Tennant 6200D Service Manual
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Tennant 6200D Service Manual

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6200D
Service Manual
330395
Rev. 01 (6- -02)
*330395*

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  • Page 1 6200D Service Manual 330395 Rev. 01 (6- -02) *330395*...
  • Page 2 Hydraulics: Cylinder replacement, pump (s) replacement, hydraulic motor replacement, hydraulic schematic, and hydraulic troubleshooting. Engine - - D: Air filter replacement, oil changing, cooling system maintenance, engine troubleshooting, engine removal, and engine repairs. Manual Number -- 330395 Revision: 01 Published: 6--02 Copyright E 1999, 2002 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 6200D 330395 (6- -02)
  • Page 4 GENERAL INFORMATION 6200D 330395 (8- -99)

  • Page 5: Safety Precautions

    Engage hopper support bar. - - Use cardboard to locate leaking hydraulic fluid under pressure. FOR SAFETY: - - Use Tennant supplied or equivalent replacement parts. 1. Do not operate machine: - - Unless trained and authorized. 7. When loading/unloading machine...
  • Page 6 FOR SAFETY LABEL - - LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT. HOPPER LIFT ARMS LABEL - - LOCATED ON BOTH LIFT ARMS. HOPPER SUPPORT LABEL - - LOCATED ON BOTH LIFT ARMS AND THE HOPPER SUPPORT BAR. 6200D 330395 (6- -02)

  • Page 7: Specifications

    Maximum reverse speed 4.8 km/h Minimum aisle turn 2095 mm Minimum turning radius, left 1400 mm Minimum turning radius, right 1400 mm Maximum rated incline with empty hopper 10_/18% Maximum rated incline with full hopper 6_/11% 6200D 330395 (6- -02)

  • Page 8: Power Type

    TENNANT part no. 65869--above 7° C Main hydraulic total 9.48 L TENNANT part no. 65870--below 7° C Hydraulic lift reservoir 0.53 L TENNANT part no. 65870 (Hydraulic lift res. only) Hydraulic lift total 1.4 L BRAKING SYSTEM Type Operation Service brakes...

  • Page 9: Machine Dimensions

    GENERAL INFORMATION 1783 mm 1397 mm 1067 mm TOP VIEW 2035 mm 1435 mm SIDE VIEW FRONT VIEW 352945 MACHINE DIMENSIONS 6200D 330395 (6- -02)

  • Page 10: Maintenance

    Check brush pattern Fuel lines Check for damage and wear 100 Hours Engine Change oil and filter element Replace air filter element Check air filter housing dust cap Radiator Check core exterior for debris Check coolant level 6200D 330395 (6- -02)
  • Page 11 HYDO Tennant or approved hydraulic fluid . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) ..Water and permanent--type ethylene glycol anti--freeze, --34° C 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 6200D 330395 (6- -02)
  • 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. 6200D 330395 (6- -02) 1-11...

  • Page 14: Machine Jacking

    Block machine up with jack stands. STORING MACHINE Before storing the machine for an extended time, the machine needs to be serviced to lessen the chance of rust, sludge, and other undesirable deposits from forming. 1-12 6200D 330395 (6- -02)

  • Page 15: Hardware Information

    (291--380) (424--552) Locktite 515 sealant -- gasket forming 1.00 in 500--650 757--984 material. TENNANT Part No. 75567,15 oz (678--881) (1026--1334) (440 ml) cartridge. 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 6200D 330395 (8- -99)

  • Page 17: Machine Troubleshooting

    Hopper dust filter clogged Shake and/or clean or replace dust filter Machine will not start Engine oil level low Check and fill Fuel tank valve closed Open valve beneath fuel tank Fuel tank empty Fill fuel tank 6200D 330395 (6- -02) 1-15...
  • Page 18 GENERAL INFORMATION 1-16 6200D 330395 (8- -99)
  • Page 19 ....2--34 TO REPLACE FRONT DRIVE ASSEMBLY INNER WHEEL BEARING ....2--36 6200D 330395 (8- -99)
  • Page 20 CHASSIS 6200D 330395 (8- -99)

  • Page 21: Introduction

    CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat, steering, brakes, and tires. 6200D 330395 (8- -99)

  • Page 22: Operator Seat

    The adjustments are for the lumbar support, backrest angle, operator weight adjustment and front to back adjustment. The lumbar adjustment knob controls the firmness of the lumbar support. Increase firmness:Turn knob clockwise. Decrease firmness:Turn knob counterclockwise. 6200D 330395 (8- -99)
  • Page 23 The front- -to- -back adjustment lever adjusts the seat position. Adjust: Pull the lever out and slide the seat forward or backward to the desired position. Release the lever. 6200D 330395 (8- -99)

  • Page 24: Static Drag Chain

    The parking brake is located on the front wheel assembly. It is actuated with a smaller toe lever on the top of the foot brake pedal in the operators compartment. It is deactivated by simply pushing on the foot brake pedal. 6200D 330395 (8- -99)

  • Page 25: To Adjust Service Brakes

    5. Move the cable away from the brake lever far enough to remove the slack in the pedal movement. 6. Re--tighten the two jam nuts firmly. Operate the machine and check the brake pedal for a shorter stroke. 6200D 330395 (8- -99)

  • Page 26: To Adjust Parking Brake

    5. Move the cable away from the brake lever far enough to remove the slack in the pedal movement. 6. Re--tighten the two jam nuts firmly. Operate the machine and check the brake pedal for a shorter stroke. 6200D 330395 (8- -99)

  • Page 27: To Replace Drive Assembly Brake Shoes

    4. Remove the four hex screws holding the outer plate, motor, and drive hub to the main drive assembly. 5. Pull the outer plate, motor, and drive hub off the main drive assembly. 6200D 330395 (8- -99)
  • Page 28 12. Reinstall the ”C” spring on the new brake shoes. 13. Reinstall the axle/tire/wheel assembly into the drive assembly. Make sure the inner and outer wheel bearings are completely greased when re--assembling. 2-10 6200D 330395 (8- -99)
  • Page 29 (150 ft lb) while holding the hex sleeve from turning. 16. Reinstall the hub cap in the drive assembly. 17. Go to the other side of the drive assembly and install the plate, hub, and motor assembly onto the drive assembly. 6200D 330395 (8- -99) 2-11...
  • Page 30 20. Remove the jack stands and lower the machine. 21. Reconnect the battery cables. 22. Drive the machine and check the brakes for proper operation. Adjust if necessary. See TO ADJUST SERVICE BRAKES instructions. 2-12 6200D 330395 (8- -99)

  • Page 31: Rear Tires And Wheels

    CHASSIS REAR TIRES AND WHEELS The rear tires on the model 6200D are semi--pneumatic. The rear tire and wheel assemblies are idler wheels only----they have no braking capabilities. TO REMOVE REAR TIRE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake.

  • Page 32: To Install Rear Tire

    3. Install the washer and nut on the axle. Tighten to 68 -- 81 Nm (50 -- 60 ft lb). 4. Remove the jack stands and lower the machine. 5. Drive the machine and check for proper operation. 2-14 6200D 330395 (8- -99)

  • Page 33: To Replace Rear Wheel Bearings

    Remove the bearing housing. 3. Use a press to remove the wheel bearings from the housing. 4. Press the new wheel bearings into the housing. Press the bearing in until the flange is seated on the housing. 6200D 330395 (8- -99) 2-15...
  • Page 34 58 -- 76 Nm (43 -- 56 ft lb). NOTE: The lug nuts must face the outside of the machine. 6. Reinstall the rear wheel assembly in the machine. See TO INSTALL REAR TIRE instructions. 2-16 6200D 330395 (8- -99)

  • Page 35: Front Tire And Wheel, And Wheel Drive Support

    FRONT WHEEL SUPPORT CASTER BEARING ASSEMBLY The front wheel support caster bearing is located between the bottom swivel plate and the upper swivel plate weldment. The bearing is a flat needle bearing style. 6200D 330395 (8- -99) 2-17...

