray up and re--latch the latches. 13. Reinstall the debris hopper and lock the retainer bracket. 3-- 9 6100E 330255 (9- -00)
Page 92: Main Brush
FOR SAFETY: Before leaving or servicing machine, stop on level surface, set parking brake, turn off machine, and remove key. 2. Open the left side main brush access door. 3-- 10 6100E 330255 (9- -00)
Page 93 6. Slide the main brush onto the drive plug. Rotate the brush until it engages the drive plug, and push it all the way onto the plug. 3-- 11 6100E 330255 (9- -00)
Page 94 8. Slide the main brush idler arm plug onto the main brush. 9. Secure the idler arm on the bolts. Hand tighten the mounting knobs. 10. Close the main brush access door. 3-- 12 6100E 330255 (9- -00)
Page 95: Checking And Adjusting Main Brush Pattern
NOTE: If chalk or other material is not available, allow the brushes to spin on the floor for two minutes. A polish mark will remain on the floor. 4. Raise the main brush. 5. Drive the machine off the test area. 3-- 13 6100E 330255 (9- -00)
Page 96 2. Allow the brush to operate and float into position for approximately 30 seconds. 3. Tighten the adjustment bolt and idler arm securing knob. 4. Check the main brush pattern and readjust as necessary. 3-- 14 6100E 330255 (9- -00)
Page 97: Main Brush Belt
Remove the right hand side brush door. 2. Locate the main brush drive belt idler pulley between the small motor drive pulley and the larger brush pulley. 3-- 15 6100E 330255 (9- -00)
Page 98 7. Move the idler pulley forward in the slot until the belt is tight. Tighten the hex nut to 18 -- 24 Nm (15 -- 20 ft lb). 3-- 16 6100E 330255 (9- -00)
Page 99 SWEEPING 8. Reinstall the right hand side brush door. 9. Operate the machine and check the main brush for proper operation. 3-- 17 6100E 330255 (9- -00)
Page 100: To Replace Main Brush Idler Plug Bearing
2. Remove the main brush idler mount plate. See TO REPLACE MAIN BRUSH instructions in this sections. 3. Remove the hex screw, nut, and washer holding the idler plug assembly to the brush lift plate. 3-- 18 6100E 330255 (9- -00)
Page 101 7. Position the new ball bearing into the idler plug. 8. Reinstall the bearing retainer plate on the idler plug. Reinstall the four screws and tighten to 8 -- 10 Nm (6 -- 7 ft lb). 3-- 19 6100E 330255 (9- -00)
Page 102 10. Reinstall the main brush idler mount plate. See TO REPLACE MAIN BRUSH instructions in this sections. 11. Close the left hand side brush door. 12. Operate the machine and check the main brush for proper operation. 3-- 20 6100E 330255 (9- -00)
Page 103: To Replace Main Brush Drive Plug Bearings
2. Open the left hand side brush door. 3. Remove the main brush idler mount plate and main brush. See TO REPLACE MAIN BRUSH instructions in this sections. 4. Remove the right hand brush door. 3-- 21 6100E 330255 (9- -00)
Page 104 8. Hold the main brush drive plug from turning. Remove the large nut from the center of the drive plug. NOTE: THIS IS A LEFT HAND THREAD NUT. 9. Remove the main brush idler plug assembly from the main brush shaft. 3-- 22 6100E 330255 (9- -00)
Page 105 18. Reinstall the main brush drive plug onto the main brush shaft on the inside. Reinstall the left hand nut. Hand tighten tight. Make sure the large washer is in place behind the brush plug. 3-- 23 6100E 330255 (9- -00)
Page 106 REPLACE MAIN BRUSH DRIVE BELT instructions in this section. 21. Reinstall the main brush. See TO REPLACE MAIN BRUSH instructions in this sections. 22. Reinstall the right hand brush door and close the left hand brush door. 3-- 24 6100E 330255 (9- -00)
Page 107 SWEEPING 23. Remove the jack stands and lower the machine. 24. Operate the machine and check the main brush for proper operation. 3-- 25 6100E 330255 (9- -00)
Page 108: To Replace Main Brush Drive Belt Idler Pulley
Remove the right hand side brush door. 2. Locate the main brush drive belt idler pulley between the small jackshaft pulley and the larger brush pulley. 3. Loosen the hex nut in the center of the idler pulley. 3-- 26 6100E 330255 (9- -00)
Page 109 6. Remove the hex nut in the center of the idler pulley. Remove and discard the pulley. 7. Install the new idler pulley onto the hex bolt. Reinstall the hex nut. Leave loose for now. 3-- 27 6100E 330255 (9- -00)
Page 110 Tighten the pulley nut to 18 -- 24 Nm (15 -- 20 ft lb). 10. Reinstall the right hand side brush door. 11. Operate the machine and check the main brush for proper operation. 3-- 28 6100E 330255 (9- -00)
Page 111: Side Brush
50 mm (2 in) in length. You may need to replace the side brush sooner if you are sweeping light litter or use a brush with shorter bristles if you are sweeping heavy debris. 3-- 29 6100E 330255 (9- -00)
Page 112: To Replace Side Brush
3. Slide the side brush off the side brush drive shaft. 4. Slide the new side brush onto the side brush drive shaft. 3-- 30 6100E 330255 (9- -00)
Page 113 8. Move the pulley mount bracket up or down to achieve the proper side brush pattern. Retighten the hex screw. 3-- 31 6100E 330255 (9- -00)
Page 114: Side Brush Guard
SIDE BRUSH PIVOT The side brush pivot should be checked for excessive movement after every 200 hours of operation. Torque the front and rear compression springs to reduce excessive movement. 3-- 32 6100E 330255 (9- -00)
Page 115: To Replace Side Brush Lift Cable
3. Go to the operators compartment. Remove the three cable pulleys, sleeves, and cable clips from the side brush lift assembly. Note the orientation of the cable clips for proper re--assembly. 3-- 33 6100E 330255 (9- -00)
Page 116 18 -- 24 Nm (15 -- 20 ft lb). 7. Connect the new side brush lift cable to the side brush pivot screw. Hand tighten the hex nut. Cable should pivot on the hardware. 8. Raise the side brush. 3-- 34 6100E 330255 (9- -00)
Page 117: Skirts And Seals
Check the skirts for wear or damage and adjustment daily. NOTE: The recirculation skirt must be folded in between the brush and the machine frame before the brush door is mounted on for the machine to work properly. 3-- 35 6100E 330255 (9- -00)
Page 118: Side Skirts
Check the skirts for wear or damage daily. TO ADJUST SIDE SKIRTS FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the LH brush door . 2. Remove the RH brush door. 3-- 36 6100E 330255 (6- -01)
Page 119 4. Place a flat washer under the bottom edge of the skirts. Make sure the skirt is touching the washer. Tighten the hardware to 560Ncm. 5. Close the LH brush door. 6. Reinstall the RH brush door. 3-- 37 6100E 330255 (9- -00)
Page 120: Large Debris Trap Skirt
FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. The front flap skirt must roll to the rear of the machine .75 in (3/4 in) +/-- .125 in (1/8 in) 3-- 38 6100E 330255 (9- -00)
Page 121: Hopper Seals
Check the seals for wear or damage after every 100 hours of operation. The upper hopper seal is located above the hopper on the bottom of the filter weldment. Check the seal for wear or damage after every 100 hours of operation. 3-- 39 6100E 330255 (6- -01)
Page 122: To Adjust Recirculating Skirt Cam
Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Pull the brush lift handle forward. 2. Lift the recirculation cam until it hits the frame. 3. Slowly lower the brush lift handle to the down position. 3-- 40 6100E 330255 (9- -00)
Page 123 4. If the cam follows the lever, do NOT adjust. 5. If the lever does not lower, Loosen the hardware and move the lever. NOTE: The lever must not move to the front of the cam. 3-- 41 6100E 330255 (9- -00)
Page 124: Vacuum Fan
200 hours of operation. The correct tension is when the belt deflects 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. WARNING: Moving belt and fan. Keep away. 3-- 42 6100E 330255 (9- -00)
Page 125: To Replace Vacuum Fan Drive Belt
2. Remove the four screws holding the right hand brush door to the machine frame. Remove the right hand side brush door. 3. Loosen the four hex screws holding the vacuum fan housing to the machine frame. 3-- 43 6100E 330255 (9- -00)
Page 126 V--belt pulley. Remove the cover. 6. Remove the vacuum fan V--belt from both pulleys. Remove the old V--belt from the machine. 7. Install the new vacuum fan V--belt over both pulleys. 3-- 44 6100E 330255 (9- -00)