  • Page 36: To Remove Front Drive Assembly

    4. Go in operators compartment and loosen the lower steering shaft mount screws. 5. Pull the mount back to give the steering chain slack. Locate and remove the master link and steering chain. 2-18 6200D 330395 (8- -99)
  • Page 37 9. Go to the operators compartment and locate the 4 button head screws holding the drive assembly to the floor plate. Remove the 4 screws while supporting the drive assembly. 10. Remove the drive assembly from the machine. 6200D 330395 (8- -99) 2-19...

  • Page 38: To Install Front Drive Assembly

    6. Install the four button head screws and tighten to 64 -- 83 Nm (47 -- 61 ft lb). 7. Reinstall the steering chain and master link. Adjust the steering chain. See TO ADJUST STEERING CHAIN instructions. 2-20 6200D 330395 (8- -99)
  • Page 39 11. Remove the jack stands and lower the machine. 12. Reconnect the battery cables. 13. Operate the machine and check for proper operation. Check the brakes for proper operation. Adjust if necessary. See TO ADJUST SERVICE BRAKES instructions. 6200D 330395 (8- -99) 2-21...

  • Page 40: To Replace Drive Assembly Caster Bearing And Thrust Washers

    2. Remove the four hex screws holding the outer plate, drive motor, and drive hub to the main drive assembly. 3. Pull the drive hub, outer plate, and hydraulic motor out of the drive wheel and away from the drive assembly. 2-22 6200D 330395 (8- -99)
  • Page 41 6. Remove the cotter pin and castle nut from the upper swivel plate weldment. 7. Remove the flat washer and cone bearing from the bottom swivel plate. 8. Lift the bottom swivel plate off the upper swivel plate weldment. 6200D 330395 (8- -99) 2-23...
  • Page 42 Make sure the grease seal is in place on the upper swivel plate weldment. 14. Reinstall the bearing cone and flat washer on the bottom swivel plate. Make sure the bearing cone is greased. 2-24 6200D 330395 (8- -99)
  • Page 43 18. Install the drive hub, outer plate, and drive motor assembly onto the pins of the drive assembly. 19. Install the 4 hex screws and washers. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 6200D 330395 (8- -99) 2-25...
  • Page 44 20. Reinstall the drive assembly in the machine. See TO INSTALL FRONT DRIVE ASSEMBLY instructions. 21. Operate the machine and check for smooth steering operation. Check the brakes for proper operation. Adjust if necessary. See TO ADJUST SERVICE BRAKES instructions. 2-26 6200D 330395 (8- -99)

  • Page 45: To Replace Drive Assembly Pivot Cone Bearing

    3. Pull the drive hub, outer plate, and drive motor assembly out of the drive wheel and away from the drive assembly. 6200D 330395 (8- -99) 2-27...
  • Page 46 9. Reinstall the castle nut and tighten to 200 Nm (150 ft lbs). Then tighten to the next nearest hole and install the cotter pin. 10. Reinstall the sprocket on the pivot assembly. 2-28 6200D 330395 (8- -99)
  • Page 47 14. Reinstall the drive assembly in the machine. See TO INSTALL FRONT DRIVE ASSEMBLY instructions. 15. Operate the machine and check for smooth steering operation. Check the brakes for proper operation. Adjust if necessary. See TO ADJUST SERVICE BRAKES instructions. 6200D 330395 (8- -99) 2-29...

  • Page 48: To Replace Front Tire And Wheel Assembly

    4. Remove the four hex screws holding the outer plate, drive motor, and drive hub assembly to the main drive assembly. 5. Pull the drive hub, outer plate, and drive motor out of the drive wheel and away from the drive assembly. 2-30 6200D 330395 (8- -99)
  • Page 49 9. The inner bearing, axle shaft, and tire/wheel assembly can now be removed from the drive assembly. Use a press to remove the inner bearing from the existing tire/wheel assembly. 10. Install the inner bearing on the new tire/wheel assembly. 6200D 330395 (8- -99) 2-31...
  • Page 50 13. Install the lock bolt in the end of the hex sleeve. Tighten the lock bolt to 200 Nm (150 ft lb) while holding the hex sleeve from turning. 14. Reinstall the hub cap in the drive assembly. 2-32 6200D 330395 (8- -99)
  • Page 51 Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 17. Reconnect the hydraulic hoses to the drive motor. 18. Reconnect the battery cables. 19. Remove the jack stands and lower the machine. 20. Drive the machine and check for proper operation. 6200D 330395 (8- -99) 2-33...

  • Page 52: To Replace Front Drive Assembly Outer Wheel Bearing

    6. Use a press to remove the old outer bearing cone from the hex sleeve. Install a new outer bearing on the hex sleeve or replace the bearing and sleeve assembly. Apply grease to the new bearing. 2-34 6200D 330395 (8- -99)
  • Page 53 9. Reinstall the hub cap in the drive assembly. 10. Reconnect the battery cables. 11. Remove the jack stands and lower the machine. 12. Drive the machine and check for proper operation. 6200D 330395 (8- -99) 2-35...

  • Page 54: To Replace Front Drive Assembly Inner Wheel Bearing

    5. Pull the drive hub, outer plate, and drive motor assembly out of the drive wheel and away from the drive assembly. 2-36 6200D 330395 (8- -99)
  • Page 55 Use a press to remove the inner bearing from the existing tire/wheel assembly. Discard the old wheel bearing. 10. Press a new inner wheel bearing on the wheel shaft. Apply grease to the new bearing. 6200D 330395 (8- -99) 2-37...
  • Page 56 13. Install the lock bolt in the end of the hex sleeve. Tighten the lock bolt to 200 Nm (150 ft lb) while holding the hex sleeve from turning. 14. Reinstall the hub cap in the drive assembly. 2-38 6200D 330395 (8- -99)
  • Page 57 Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 17. Reconnect the hydraulic hoses to the drive motor. 18. Reconnect the battery cables. 19. Remove the jack stands and lower the machine. 20. Drive the machine and check for proper operation. 6200D 330395 (8- -99) 2-39...

  • Page 58: Steering

    CHASSIS STEERING The steering on the model 6200D is controlled with two sprockets and one chain. A large diameter sprocket is mounted on the top of the front drive assembly and a small diameter sprocket is mounted on the bottom of the steering shaft.

  • Page 59: To Replace Steering Chain

    7. Route the new chain around both steering sprockets. Install the master link. 8. Remove the jack stands and lower the machine. Reconnect the battery cables. 9. Operate the machine and check the steering for proper operation. 6200D 330395 (8- -99) 2-41...

  • Page 60: To Replace Large Steering Sprocket

    3. Remove the old sprocket from the pivot assembly. 4. Install the new sprocket on the pivot assembly. NOTE: Make sure the roll pin in the top of the drive assembly lines up with the hole in the sprocket. 2-42 6200D 330395 (8- -99)
  • Page 61 68 -- 81 Nm (50 -- 60 ft lb). 6. Reinstall the drive assembly in the machine. See TO INSTALL FRONT DRIVE ASSEMBLY instructions. 7. Reconnect the battery cables. 8. Operate the machine and check for smooth steering operation. 6200D 330395 (8- -99) 2-43...

  • Page 62: To Replace Small Steering Sprocket

    4. Go under the machine and locate the steering chain. 5. Rotate the steering wheel until the master link on the chain is accessible. 6. Remove the chain master link. Remove the steering chain from both sprockets. 2-44 6200D 330395 (8- -99)
  • Page 63 Install the master link. 10. Adjust the steering chain. See TO ADJUST STEERING CHAIN instructions. 11. Remove the jack stands and lower the machine. 12. Operate the machine and check the steering for proper operation. 6200D 330395 (8- -99) 2-45...

  • Page 64: To Replace Steering Housing Bearings

    4. Pull the steering wheel and long steering shaft up and out of the top of the steering U--joint. 5. Remove the two hex screws holding the steering bearing housing to the machine frame. Push the bearing housing back in the slots. 2-46 6200D 330395 (8- -99)
  • Page 65 8. Remove the steering housing from the machine. 9. Loosen the two set screws holding the U--joint to the top of the short steering shaft. Remove and retain the U--joint and square key. 6200D 330395 (8- -99) 2-47...
  • Page 66 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. 2-48 6200D 330395 (8- -99)
  • Page 67 Tighten the two hex screws to 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. 6200D 330395 (8- -99) 2-49...