Page 127 9. Reinstall the V--belt cover. Tighten the two screws hand tight. 10. Reinstall the right hand side brush door. 11. Reinstall the right hand machine cover. 12. Operate the machine. Check the vacuum fan for proper operation. 3-- 45 6100E 330255 (9- -00)
Page 128: To Tension Vacuum Fan Drive Belt
3. Pull the vacuum fan assembly toward the back of the machine to tighten the V--belt. The correct tension is when the belt deflects 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. 3-- 46 6100E 330255 (9- -00)
Page 129 SWEEPING 4. Tighten the four mounts screws hand tight. 5. Reinstall the right hand machine cover. 6. Operate the machine. Check the vacuum fan for proper operation. 3-- 47 6100E 330255 (9- -00)
Page 130: To Replace Vacuum Fan Impeller
2. Loosen the four hex screws holding the vacuum fan housing to the machine frame. 3. Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V--belt. 3-- 48 6100E 330255 (9- -00)
Page 131 Remove the assembly from the machine. Make sure to retain the two steel sleeves from the bottom two hex screws. 7. Place the assembly on a work bench with the vacuum fan inlet plate facing up. 3-- 49 6100E 330255 (9- -00)
Page 132 10. Install the new vacuum fan impeller onto the fan shaft. Make sure to reinstall the square key on the fan shaft. 11. Reinstall the nyloc nut onto the fan shaft. Tighten to 11 -- 14 Nm (7 -- 10 ft lb). 3-- 50 6100E 330255 (9- -00)
Page 133 V--belt. The correct tension is when the belt deflects 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. 16. Tighten the four mounts screws hand tight. 3-- 51 6100E 330255 (9- -00)
Page 134 SWEEPING 17. Reinstall the V--belt cover. Tighten the two screws hand tight. 18. Reinstall the right hand machine cover. 19. Operate the machine. Check the vacuum fan for proper operation. 3-- 52 6100E 330255 (9- -00)
Page 135: To Replace Vacuum Fan Impeller Bearings
2. Loosen the four hex screws holding the vacuum fan housing to the machine frame. 3. Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V--belt. 3-- 53 6100E 330255 (9- -00)
Page 136 Remove the assembly from the machine. Make sure to retain the two steel sleeves from the bottom two hex screws. 7. Place the assembly on a work bench with the vacuum fan inlet plate facing up. 3-- 54 6100E 330255 (9- -00)
Page 137 10. Loosen the two set screws holding the V--belt pulley to the fan shaft. Remove the pulley. 11. Remove the four hex screws holding the vacuum fan bearing assembly to the bearing plate. Remove the bearing assembly. 3-- 55 6100E 330255 (9- -00)
Page 138 The long end of the shaft is on the side with the sound foam. Reinstall the four hex screws and washers. Tighten to 8 -- 10 Nm (6 -- 8 ft lb). 3-- 56 6100E 330255 (9- -00)
Page 139 Reinstall the five steel sleeves, hex screws, and nuts. Center the hole in the plate over the impeller fins. Tighten the hardware to 18 -- 24 Nm (15 -- 20 ft lb). 3-- 57 6100E 330255 (9- -00)
Page 140 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. 22. Tighten the four mounts screws hand tight. 23. Reinstall the V--belt cover. Tighten the two screws hand tight. 3-- 58 6100E 330255 (9- -00)
Page 141 SWEEPING 24. Reinstall the right hand machine cover. 25. Operate the machine. Check the vacuum fan for proper operation. 3-- 59 6100E 330255 (9- -00)
Page 142: Machine Troubleshooting
Check and charge batteries Operator not in seat Sit in operator seat Vacuum Wand does not Auto switch not adjusted Adjust switch come on Low battery power Check and charge batteries Wand holding bracket bent Straighten bracket 3-- 60 6100E 330255 (8- -98)
Page 143 ....4--70 TROUBLESHOOTING ....4--73 4-- 1 6100E 330255 (6- -01)
Page 144 ELECTRICAL 4-- 2 6100E 330255 (9- -00)
Page 145: Introduction
ELECTRICAL INTRODUCTION The 6100E electrical system consists of the batteries, instrument panel, drive motor, switches, relays, and circuit breakers. 4-- 3 6100E 330255 (9- -00)
Page 146: Electrical System
ELECTRICAL ELECTRICAL SYSTEM The model 6100E is a battery powered, all electric machine. The batteries are used to power the front drive motor, vacuum fan motor, main brush motor, side brush motor, and the filter shaker. BATTERIES The batteries are unique in that they hold their power for long periods of time.
Page 147: To Charge Batteries
2. Stop the machine, set the parking brake and turn the machine power off. FOR SAFETY: Before leaving or servicing machine, stop on level surface, set parking brake, turn off machine, and remove key. 3. Open the seat support. 4-- 5 6100E 330255 (9- -00)
Page 148 Keep covers open when charging. NOTE: Plug the charger connector into connector that runs to the batteries. Do not plug charger into mounted connector. Damage may occur to the machine. 4-- 6 6100E 330255 (6- -01)
Page 149 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 150: To Replace Batteries
Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine batteries. 3. Remove the five small battery cables from the batteries. 4-- 8 6100E 330255 (9- -00)
Page 151 6. Pull the three batteries nearest the front of the machine toward the rear of the battery tray. Remove these batteries next. 7. Install the front three batteries first. Push these batteries toward the front of the machine. 4-- 9 6100E 330255 (9- -00)
Page 152 8. Install the rear three batteries next. 9. Reinstall the five small battery cables onto the new batteries. 10. Reinstall the connector assembly onto the batteries. 11. Reconnect the battery connect to the machine connector. 4-- 10 6100E 330255 (9- -00)
Page 153 ELECTRICAL 12. Disengage the prop rod and lower the seat support. 13. Start the machine and check the new batteries for proper operation. 4-- 11 6100E 330255 (9- -00)
Page 154: Instrument Panel
ELECTRICAL INSTRUMENT PANEL The instrument panel on the model 6100E contains the switches, gauges, and instruments needed to run the machine functions. TO ACCESS INSTRUMENT PANEL FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake.
Page 155 5. Remove the four hex screws and two pan screws holding the instrument panel to the front shroud. 6. Pull the instrument panel back away from the front shroud for better access to the circuit breakers. 4-- 13 6100E 330255 (9- -00)
Page 156 Reinstall the hardware and hand tighten tight. 8. Remove the tie holding the side brush in the up position. 9. Open the seat support and engage the prop rod. 10. Reconnect the batteries. 4-- 14 6100E 330255 (9- -00)
Page 157 ELECTRICAL 11. Disengage the prop rod and lower the seat support. 12. Start the machine and check for proper operation. 4-- 15 6100E 330255 (9- -00)
Page 158: To Replace Instrument Panel Circuit Breaker
Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine batteries. 3. Disengage the prop rod and lower the seat support. 4-- 16 6100E 330255 (9- -00)
Page 159 6. Pull the instrument panel back away from the front shroud for better access to the circuit breakers. 7. Locate the circuit breaker that needs to be changed. 4-- 17 6100E 330255 (9- -00)
Page 160 12. Install the metal retainer ring onto the back of the new circuit breaker. Push the retainer all the way down the circuit breaker. 13. Install the rubber boot onto the out side of the new circuit breaker. 4-- 18 6100E 330255 (9- -00)
Page 161 15. Position the instrument panel back onto the front shroud. Reinstall the hardware and hand tighten tight. 16. Remove the tie holding the side brush in the up position. 17. Open the seat support and engage the prop rod. 4-- 19 6100E 330255 (9- -00)
Page 162 ELECTRICAL 18. Reconnect the batteries. 19. Disengage the prop rod and lower the seat support. 20. Start the machine and check for proper operation. 4-- 20 6100E 330255 (9- -00)
Page 163: Electrical Panel
ELECTRICAL ELECTRICAL PANEL The electrical panel on the model 6100E is located at the left, rear corner of the machine. The electrical panel contains the propel controller, relays, contactors, circuit breakers, and fuse. TO ACCESS ELECTRICAL PANEL FOR SAFETY: Before Leaving Or Servicing Machine;...