  • Page 68: To Replace Steering U--Joint

    U--joint. 4. Loosen the two set screws holding the U--joint to the top of the short steering shaft. Remove and discard the U--joint and square key. 2-50 6200D 330395 (8- -99)
  • Page 69 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. 6200D 330395 (8- -99) 2-51...

  • Page 70: Directional Pedal

    Use the brake pedal to stop the machine. 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. 2-52 6200D 330395 (8- -99)
  • Page 71 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. 6200D 330395 (8- -99) 2-53...

  • Page 72: 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). 2-54 6200D 330395 (8- -99)
  • Page 73 Position the ball joint into the hole on the pivot. Tighten the nut. 6. Reconnect the battery cables. 7. Disengage the prop rod and lower the seat support. 8. Start the machine and check for proper operation. 6200D 330395 (8- -99) 2-55...
  • Page 74 CHASSIS 2-56 6200D 330395 (8- -99)
  • Page 75 ....3-55 TO REPLACE VACUUM FAN IMPELLER BEARINGS ..3-60 MACHINE TROUBLESHOOTING . . . 3-63 6200D 330395 (6- -02)
  • Page 76 SWEEPING 6200D 330395 (8- -99)

  • Page 77: Introduction

    SWEEPING INTRODUCTION This section includes information on the sweeping operation of the model 6200D. 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 78: Debris Hopper

    The lift cylinder is provided hydraulic flow from a electro/hydraulic unit. The electro/hydraulic unit is activated with a dash mounted switch. The hopper is held in the raised position with a prop arm. 6200D 330395 (8- -99)

  • Page 79: Hopper Dust Filter

    Rinse the dust filter until it is clean. 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. 6200D 330395 (8- -99)

  • Page 80: Replacing Hopper Dust Filter

    Do not unplug the connections from the shaking mechanism. Do not pull on the wires. Damage could occur to the wires or the shaking mechanism. 4. Lift dust filter assembly out of hopper. 6200D 330395 (6- -02)
  • Page 81 6. Lift the VCSt system filter shaker off of the filter. 7. Clean or discard the Instant Accesst filter as required. 8. Replace the VCSt system filter shaker. Use care to insert the shaking pin into the filter comb correctly. 6200D 330395 (8- -99)
  • Page 82 The gap should be the same width as the tab. If it is not, loosen the mounting screws, adjust the gap by repositioning the shaker solenoid, then retighten the screws. 12. Return the filter back to the machine. 6200D 330395 (6- -02)
  • Page 83 SWEEPING 13. Reconnect the main harness to the shaker mechanism. 14. Check the dust filter seals. 15. Replace hopper cover and secure with latches. 6200D 330395 (6- -02)

  • Page 84: Main Brush

    1. Stop the machine, set the parking brake and turn the machine power off. 2. Open the left side main brush access door. 3. Loosen the idler arm mounting knob and three other side skirt mounting knobs. Remove the brush idler arm assembly. 3-10 6200D 330395 (6- -02)
  • Page 85 8. Slide the main brush idler arm plug onto the main brush. 9. Secure the idler arm on the bolts. Hand tighten the mounting knobs. 10. Close the main brush access door. 6200D 330395 (8- -99) 3-11...

  • Page 86: Checking And Adjusting Main Brush Pattern

    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. 3-12 6200D 330395 (8- -99)

  • Page 87: Main Brush Belts

    3. Locate the main brush drive belt idler pulley between the small drive pulley and the larger brush pulley. 4. Loosen the hex nut in the center of the idler pulley. 5. Push the idler pulley back in the slot. 6200D 330395 (6- -02) 3-13...
  • Page 88 9. Reinstall the vacuum fan drive belt onto the lower sheave. See TO REPLACE VACUUM FAN DRIVE BELT instructions in this section. 10. Reinstall the right hand side brush door. 11. Operate the machine and check the main brush for proper operation. 3-14 6200D 330395 (8- -99)

  • Page 89: To Replace Main Brush Idler Plug Bearing

    See TO REPLACE MAIN BRUSH instructions in this sections. 3. Remove the idler arm from the brush lift plate. 4. Remove the hex screw, nut, and washer holding the idler plug assembly to the brush lift plate. 6200D 330395 (8- -99) 3-15...
  • Page 90 8. Position the new ball bearing into the idler plug. 9. Reinstall the bearing retainer plate on the idler plug. Reinstall the four screws and tighten to 8 -- 10 Nm (6 -- 7 ft lb). 3-16 6200D 330395 (8- -99)
  • Page 91 12. Reinstall the main brush idler mount plate. See TO REPLACE MAIN BRUSH instructions in this sections. 13. Close the left hand side brush door. 14. Operate the machine and check the main brush for proper operation. 6200D 330395 (8- -99) 3-17...

  • Page 92: To Replace Main Brush Drive Plug Shaft Bearings

    4. Remove the main brush. See TO REPLACE MAIN BRUSH instructions in this sections. 5. Remove the main brush drive belt. See TO REPLACE MAIN BRUSH DRIVE BELT instructions in this section. 3-18 6200D 330395 (8- -99)
  • Page 93 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. 6200D 330395 (8- -99) 3-19...
  • Page 94 17. Install the new bearing and main brush shaft assembly into the main brush bearing housing. Install the nut onto the inside of the main brush shaft. Use a hammer to lightly tap the bearing and shaft into the housing. 3-20 6200D 330395 (8- -99)
  • Page 95 (39 -- 51 ft lb). 20. Reinstall the main brush drive belt. See TO REPLACE MAIN BRUSH DRIVE BELT instructions in this section. 21. Reinstall the main brush. See TO REPLACE MAIN BRUSH instructions in this sections. 6200D 330395 (8- -99) 3-21...
  • Page 96 22. Reinstall the right hand brush door and close the left hand brush door. 23. Remove the jack stands and lower the machine. 24. Operate the machine and check the main brush for proper operation. 3-22 6200D 330395 (8- -99)

  • Page 97: To Replace Main Brush Drive Belt Idler Pulley

    3. Loosen the hex nut in the center of the idler pulley. 4. Push the idler pulley back in the slot. 5. Remove the main brush drive belt from the two remaining pulleys. 6200D 330395 (8- -99) 3-23...
  • Page 98 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. 3-24 6200D 330395 (8- -99)

  • Page 99: Jack Shaft Brush Belt

    Disconnect the battery cables. 2. Remove the main brush. See TO REPLACE MAIN BRUSH instructions in this section. 3. Locate the main brush jack shaft belt tension idler pulley mount plate near the flywheel sheave. 6200D 330395 (8- -99) 3-25...
  • Page 100 6. Remove the V--belt from the engine sheave, idler sheaves, and main brush jack shaft sheave. Remove the V--belt from the machine. 7. Install the new V--belt onto the engine sheave, idler sheaves, and main brush shaft sheave. 3-26 6200D 330395 (8- -99)
  • Page 101 4.5 in. long. 9. Reinstall the main brush. 10. Disengage the seat rod and close the seat assembly. 11. Operate the machine and check the main brush for proper operation. 6200D 330395 (8- -99) 3-27...