Page 164 3. Remove the left side machine panel by lifting up and back on the panel. 4. Make any repairs to the electrical components located on the electrical panel. 5. Reinstall the left side panel. 6. Reconnect the batteries. 4-- 22 6100E 330255 (9- -00)
Page 165 ELECTRICAL 7. Disengage the prop rod and lower the seat support. 8. Start the machine and check for proper operation. 4-- 23 6100E 330255 (9- -00)
Page 166: To Replace Propel Controller
Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine batteries. 3. Remove the left side machine panel by lifting up and back on the panel. 4-- 24 6100E 330255 (9- -00)
Page 167 6. Install the new controller onto the electrical panel in the same orientation as the old one. Reinstall the hardware and hand tighten. Do not over tighten. 7. Reconnect the wires to the new controller. See schematic in this section. 4-- 25 6100E 330255 (9- -00)
Page 168 ELECTRICAL 8. Reinstall the left side panel. 9. Reconnect the batteries. 10. Disengage the prop rod and lower the seat support. 11. Start the machine and check for proper operation. 4-- 26 6100E 330255 (9- -00)
Page 169: Circuit Breakers
CB-6 15 A Option CB-7 10 A Side Brush CB-8 25 A Main Brush CB-9 25 A Vac Fan Motor CB-10 20 A Vac Wand (Option) CB-10 40 A Dual Motor, Vac Wand (Option) 4-- 27 6100E 330255 (9- -00)
Page 170: To Replace Electrical Panel Circuit Breaker
Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine batteries. 3. Remove the left side machine panel by lifting up and back on the panel. 4-- 28 6100E 330255 (9- -00)
Page 171 6. Mark and disconnect the wires leading to the bottom of the circuit breaker. 7. Connect the electrical wires to the new circuit breaker. See schematic in the ELECTRICAL section. 4-- 29 6100E 330255 (9- -00)
Page 172 Reinstall the two pan screws and hand tighten tight. 9. Reinstall the machine side panel. 10. Reconnect the batteries. 11. Disengage the prop rod and lower the seat support. 12. Start the machine and check for proper operation. 4-- 30 6100E 330255 (9- -00)
Page 173: Fuses
TO REPLACE ELECTRICAL PANEL 40 AMP FUSE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine batteries. 4-- 31 6100E 330255 (9- -00)
Page 174 Remove and discard the fuse. 7. Install the new fuse under the two hex screws. Hand tighten the hex screws tight. 8. Reinstall the machine side panel. 4-- 32 6100E 330255 (9- -00)
Page 175 ELECTRICAL 9. Reconnect the batteries. 10. Disengage the prop rod and lower the seat support. 11. Start the machine and check for proper operation. 4-- 33 6100E 330255 (9- -00)
Page 176: Directional Pedal
TO REMOVE DIRECTIONAL PEDAL ASSEMBLY FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine batteries. 4-- 34 6100E 330255 (9- -00)
Page 177 6. Go the the operators compartment and locate the directional pedal assembly. Remove the four thread rolling screws holding the directional pedal to the floor plate. 7. Remove the pedal assembly from the machine. 4-- 35 6100E 330255 (9- -00)
Page 178: To Install Directional Pedal Assembly
3. Line up the mount holes in the pedal assembly plate with the mount holes in the machines floor plate. 4. Reinstall the four thread rolling screws and tighten to 8 -- 10 Nm (6 -- 7 ft lb). 4-- 36 6100E 330255 (9- -00)
Page 179 8. Disengage the prop rod and lower the seat support. 9. Start the machine and check for proper operation. Set the pedal neutral if needed. See TO SET POTENTIOMETER NEUTRAL instructions in this section. 4-- 37 6100E 330255 (9- -00)
Page 180: To Replace Directional Pedal Potentiometer
2. Loosen the hex screw and nut holding the accelerator lever to the potentiometer. Remove the accelerator lever from the potentiometer shaft. 3. Remove the thin hex nut from the potentiometer shaft. 4-- 38 6100E 330255 (9- -00)
Page 181 If an adjustment needs to be made, loosen the upper jam nut and turn the rod. Re--tighten the jam nut. 8. Reinstall the directional pedal assembly into the machine. See TO INSTALL DIRECTIONAL PEDAL ASSEMBLY instructions in this section. 4-- 39 6100E 330255 (9- -00)
Page 182 ELECTRICAL 9. Check the new potentiometer for neutral. See TO SET POTENTIOMETER NEUTRAL instructions in this section. 10. Operate the machine. Check the new potentiometer for proper operation. 4-- 40 6100E 330255 (9- -00)
Page 183: To Set Potentiometer Neutral
FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the seat support and engage the prop rod. 2. Disconnect the machine batteries. 3. Lower the side brush. 4-- 41 6100E 330255 (9- -00)
Page 184 7. The meter reading should be 2500 OHMS (=/-- 50 OHMS). 8. Loosen the upper jam nut on the threaded rod. Turn the rod to achieve the proper OHM reading. Tighten the jam nut. 4-- 42 6100E 330255 (9- -00)
Page 185 ELECTRICAL 9. Reconnect the batteries. 10. Disengage the prop rod and lower the seat support. 11. Operate the machine. Check the machine for proper neutral operation. 4-- 43 6100E 330255 (9- -00)
Page 186: Electric Motors
Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Jack up the front of the machine at the jack point. Install jack stands under the machine frame. 2. Open the seat support and engage the prop rod. 4-- 44 6100E 330255 (9- -00)
Page 187 6. Turn the front tire until the master link is visible at the bottom of the drive sprocket. Remove the master link from the drive chain. Make sure to retain the four small O- -rings from behind the master link clip. 4-- 45 6100E 330255 (9- -00)
Page 188 9. Finish removing the three nuts and washers holding the gearbox assembly to the wheel support. Remove the gearbox assembly from the machine. 10. Remove the four hex screws holding the smaller black cover to the side of the gearbox. 4-- 46 6100E 330255 (9- -00)
Page 189 14. Loosen the set screws holding the small timing sprocket to the drive motor. Slide the sprocket off the shaft. Make sure to retain the square key. 4-- 47 6100E 330255 (9- -00)
Page 190 Squeeze the pliers until the belt is tight (1/16 inch play at midpoint). Tighten the two motor mount screws to 18 -- 24 Nm (15 -- 20 ft lb). 4-- 48 6100E 330255 (9- -00)
Page 191 23. Reinstall the drive chain around the drive sprocket on the drive motor and front wheel assembly. Reinstall the master link. Make sure the four small O- -rings are in place behind the master link clip. 4-- 49 6100E 330255 (9- -00)
Page 192 18 -- 24 Nm (15 -- 20 ft lb). 26. Reconnect the drive motor to the main electrical harness. 27. Remove the jack stands and lower the machine to the floor. Operate the machine and check the gearbox assembly for proper operation. 4-- 50 6100E 330255 (9- -00)
Page 193 ELECTRICAL 28. Reconnect the batteries. 29. Disengage the prop rod and lower the seat support. 30. Operate the machine. Check the machine for proper operation. 4-- 51 6100E 330255 (9- -00)
Page 194: To Replace Main Brush Motor
1. Jack up the front of the machine at the jack point. Install jack stands under the machine frame. 2. Lower the main brush lever. 3. Open the seat support and engage the prop rod. 4-- 52 6100E 330255 (9- -00)