  • Page 102: To Replace Main Brush Jackshaft Inner Bearing

    1. Open the seat support and engage the prop rod. Disconnect the battery cables. 2. Remove the main brush. See TO REPLACE MAIN BRUSH instructions in this section. 3. Locate the main brush jack shaft belt on the engine mounted sheave plate. 3-28 6200D 330395 (8- -99)
  • Page 103 6. Remove the V--belt from the main brush jack shaft sheave. 7. Locate the main brush jack shaft V--belt sheave in the brush compartment area. Loosen the two set screws. Remove the sheave from the jack shaft. Retain the square key. 6200D 330395 (8- -99) 3-29...
  • Page 104 9. Remove the two hex screws and nuts holding the bearing flanges to the mount bracket. 10. Remove the outer bearing flange from the mount bracket. 11. Pull the inner bearing off the jack shaft. Leave the inner bearing flange in place. 3-30 6200D 330395 (8- -99)
  • Page 105 Make sure the square key is in place on the jack shaft. Position the sheave so the face is flush with the end of the shaft. Hand tighten the two sheave set screws tight. 6200D 330395 (8- -99) 3-31...
  • Page 106 Tighten the jam nuts on the threaded rod until the tension spring is 4.5 in. long. 18. Reinstall the main brush. 19. Start the machine and operate the main brush. Check for proper operation. 3-32 6200D 330395 (8- -99)

  • Page 107: To Replace Main Brush Jackshaft Outer Bearing

    1. Open the seat support and engage the prop rod. Disconnect the battery cables. 2. Remove the main brush. See TO REPLACE MAIN BRUSH instructions in this section. 3. Locate the main brush jack shaft belt on the engine mounted sheave plate. 6200D 330395 (8- -99) 3-33...
  • Page 108 V--belt. 6. Remove the V--belt from the main brush jack shaft sheave. 7. Remove the four screws holding the right hand brush door to the machine frame. Remove the right hand side brush door. 3-34 6200D 330395 (8- -99)
  • Page 109 13. Loosen the hex nut in the center of the idler pulley. 14. Push the idler pulley back in the slot. Remove the main brush V--belt from the jack shaft sheave. 6200D 330395 (8- -99) 3-35...
  • Page 110 17. Loosen the hardware holding each of the two jack shaft bearing flanges to the mount brackets. 18. Push the jack shaft in, toward the center of the machine. Push the shaft in far enough so it clears the outer bearing. 3-36 6200D 330395 (8- -99)
  • Page 111 23. Go under the machine in the brush wrap area. Tighten the hardware holding the two jack shaft bearing flanges to the mount brackets. Tighten the hardware to 18 -- 24 Nm (15 -- 20 ft lb). 6200D 330395 (8- -99) 3-37...
  • Page 112 26. Position the V--belt over the jack shaft sheave. 27. Pull the tension idler pulley mount plate and reconnect the tension spring. Tighten the jam nuts on the threaded rod until the tension spring is 4.5 in. long. 3-38 6200D 330395 (8- -99)
  • Page 113 31. 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). 32. Install the vacuum fan V--belt over the jack shaft sheave. 6200D 330395 (8- -99) 3-39...
  • Page 114 34. Tighten the five mounts screws hand tight. 35. Reinstall the right hand machine cover. 36. Reinstall the right hand side brush door. 37. Operate the machine and check the main brush for proper operation. 3-40 6200D 330395 (8- -99)

  • Page 115: Side Brush

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 2. Remove the side brush retaining pin from the side brush drive shaft by pulling the pin keeper off over the end of the pin. 6200D 330395 (6- -02) 3-41...
  • Page 116 Move the pulley mount bracket up or down to achieve the proper side brush pattern. Retighten the hex screw. 3-42 6200D 330395 (8- -99)

  • Page 117: 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. 6200D 330395 (6- -02) 3-43...

  • Page 118: To Replace Side Brush Lift Cable

    3. Go to the operators compartment. Remove the two cable pulleys, sleeves, and cable clips from the side brush lift cable. NOTE: Note the orientation of the cable clips for proper re- -assembly. 3-44 6200D 330395 (8- -99)
  • Page 119 6. Route the new side brush lift cable in the machine. 7. Reinstall the three cable pulleys, sleeves, and cable clips. Make sure the cable clips are in the correct orientation. Tighten the hardware to 18 -- 24 Nm (15 -- 20 ft lb). 6200D 330395 (8- -99) 3-45...
  • Page 120 Hand tighten the hex nut. Cable should pivot on the hardware. 9. Connect the side brush lift cable to the lift handle. 10. Raise the side brush. Check the new cable for smooth operation. 3-46 6200D 330395 (8- -99)

  • Page 121: Skirts And Seals

    SIDE SKIRTS The side skirts are located on both sides of the main brush compartment. The skirts should clear the floor up to 5 mm. 6200D 330395 (8- -99) 3-47...

  • Page 122: Large Debris Trap Skirt

    Raising the front skirt will allow large debris to enter the main brush area and be deposited into the hopper. Check the seal for wear or damage after every 100 hours of operation. 3-48 6200D 330395 (8- -99)

  • Page 123: Hopper Seals

    The hopper lip seal is located on the inside of the rear lip of the hopper door and seals the inside lip of the hopper door with the hopper. Check the seal for wear or damage after every 100 hours of operation. 6200D 330395 (6- -02) 3-49...

  • Page 124: Vacuum Fan

    100 hours of operation. The correct tension is when the belt deflects 13.0 mm (0.50 in) from a force of 15 kg (30 to 40 lb) at belt midpoint. WARNING: Moving belt and fan. Keep away. 3-50 6200D 330395 (6- -02)

  • Page 125: To Replace Vacuum Fan Drive Belt

    2. Remove the right hand side brush door. 3. Loosen the five hex screws holding the vacuum fan housing to the machine frame. 4. Push the vacuum fan assembly forward in the slots to loosen the vacuum fan V--belt. 6200D 330395 (8- -99) 3-51...
  • Page 126 8. Pull the vacuum fan assembly toward the back of the machine to tighten the V--belt. Tighten the five mounts screws hand tight. 9. Reinstall the V--belt cover. Tighten the two screws hand tight. 3-52 6200D 330395 (8- -99)
  • Page 127 SWEEPING 10. Reinstall the right hand machine cover. 11. Reinstall the right hand brush door. 12. Operate the machine. Check the vacuum fan for proper operation. 6200D 330395 (8- -99) 3-53...

  • Page 128: To Tension Vacuum Fan Drive Belt

    (.88 to .93 lb) at belt midpoint. 4. Tighten the four vacuum housing mount screws hand tight. 5. Reinstall the right hand machine cover. 6. Operate the machine. Check the vacuum fan for proper operation. 3-54 6200D 330395 (8- -99)

  • Page 129: To Replace Vacuum Fan Impeller

    V--belt. 5. Remove the two hex screws holding the cover over the V--belt pulley. Remove the cover. 6. Remove the vacuum fan V--belt from the vacuum fan sheave. 6200D 330395 (8- -99) 3-55...
  • Page 130 11. Remove the five hex screws and nuts holding the vacuum fan inlet plate to the bearing housing plate. Remove the inlet plate from the housing. NOTE: Make sure to retain the five steel sleeves. 3-56 6200D 330395 (8- -99)
  • Page 131 16. Position the vacuum fan assembly onto the right side off the machine. Reinstall the five hex screws and nuts. Make sure to install the two steel sleeves on the bottom two hex screws. Leave the hardware loose for now. 6200D 330395 (8- -99) 3-57...
  • Page 132 8.38 mm (0.41 in) from a force of .42 kg (.88 to .93 lb) at belt midpoint. 19. Tighten the five mounts screws hand tight. 20. Reinstall the V--belt cover. Tighten the two screws hand tight. 21. Connect the wires to the Thermo Sentryt. 3-58 6200D 330395 (8- -99)
  • Page 133 23. Reinstall the right hand machine cover. 24. Start the machine, raise the hopper, disengage the prop arm. Lower the hopper. 25. Operate the machine. Check the vacuum fan for proper operation. 6200D 330395 (8- -99) 3-59...