Page 195 Remove the right hand side brush door. 6. Locate the main brush drive belt idler pulley between the small motor drive pulley and the larger brush pulley. 7. Loosen the hex nut in the center of the idler pulley. 4-- 53 6100E 330255 (9- -00)
Page 196 V--belt pulley to the main brush motor shaft. Pull the pulley off the shaft. Retain the square key. 11. Remove the two hex screws holding the brush arm lift link to the front of the brush arm weldment. 4-- 54 6100E 330255 (9- -00)
Page 197 Note the orientation of the motor and electrical wires. 15. Install the new main brush motor into the machine. Make sure to orientate the motor so the wires are pointed to the front of the machine 4-- 55 6100E 330255 (9- -00)
Page 198 Line up the small V--belt pulley with the larger V--belt pulley. Make sure the square key is installed on the shaft. Hand tighten the two set screws tight. 4-- 56 6100E 330255 (9- -00)
Page 199 22. Move the idler pulley forward in the slot until the belt is tight. Tighten the hex nut to 18 -- 24 Nm (15 -- 20 ft lb). 23. Reinstall the right hand side brush door. 4-- 57 6100E 330255 (9- -00)
Page 200 25. Disengage the prop rod and lower the seat support. 26. Remove the jack stands and lower the machine to the floor. Operate the machine and check the new main brush motor for proper operation. 4-- 58 6100E 330255 (9- -00)
Page 201: To Replace Vacuum Fan Motor
1. The main brush motor must be removed before the vacuum fan motor can be removed. See TO REPLACE MAIN BRUSH MOTOR instructions in this section. 2. Open the seat support and engage the prop rod. 3. Disconnect the machine batteries. 4-- 59 6100E 330255 (9- -00)
Page 202 Remove the right hand side brush door. 6. Loosen the four hex screws holding the vacuum fan housing to the machine frame. 7. Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V--belt. 4-- 60 6100E 330255 (9- -00)
Page 203 Disconnect the vacuum fan motor from the main harness. 12. Remove the vacuum fan motor from the machine. Note the orientation of the motor and electrical wires. 4-- 61 6100E 330255 (9- -00)
Page 204 Line up the V--belt pulley with the V--belt pulley up at the impeller. Make sure the square key is installed on the shaft. Hand tighten the two set screws tight. 4-- 62 6100E 330255 (9- -00)
Page 205 8.38 mm (0.33 in) from a force of .42 kg (.90 to .95 lb) at belt midpoint. Tighten the screws hand tight. 18. Reinstall the right hand side brush door. 19. Reinstall the right hand machine cover. 20. Reconnect the batteries. 4-- 63 6100E 330255 (9- -00)
Page 206 21. Disengage the prop rod and lower the seat support. 22. Remove the jack stands and lower the machine to the floor. Operate the machine and check the new vacuum fan motor for proper operation. 4-- 64 6100E 330255 (9- -00)
Page 207: To Replace Side Brush Motor
1. Jack up the front of the machine at the jack point. Install jack stands under the machine frame. 2. Lower the side brush. 3. Remove the side brush from the motor assembly. See TO REPLACE SIDE BRUSH instructions in the SWEEPING section. 4-- 65 6100E 330255 (9- -00)
Page 208 6. Drop the motor out of the mount bracket and past the brush guard. 7. Position the new side brush motor onto the motor mount bracket. The motor is positioned to the rear of the machine. 4-- 66 6100E 330255 (9- -00)