  • Page 134: To Replace Vacuum Fan Impeller Bearings

    2. Loosen the two set screws holding the V--belt pulley to the fan shaft. Remove the pulley. 3. Remove the four hex screws holding the vacuum fan bearing assembly to the bearing plate. Remove the bearing assembly. 3-60 6200D 330395 (8- -99)
  • Page 135 Tighten to 8 -- 10 Nm (6 -- 8 ft lb). 7. Reinstall the V--belt pulley on the short end of the fan shaft. The recessed side of the pulley goes to the inside. Hand tighten the set screws tight. 6200D 330395 (8- -99) 3-61...
  • Page 136 Make sure to reinstall the square key on the fan shaft. 9. See TO REPLACE VACUUM FAN IMPELLER instructions to install the vacuum fan impeller and the vacuum fan assembly into the machine. 3-62 6200D 330395 (8- -99)

  • Page 137: Machine Troubleshooting

    Hopper dust filter clogged Shake and/or clean or replace dust filter Machine will not start Engine oil level low Check and fill Fuel tank valve closed Open valve beneath fuel tank Fuel tank empty Fill fuel tank 6200D 330395 (6- -02) 3-63...
  • Page 138 SWEEPING 3-64 6200D 330395 (6- -02)
  • Page 139 ....4-33 ELECTRICAL SCHEMATIC ..4-38 WIRE HARNESSES GROUP ..4-39 6200D 330395 (6- -02)
  • Page 140 ELECTRICAL 6200D 330395 (8- -99)

  • Page 141: Introduction

    ELECTRICAL INTRODUCTION The model 6200D electrical system consists of the battery, instrument panel, side brush motor, switches, relays, and circuit breakers. 6200D 330395 (8- -99)

  • Page 142: Electrical System

    ELECTRICAL ELECTRICAL SYSTEM The electrical system on the model 6200D is a 12 volt system consisting of a battery, alternator, circuit breakers, relays, and switches. BATTERY The battery is located under the operator’s seat and can be accessed by lifting the seat up.

  • Page 143: To Charge Battery

    4. Start the charger. Check the voltage meter on the charger for proper charge voltage. 5. Remove the charger after the voltage meter reads a full charge. 6200D 330395 (8- -99)
  • Page 144 ELECTRICAL 6. Reinstall the negative battery cable and start the machine. Check the battery for proper operation. 7. Disengage the prop rod and lower the seat support. 6200D 330395 (8- -99)

  • Page 145: To Replace Battery

    1. Open the seat support and engage the prop rod. 2. Locate the battery at the right hand side of the machine, in front of the hydraulic tank. 3. Remove the battery negative cable and positive cable from the battery terminals. 6200D 330395 (8- -99)
  • Page 146 5. Install the new battery in the machine in the same orientation as the old one. 6. Reconnect the battery cables to the battery (red cable to positive post, black cable to negative post). 7. Reinstall the battery hold down bracket. 6200D 330395 (8- -99)
  • Page 147 ELECTRICAL 8. Disengage the prop rod and lower the seat support. 9. Check the new battery for proper operation. If battery needs charging, see TO CHARGE BATTERY instructions in this section. 6200D 330395 (8- -99)

  • Page 148: Instrument Panel

    ELECTRICAL INSTRUMENT PANEL The instrument panel on the model 6200D contains the switches, gauges, and instruments needed to run the machine functions. TO ACCESS CIRCUIT BREAKER OR INSTRUMENT PANEL FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake.
  • Page 149 5. Pivot the circuit breaker panel back away from the front shroud. 6. With the circuit breaker panel pivoted down, electrical components on the circuit breaker panel and the main instrument panel can be accessed. 4-11 6200D 330395 (8- -99)
  • Page 150 8. Open the seat support and engage the prop rod. 9. Reconnect the battery. 10. Disengage the prop rod and lower the seat support. 11. Start the machine and check for proper operation. 4-12 6200D 330395 (8- -99)

  • Page 151: Circuit Breakers

    15 A Side brush(es) CB-4 40 A Hopper lift motor CB-5 15 A Main CB-6 15 A Hopper door CB-7 15 A Headlight, Taillight- Warning light CB-8 15 A Glow plugs CB-9 15 A Fuel solenoid 4-13 6200D 330395 (6- -02)

  • Page 152: To Replace Circuit Breaker

    See TO ACCESS CIRCUIT BREAKER OR INSTRUMENT PANEL instructions. 2. Locate the circuit breaker that needs to be changed. 3. Mark and disconnect the wires leading to the back of the circuit breaker. 4-14 6200D 330395 (8- -99)
  • Page 153 8. Install the black threaded bushing onto the new circuit breaker. 9. Install the rubber boot onto the out side of the new circuit breaker. 10. Reconnect the electrical wires to the new circuit breaker. See schematic in the ELECTRICAL section. 4-15 6200D 330395 (8- -99)
  • Page 154 11. Pivot the instrument panel back onto the front shroud. Reinstall the hardware and hand tighten tight. See TO ACCESS CIRCUIT BREAKER OR INSTRUMENT PANEL instructions. 12. Start the machine and check the new circuit breaker for proper operation. 4-16 6200D 330395 (8- -99)

  • Page 155: Solenoid Control Module

    GLOW PLUG TIMER The glow plug timer is used to operate the glow plugs to ease the starting of the engine on the 6200D. 4-17 6200D 330395 (8- -99)

  • Page 156: To Replace Engine Fuel Shutoff Solenoid

    1. Open the seat support. 2. Remove the battery negative cable. 3. Go to the left hand side of the engine. Locate the fuel shutoff solenoid in the area to the right of the steel injector lines. 4-18 6200D 330395 (8- -99)
  • Page 157 7. Position the new solenoid on the engine. Place the pin on the end of the solenoid plunger rod into the hook on the throttle arm. Reinstall the two hex screws. Leave loose for now. 4-19 6200D 330395 (8- -99)
  • Page 158 The fuel solenoid plunger should move along with the throttle arm NOTE: The fuel solenoid should make an audible click when the key is turned on. 12. Lower the seat support. 13. Start the machine and check for proper operation. 4-20 6200D 330395 (8- -99)

  • Page 159: To Replace Dump Door Actuator

    (one each side of the hopper) go slack. 2. Un--latch and remove the hopper filter cover. 3. Locate the dump door actuator on the left side of the hopper panel filter and shaker. 4-21 6200D 330395 (8- -99)
  • Page 160 6. Install the new dump door actuator into the machine in the same orientation as the old one. 7. Reinstall the hair pin and clevis pin into each end of the new actuator. 4-22 6200D 330395 (8- -99)
  • Page 161 9. Reinstall the hopper cover and latch it down. 10. Turn on the key and close the dump door. Remove the wood block from under the dump door. 11. Operate the machine and check the new dump door actuator for proper operation. 4-23 6200D 330395 (8- -99)

  • Page 162: Thermo Sentryt

    If fire is detected in the hopper filter area, the Thermo Sentryt sends a signal to the shut off solenoid. The solenoid in turn closes the shut off valve plate in the vacuum tube. 4-24 6200D 330395 (8- -99)

  • Page 163: To Replace Thermo Sentryt4-25

    1. Un--latch and remove the hopper filter cover. 2. Locate the Thermo Sentryt at the back side of the 90 degree section of the vacuum tube. 3. Remove the wires leading to the Thermo Sentryt. 4-25 6200D 330395 (8- -99)
  • Page 164 5. Install the new Thermo Sentryt onto the vacuum tube. Reinstall the hardware and hand tighten. Make sure the gasket is installed under the Thermo Sentryt. 6. Reconnect the wires to the Thermo Sentryt. 7. Reinstall the hopper cover. 4-26 6200D 330395 (8- -99)

  • Page 165: To Replace Vacuum Fan Shut Off Solenoid

    1. Un--latch and remove the hopper filter cover. 2. Locate the shut off solenoid at the front side of the 90 degree section of the vacuum tube. 3. Remove the wires leading to the shut off solenoid. 4-27 6200D 330395 (8- -99)
  • Page 166 6. Remove the clevis pin holding the solenoid plunger to the shut off lever. Remove the solenoid from the machine. 7. Install the new vacuum fan shut off solenoid onto the mount bracket. Hand tighten the jam nut. 4-28 6200D 330395 (8- -99)
  • Page 167 8. Reinstall the clevis pin into the end of the solenoid plunger and shut off lever arm. 9. Reconnect the tension spring to the shut off lever arm. 10. Reconnect the main harness to the new solenoid. 11. Reinstall the hopper cover. 4-29 6200D 330395 (8- -99)

  • Page 168: To Replace Engine Starter

    1. Tilt the seat assembly forward and engage the prop rod. Disconnect the battery cables from the battery. 2. Locate the alternator on the right side of the engine. 3. Disconnect the wires from the starter motor. 4-30 6200D 330395 (8- -99)
  • Page 169 Re--use the two hex screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 6. Reconnect the electrical wires to the starter. See schematic in this section. 7. Reconnect the battery cables to the battery. 4-31 6200D 330395 (8- -99)
  • Page 170 ELECTRICAL 8. Disengage the seat prop rod and pivot the seat assembly down. 9. Check the new starter for proper operation. 4-32 6200D 330395 (8- -99)

  • Page 171: To Replace Machine Alternator

    Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Tilt the seat assembly forward and engage the prop rod. 2. Disconnect the battery cables from the battery. 3. Locate the alternator on the right side of the engine. 4-33 6200D 330395 (8- -99)
  • Page 172 5. Loosen the hex screw holding the top of the alternator to the pivot bracket. 6. Loosen the hex screw on the bottom of the alternator. 7. Pivot the alternator in toward the engine and remove the fan belt from the sheave. 4-34 6200D 330395 (8- -99)
  • Page 173 10. Reinstall the longer, lower hex bolt and nut. Leave loose for now. 11. Reinstall the shorter hex bolt in the top of the alternator. Leave loose for now. 12. Reinstall the fan/alternator belt. 4-35 6200D 330395 (8- -99)
  • Page 174 WARNING: Moving Belt And Fan Blades. Keep Away. 14. Firmly tighten the lower hex bolt. 15. Reconnect the wires to the back of the alternator. See schematic in this section. 16. Reconnect the battery cables. 4-36 6200D 330395 (8- -99)
  • Page 175 ELECTRICAL 17. Close the seat support. 18. Operate the machine. Check the new alternator for proper operation. 4-37 6200D 330395 (8- -99)

  • Page 176: Electrical Schematic

    ELECTRICAL ELECTRICAL SCHEMATIC 353188 - - D 4-38 6200D 330395 (6- -02)
  • Page 177 ELECTRICAL WIRE HARNESSES GROUP 352986 - - 353189 - - D 4-39 6200D 330395 (6- -02)

  • Page 178: Wire Harnesses Group

    ELECTRICAL WIRE HARNESSES GROUP 352986 - - 353189 - - D 4-40 6200D 330395 (6- -02)
  • Page 179 ELECTRICAL WIRE HARNESSES GROUP 352986 - - 353189 - - D 4-41 6200D 330395 (6- -02)
  • Page 180 ELECTRICAL WIRE HARNESSES GROUP 352986 - - 353189 - - D 4-42 6200D 330395 (6- -02)
  • Page 181 ELECTRICAL WIRE HARNESSES GROUP 352986 - - 353189 - - D 4-43 6200D 330395 (6- -02)
  • Page 182 ELECTRICAL WIRE HARNESSES GROUP 352986 - - 353189 - - D 4-44 6200D 330395 (6- -02)
  • Page 183 ....5-34 HOPPER WILL NOT RAISE/LOWER . . . 5-35 PROPEL MOTOR WILL NOT PROPEL 5-36 EATON REPAIR INFORMATION ..5-37 6200D 330395 (6- -02)
  • Page 184 HYDRAULICS 6200D 330395 (8- -99)

  • Page 185: Introduction

    HYDRAULICS INTRODUCTION The hydraulic system on the model 6200D consists of the hydraulic pump, directional control valve, electro/hydraulic pump, reservoir, hopper lift cylinder, and drive motor. 6200D 330395 (8- -99)

  • Page 186: Hydraulic Fluid Reservoir

    800 hours of operation. The hydraulic fluid filter is located in front of the hydraulic reservoir near the rear of the engine compartment. Replace the filter element every 800 hours of operation. 6200D 330395 (8- -99)

  • Page 187: Hydraulic Fluid

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

  • Page 188: Hydraulic Fluid Filter

    1. Open the seat support and engage the prop rod. 2. Locate the hydraulic fluid filter in front of the hydraulic tank. 3. Place a small drip pan or rag under the filter. 6200D 330395 (8- -99)
  • Page 189 Tighten until snug then 1/4 turn. 7. Remove the drain pan or rag. 8. Disengage the prop rod and close the seat support. 9. Start the machine and check the new hydraulic fluid filter for any leaks. 6200D 330395 (8- -99)

  • Page 190: Hydraulic Pump

    1. Tilt the seat assembly forward and engage the prop rod. Disconnect the battery cables from the battery. 2. Mark, disconnect, and plug the two hoses leading to the hydraulic pump. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 6200D 330395 (8- -99)
  • Page 191 Make sure to retain the square key. 6. Install the V--belt sheave onto the shaft of the new hydraulic pump in the same orientation that it was removed. Leave the set screws loose for now. 6200D 330395 (8- -99)
  • Page 192 V--belt. Hand tighten the hardware tight. The correct tension is when the belt deflects 4.0 mm (0.16 in) from a force of .45 kg (10.0 lb) at belt midpoint of the longest span. 5-10 6200D 330395 (8- -99)
  • Page 193 12. Reconnect the battery cables. 13. Start the machine and check the new pump for proper operation and for leaks. 14. Disengage the prop rod and lower the seat support. 5-11 6200D 330395 (8- -99)

  • Page 194: To Replace Hydraulic Pump V--Belt

    Push forward on the V--belt idler arm and remove the V--belt from the flywheel sheave. 3. Loosen the hardware holding the hydraulic pump to the mount bracket. Push the pump down and remove the V--belt from the pump sheave. 5-12 6200D 330395 (8- -99)
  • Page 195 (114.3 mm) in length. The correct tension is when the belt deflects 6.0 mm (0.25 in) from a force of .45 kg (10.0 lb) at belt midpoint of the longest span. 7. Reconnect the battery cables. 5-13 6200D 330395 (8- -99)
  • Page 196 HYDRAULICS 8. Start the machine and check the pump for proper operation and for leaks. 9. Disengage the prop rod and lower the seat support. 5-14 6200D 330395 (8- -99)

  • Page 197: Hydraulic Drive Motor

    HYDRAULICS HYDRAULIC DRIVE MOTOR The front drive wheel motor propels the 6200D forward and reverse. The propel pump provides hydraulic flow to the drive motor through the foot operated control valve. TO REPLACE DRIVE MOTOR FOR SAFETY: Before Leaving Or Servicing Machine;...
  • Page 198 8. Remove the hardware holding the old drive motor to the mount plate. Remove the drive motor from the mount plate. NOTE: Note the orientation of the motor to the mount plate. 5-16 6200D 330395 (8- -99)
  • Page 199 12. Position the new motor, drive hub, and mount plate onto the drive assembly. Reinstall the 4 hex screws and washers. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 5-17 6200D 330395 (8- -99)
  • Page 200 14. Reconnect the battery cables. 15. Disengage the prop rod and lower the seat support. 16. Remove the jack stands and lower the machine to the floor. Operate the machine and check for proper operation. 5-18 6200D 330395 (8- -99)

  • Page 201: Directional Control Valve

    2. Raise the front of the machine and install jackstands under the machine frame. 3. Go under the machine in the front, right corner and locate the valve under the directional pedal. 5-19 6200D 330395 (8- -99)
  • Page 202 7. Remove the cotter pin and clevis pin holding the pivot linkage to the spool on top of the control valve. 8. Remove the two screws and nuts holding the control valve to the mount plate. Remove the valve from the mount plate. 5-20 6200D 330395 (8- -99)
  • Page 203 Reinstall the mounting hardware and tighten to 11 -- 14 Nm (7 -- 10 ft lb). 13. Reconnect the hydraulic hoses to the new valve. See schematic in this section. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-21 6200D 330395 (8- -99)
  • Page 204 15. Remove the jackstands and lower the 7- -3/8 inch machine. 16. Reconnect the battery cables. 17. Disengage the prop rod and lower the seat support. 18. Start the machine and check the new directional control valve for proper operation. 5-22 6200D 330395 (8- -99)

  • Page 205: Electro/Hydraulic Fluid Reservoir

    Damage to the machine hydraulic system may result. Drain and refill the hydraulic fluid reservoir with new hydraulic fluid after every 800 hours of operation. 5-23 6200D 330395 (8- -99)