Page 209 10. Wire tie the motor wires to the motor housing. 11. Reinstall the side brush. See TO REPLACE SIDE BRUSH instructions in the SWEEPING section. 12. Operate the machine. Check the side brush for proper operation. 4-- 67 6100E 330255 (9- -00)
Page 210: Electrical Schematic
ELECTRICAL ELECTRICAL SCHEMATIC 4-- 68 6100E 330255 (6- -01)
Page 211 ELECTRICAL ELECTRICAL SCHEMATIC 4-- 69 6100E 330255 (6- -01)
Page 212: Wire Harness
ELECTRICAL WIRE HARNESS 4-- 70 6100E 330255 (6- -01)
Page 213 ELECTRICAL WIRE HARNESS 4-- 71 6100E 330255 (6- -01)
Page 214 ELECTRICAL WIRE HARNESS 4-- 72 6100E 330255 (6- -01)
Page 215: Troubleshooting
ELECTRICAL TROUBLESHOOTING The troubleshooting charts that follow are organized so they lead you through the circuits. They include flow charts and instructions for you as to where to insert your test instruments. 4-- 73 6100E 330255 (9- -00)
Page 216 CHECK VOLTAGE ON WIRE 6/BLU AT RELAY M1. 0 VOLTS B+ VOLTAGE REPLACE RELAY M1 6/BLU, 4/GRN, 7/PUR, CB- -1, D- -1, OR THE KEYSWITCH PIN 30 TO PIN 15 IN THE RUN POSITION ARE OPEN. 4-- 74 6100E 330255 (9- -00)
Page 217 OHMS TO 5000 OHMS WHEN THE POTENTIOMETER IS TURNED. 3. WHEN THE POTENTIOMETER IS CENTERED THE RESISTANCE BE- TWEEN CONNECTOR POSITION B AND POSITION A OR C SHOULD BE HALF OF THE TOTAL RESISTANCE. (ABOUT 2500 OHMS) 4-- 75 6100E 330255 (9- -00)
Page 218 WIRES 35/YEL, 36/ORA, OR THE MOTOR CONNECTOR TERMINALS ARE OPEN. THE PROPEL MOTOR OR ASSOCIATED WIRES AND CONNECTOR ARE OPEN. REPLACE THE MOTOR. NOTE: THE RESISTANCE OF A TYPICAL PROPEL MOTOR IS 1.6 OHMS. 4-- 76 6100E 330255 (9- -00)
Page 219 OHMS TO 5000 OHMS WHEN THE POTENTIOMETER IS TURNED. 3. WHEN THE POTENTIOMETER IS CENTERED THE RESISTANCE BE- TWEEN CONNECTOR POSITION B AND POSITION A OR C SHOULD BE HALF OF THE TOTAL RESISTANCE. (ABOUT 2500 OHMS) CONTINUED ON NEXT PAGE 4-- 77 6100E 330255 (9- -00)
Page 220 WIRES 35/YEL, 36/ORA, OR THE MOTOR CONNECTOR TERMINALS ARE OPEN. THE PROPEL MOTOR OR ASSOCIATED WIRES AND CONNECTOR ARE OPEN. REPLACE THE MOTOR. NOTE: THE RESISTANCE OF A TYPICAL PROPEL MOTOR IS 1.6 OHMS. 4-- 78 6100E 330255 (9- -00)
Page 221 DISCONNECT BRUSH MOTOR AND CHECK VOLTAGE ACROSS 3/GRY AND 13A/BLK AT THE CONNECTOR. B+ VOLTAGE 0 VOLTS BRUSH MOTOR OR ITS AS- SOCIATED WIRES ARE OPEN. WIRE 3/GRY OR 13A/BLK OR BRUSH MOTOR CONNECTORS ARE OPEN. 4-- 79 6100E 330255 (9- -00)
Page 222 11A/PUR AND 13B/BLK AT THE CON- NECTOR. B+ VOLTAGE 0 VOLTS WIRE 11A/PUR 13B/BLK, OR SIDE BRUSH MOTOR CON- SIDE BRUSH MOTOR OR NECTOR ON MACHINE HAR- ITS CONNECTOR IS OPEN. NESS IS OPEN. 4-- 80 6100E 330255 (9- -00)
Page 223 DISCONNECT BRUSH MOTOR AND CHECK VOLTAGE ACROSS 14/PUR AND 13K/BLK AT THE CONNECTOR. B+ VOLTAGE 0 VOLTS BRUSH MOTOR OR ITS CONNECTOR IS OPEN. WIRE 14/PUR OR 13K/BLK OR BRUSH MOTOR CONNECTORS ARE OPEN. 4-- 81 6100E 330255 (9- -00)
Page 224 THE SOLENOID ASSEMBLY IS PHYSI- CALLY JAMMED OR THE SOLENOID IS DEFECTIVE. NOTE: IF THE SHAKER SYSTEM WORKS FOR A SHORT DURATION, THEN STOPS OR SLOWS, THE SHAKER COIL IS DRAWING EXCESSIVE CURRENT. REPLACE THE SHAKER COIL. 4-- 82 6100E 330255 (9- -00)
Page 225 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 227 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.

Tennant 6100E Service Manual

General Information

Table of Contents

Chassis

Introduction

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Chapters

Troubleshooting

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Questions and answers

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Summary of Contents for Tennant 6100E

Table of Contents