  • Page 206: To Replace Electro/Hydraulic Lift Unit

    2. Locate the hopper lift electro/hydraulic unit at the rear, left side of the machine. 3. Mark, disconnect, and plug the two hoses leading to the hopper lift electro/hydraulic unit. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-24 6200D 330395 (8- -99)
  • Page 207 7. Install the new electro/hydraulic unit onto the lift arm panel. Reinstall the two hex screws and spacers (spacers between unit and panel). Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 5-25 6200D 330395 (8- -99)
  • Page 208 10. Check the hydraulic fluid reservoir tank. 11. Reinstall the hopper cover and engage both latches. 12. Operate the machine. Check the new hopper lift electro/hydraulic unit for proper operation. 5-26 6200D 330395 (8- -99)

  • Page 209: To Replace Hopper Lift Cylinder

    2. Locate the hopper lift cylinder at the rear, center of the machine. 3. Mark, disconnect, and plug the two hoses leading to the lift cylinder. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-27 6200D 330395 (8- -99)
  • Page 210 6. Remove the hydraulic fittings from the existing lift cylinder and install in the new cylinder in the same orientation. 7. Install the new lift cylinder into the machine. Reinstall the upper and lower clevis pins and cotter pins. 5-28 6200D 330395 (8- -99)
  • Page 211 HYDRAULICS 8. Reconnect the two hydraulic hoses to the new hopper lift cylinder. 9. Reinstall the hopper cover and engage both latches. 10. Operate the machine. Check the new hopper lift cylinder for proper operation. 5-29 6200D 330395 (8- -99)

  • Page 212: Hydraulic Schematic (Propel)

    HYDRAULICS HYDRAULIC SCHEMATIC (PROPEL) 5-30 6200D 330395 (8- -99)

  • Page 213: Hydraulic Schematic (Hopper Lift)

    HYDRAULICS HYDRAULIC SCHEMATIC (HOPPER LIFT) 5-31 6200D 330395 (8- -99)

  • Page 214: Hydraulic Hose Diagram (Propel)

    HYDRAULICS HYDRAULIC HOSE DIAGRAM (PROPEL) 5-32 6200D 330395 (6- -02)

  • Page 215: Hydraulic Hose Diagram (Hopper Lift)

    HYDRAULICS HYDRAULIC HOSE DIAGRAM (HOPPER LIFT) 5-33 6200D 330395 (6- -02)

  • Page 216: Troubleshooting

    HYDRAULICS TROUBLESHOOTING The troubleshooting chart that follows is organized to lead you through the hydraulic circuits. 5-34 6200D 330395 (8- -99)

  • Page 217: Hopper Will Not Raise/Lower

    REPAIR / REPLACE ELECTRIC MOTOR ELECTRIC MOTOR CHECK CIRCUIT FLOW RESERVOIR FLUID LEVEL LIFT CYLINDER REPAIR / REPLACE FLOW OK? LIFT CYLINDER RELIEF PRESSURE REPAIR / REPLACE POWER UNIT REPAIR / REPLACE PLUMBING OK? PLUMBING 5-35 6200D 330395 (8- -99)

  • Page 218: Propel Motor Will Not Propel

    REPAIR / REPLACE VALVE SPOOL CONTROL SHIFTING OK? LINKAGE OR VALVE REPAIR / REPLACE RELIEF PRESSURE RELIEF VALVE OR CONTROL VALVE MOTOR INLET REPAIR / REPLACE FLOW OK? PROPEL MOTOR REPAIR / REPLACE PLUMBING OK? PLUMBING 5-36 6200D 330395 (8- -99)
  • Page 219 No. 7-145 Char-Lynn ® November, 1996 Hydraulic Motor Repair Information T Series ® General Purpose Geroler Motor...
  • Page 220 General Purpose Motors...
  • Page 221 General Purpose Motors Output Shaft Needle Thrust Bearing Parts Drawing Bearing Race Seal Pressure Seal Back-Up Ring Mounting Flange Exclusion Seal Screw Cap Screw End Cap Seal Geroler Seal Spacer Plate Drive Seal Housing Tools Required • Torque wrench ( 34 Nm [300 lb-in] capacity) •...
  • Page 222 General Purpose Motors T Series Geroler Motors Seal End Cap Geroler Seal Cap Screw (7) Disassembly Spacer Plate Seal Drive Figure 1 Cleanliness is extremely important when repairing hydraulic 2 Remove the seven cap screws from the end cap and disas- motors.
  • Page 223 General Purpose Motors Disassembly Caution: These screws were Loctited during assembly. Do Not exceed 56 Nm [500 lb-in] of removal torque. If the Loctite is holding the screws too tightly, heat the motor housing, with a propane torch, while turning the screw. Apply heat to where the screw threads into the motor housing, see figure 3.
  • Page 224 General Purpose Motors T Series Geroler Motors Reassembly Important: The Loctite must cure completely before the motor is put into service. Loctite curing time is six hours. 11 Lubricate and install the back-up ring and pressure seal. Use of Loctite Primer reduces curing time to 15 minutes. Use seal installation tool no.
  • Page 225 General Purpose Motors Geroler Star Valley Star Point Timing Dot Spacer Plate Threaded hole for Timing Dot Reference Standard Timing Reverse Timing Speed Sensor Installation Figure 6 Reference Notch Notch Perpendicular to Centerline of Motor Speed Sensor 9/16 inch Hex Head 90°...
  • Page 226 General Purpose Motors How to Order Replacement Parts Date Code Char-Lynn ® Each Order Must Include the Following: 00 0 Product number 1. Product Number 4. Part Number Week of Last 2. Date Code 5. Quantity of Parts Year 01 Number Eaton Corp.
  • Page 231 ® No. 7-624 Eaton October,1995 Gear Pumps Repair Information Series 26 Model 26000 Single Gear Pumps...
  • Page 232 Series 26 - Model 26000 Single Gear Pumps Introduction Table of Contents Introduction ..........................Identification ..........................Tools Required ........................... Exploded View Drawing ......................Parts List ............................ Disassembly ..........................5 & 6 Reversibility ..........................Inspection ........................... Reassembly ..........................9 & 10 Specific Backplate Parts List .......................

  • Page 233: Identification

    Series 26 - Model 26000 Single Gear Pumps Identification and Tools Required 26 0 01 - R Z A B 95 01 31 JB Serial Number Code: Product Number: Series Testers Initials 26 = Gear Pump ( SAE "A" Mount ) Day of Month (two digits) Month (two digits) Features...
  • Page 234 Series 26 - Model 26000 Single Gear Pumps Parts Cap Screws Drawing Washer Front Plate Optional Drive Gear Retaining Assembly Ring Shaft seal Drive Gear Washer Assembly Righthand (CW) Rotation Pump Plug Drive Gear Assembly Body O-ring Backup Gasket Seal Cap Screws Wear Plate Washer...

  • Page 235: Parts List

    Series 26 - Model 26000 Single Gear Pumps Disassembly Parts List Item Repair Information - Model 26000 Description Qty. Work in a clean area; cleanliness is extremely important when Front plate Assembly repairing hydraulic pumps. Before disconnecting the lines, Backplate clean port area of pump.

  • Page 236: Disassembly

    Series 26 - Model 26000 Single Gear Pumps Disassembly 8 Remove idler gear assembly from body. 11 Remove back-up gasket and seal from wear plate by extracting with a o-ring tool. 9 To separate body from the plate it remained with, place drive gear assembly in gear pocket and tap protruding end with plastic hammer or rawhide mallet.

  • Page 237: Reversibility

    Series 26 - Model 26000 Single Gear Pumps Reversibility Changing Input Rotation of Pump Place pump in a protected jaw vise with shaft end up. 7 Hold o-ring in groove of front plate with petroleum jelly. Remove the eight cap screws. Reassemble front plate over drive shaft end, being careful not to damage shaft seal.

  • Page 238: Inspection

    Series 26 - Model 26000 Single Gear Pumps Inspection Inspect Parts for Wear Front plate and Backplate Inspection General 1 Oil groove in bushings in front plate should be in line with dowel pin holes and 180° apart. The oil grooves in the 1 Clean and dry all parts.

  • Page 239: Reassembly

    Series 26 - Model 26000 Single Gear Pumps Reassembly General Information Install new seal and new backup gasket into wear plate. It is important that the relationship of the backplate, body, wear Note in the middle of the backup gasket a flat section or plate and front plate is correct.
  • Page 240 Series 26 - Model 26000 Single Gear Pumps Reassembly 7 Install new o-ring in groove of backplate. 8 Make sure port orientation is correct and then slide backplate over gear shafts until dowel pins are engaged. 9 Secure with cap screws and new washers . Tighten cap screws evenly in a crisscross pattern 34 to 38 N•m [25 to 28 lbf•ft] torque.

  • Page 241: Specific Backplate Parts List

    Series 26 - Model 26000 Single Gear Pumps Specific Backplate Parts List Relief Valve Backplate Item Description Qty. Relief Valve Backplate O-ring 19A4 Relief Valve Assembly 19A3 19A2 19A1 Relief Valve 19A1 19A2 O-ring 19A3 Backup Ring 19A4 O-ring Disasembly and Reassembly Plug Assembly 1 After removing relief valve , remove and replace o-rings 19B1...
  • Page 242 Series 26 - Model 26000 Single Gear Pumps Specific Backplate Parts List Tandem Backplate Tandem Flow Divider Backplate Disasembly and Reassembly 1 Remove relief valve plug, shim, spring, and poppet from Item backplate. Do not remove internal relief valve seat. Seat is Description Qty.
  • Page 243 Series 26 - Model 26000 Single Gear Pumps Placing Series 26 Gear Pump Back into Operation When test stand is available . Start Pump Mount Pump Connect Run For Test Stand Fluid Supply 3 Minutes Each Load Load Load Zero Intermittently Intermittently Intermittently...

  • Page 244: Trouble Shooting

    Series 26 - Model 26000 Single Gear Pumps Trouble Shooting Problem Possible Cause Correction Cavitation a. Oil too heavy. a. Change to proper viscosity b. Oil filter plugged. b. Clean filter. c. Suction line plugged or too small. c. Clean line and check size of line. Oil heating a.
  • Page 245 Series 26 - Model 26000 Single Gear Pumps Note Wear Plate Identification A product improvement has been made to the Model 26000 gear pump with a new designed wear plate. To identify the new wear plate, look for grooves placed in the seal side of the wear plate as shown below. New Groove Wear Plate Wear Plate...
  • Page 246 Order parts from 6-634 Parts Information booklet. Each order must include the following information. 1. Product and/or Part Number 2. Serial Number Code 3. Part Name 4. Quantity ACCREDITED BY THE DUTCH COUNCIL FOR CERTIFICATION Reg. No. 24 Eaton Corporation Eaton Ltd.
  • Page 247 ..6-10 TO REMOVE ENGINE ..6-12 TO INSTALL ENGINE ... 6-17 6200D 330395 (6- -02)
  • Page 248 ENGINE- -DIESEL 6200D 330395 (8- -99)

  • Page 249: Introduction

    ENGINE- -DIESEL INTRODUCTION This section includes repair information on the engine and related systems, such as fuel, electrical, and belts. Also, engine removal and installation. 6200D 330395 (8- -99)

  • Page 250: Cooling System

    FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. Flush the radiator and the cooling system every 1600 hours of operation, using a dependable cleaning compound. 6200D 330395 (8- -99)

  • Page 251: Lubrication

    4 to 5 kg (8 to 10 lb) applied at the mid-point of the longest span. Check and adjust the belt tension every 100 hours of operation. WARNING: Moving Belt And Fan Blades. Keep Away. 6200D 330395 (8- -99)

  • Page 252: Air Intake System

    Inspect the seals on the ends of the element, they should be flexible and undamaged. Install the dust cap on the air filter housing with the arrows pointing up. 6200D 330395 (8- -99)

  • Page 253: Fuel System

    Servicing Machine; Stop On Level Surface, Set Parking Brake, And Turn Off Machine. 1. Open the seat support. 2. Locate the fuel filter/water separator on the left side of the engine. NOTE: Place a drain pan under the filter. 6200D 330395 (8- -99)
  • Page 254 Clean up any spilled diesel fuel. Remove the drain pan. 8. Close the seat shroud. 9. Start the machine and check the new filter for any leaks. 6200D 330395 (8- -99)

  • Page 255: Fuel Lines

    Dirt in the lines can cause fuel injection pump malfunction. There is a valve located under the fuel tank. This valve can be used to shut off the fuel flow if the fuel lines need to be serviced. 6200D 330395 (8- -99)

  • Page 256: Priming Fuel System

    Servicing Machine; Stop On Level Surface, Set Parking Brake, And Turn Off Machine. 1. Open the seat support. Make sure the fuel tank is full. 2. Open the breather vent on top of the fuel filter/water separator. 6-10 6200D 330395 (8- -99)
  • Page 257 5. Turn the key to the start position until fuel, free from air, appears at the banjo fitting on the injector pump. Tighten the connection. 6. Clean up any spilled fuel. Operate the machine and check for proper operation. 6-11 6200D 330395 (8- -99)

  • Page 258: To Remove Engine

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set parking brake. 1. Pivot the seat support open and remove it from the machine. 2. Disconnect the battery cables. 3. Remove the left hand side panel. 6-12 6200D 330395 (8- -99)
  • Page 259 ENGINE- -DIESEL 4. Drain the radiator. 5. Disconnect the upper and lower radiator hoses from the radiator. 6. Remove the radiator and shroud from the machine. 7. Remove the seat mount brace. 6-13 6200D 330395 (8- -99)
  • Page 260 9. Mark and disconnect the alternator wires, low oil pressure switch wires, starter wires, ground cable, and a positive battery cable. 10. Shut the valve off at the fuel tank. 11. Disconnect and remove the main fuel line. 6-14 6200D 330395 (8- -99)
  • Page 261 Push forward on the V--belt idler arm and remove the V--belt from the flywheel sheave. 15. Loosen the hardware holding the hydraulic pump to the mount bracket. Push the pump down and remove the V--belt from the pump sheave. 6-15 6200D 330395 (8- -99)
  • Page 262 19. The engine can now be removed from the machine. Use a chain in the two engine hoops. Be careful not to hook any wires or hydraulic lines when lifting the engine out of the machine. 6-16 6200D 330395 (8- -99)

  • Page 263: To Install Engine

    Install the five engine mount bolts and washers. Tighten to 37 -- 48 Nm (26 -- 34 ft lb). 3. Position the hydraulic pump and hoses onto the mount bracket. Reinstall the hardware, leave loose for now. 6-17 6200D 330395 (8- -99)
  • Page 264 6.0 mm (0.25 in) from a force of .45 kg (10.0 lb) at belt midpoint of the longest span. 6. Reinstall the exhaust pipe onto the engine manifold. Reinstall the muffler and tail pipe. 7. Reconnect the main fuel line. 6-18 6200D 330395 (8- -99)
  • Page 265 11. Reinstall the remote oil drain hose onto the fitting on the engine oil pan. Fill the engine with 2.2 qt (2.5L) CD/CE grade oil. 6-19 6200D 330395 (8- -99)
  • Page 266 13. Reinstall the radiator and shroud onto the radiator mount bracket. Hand tighten the hardware tight. 14. Reconnect the upper and lower radiator hoses to the radiator. Hand tighten the wormdrive clamps. 15. Refill the radiator with coolant. 6-20 6200D 330395 (8- -99)
  • Page 267 16. Reconnect the throttle shut--off solenoid. 17. Reconnect the battery cables to the battery. 18. Reinstall the seat support. 19. Reinstall the left hand side panel. 20. Start the engine and check for proper operation. 6-21 6200D 330395 (8- -99)
  • Page 268 ENGINE- -DIESEL 6-22 6200D 330395 (8- -99)
  • Page 269 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 271 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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