Tennant 6400IC Service Manual
Tennant 6400IC Service Manual

Tennant 6400IC Service Manual

Tennant 6400ic service manual
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6400IC
Service Manual
MM433
Rev. 02
*MM433*
Home Find... Go To..

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Summary of Contents for Tennant 6400IC

  • Page 1 6400IC Service Manual MM433 Rev. 02 *MM433* Home Find... Go To..
  • Page 2 Published: 12--01 CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Copyright E 1999, 2001 TENNANT, Printed in U.S.A. Home Find... Go To..
  • Page 3: Table Of Contents

    1--23 HYDRAULIC O--RING FITTING TORQUE CHART ....1--23 MACHINE TROUBLESHOOTING ..1--24 6400IC MM433 (12- -01) 1-- 1 Home Find... Go To..
  • Page 4 GENERAL INFORMATION 1-- 2 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 5: Safety Precautions

    - - Use cardboard to locate leaking understood. hydraulic fluid under pressure. - - In flammable or explosive areas unless - - Use Tennant supplied or approved designed for use in those areas. replacement parts. - - In areas with possible falling objects unless equipped with overhead guard.
  • Page 6 Keep engine properly tuned. WARNING: Lift arm pinch point. Stay clear of hopper lift arms. WARNING: Raised hopper may fall. Engage hopper support bar. WARNING: Moving belt and fan. Keep away. 1-- 4 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 7 VACUUM FAN HOUSING AND BELT SHROUD. HOPPER SUPPORT LABEL - - LOCATED ON HOPPER LIFT ARMS LABEL - - LOCATED ON BOTH LIFT ARMS AND THE HOPPER BOTH LIFT ARMS. SUPPORT BAR. 6400IC MM433 (9- -96) 1-- 5 Home Find... Go To..
  • Page 8: Specifications

    1490 mm (58.7 in) Minimum turning radius, left 1135 mm (44.7 in) Maximum rated incline with empty hopper 10_ / 17.6% Maximum rated incline with full hopper 8_ / 14.1% 1-- 6 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 9: Power Type: Gas Air Cooled

    Spark plug gap Valve clearance, cold Engine lubricating oil with filter 1 mm (0.043 in) 0.145 to 0.185 mm (0.0057 to 3.25 L (3.4 qt) 10W30 0.0072 in) intake and exhaust SAE--SG/SH 6400IC MM433 (12- -01) 1-- 7 Home Find... Go To..
  • Page 10: Power Type: Diesel Liquid Cooled

    HYDRAULIC SYSTEM System Capacity Fluid Type TENNANT part no. 65869 -- above 7_ C (45_ F) Hydraulic reservoir 19.3 L ( 5.12 gal) TENNANT part no. 65870 -- below 7_ C (45_ F) Hydraulic total 20.8 L ( 5.5 gal)
  • Page 11: Machine Dimensions

    2260 mm (89 in) TOP VIEW 2085 mm (82 in) 1435 mm (56.5 in) 1135 mm 1135 mm (44.7 in) (44.7 in) SIDE VIEW FRONT VIEW 350158--- 350165 MACHINE DIMENSIONS 6400IC MM433 (12- -01) 1-- 9 Home Find... Go To..
  • Page 12: Maintenance

    Check brush pattern Side brush Check for damage or wear Check brush pattern Hopper dust filter Shake 25 Hours Engine Clean air filter pre--cleaner element 50 Hours Main brush Rotate end-for-end 1-- 10 6400IC MM433 (9- -96) Home Find... Go To..
  • Page 13 Tennant or approved hydraulic fluid . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) NOTE: Also check procedures indicted (H) after the first 50 hours of operation. NOTE: More frequent intervals may be required in extremely dusty conditions.
  • Page 14: Maintenance Chart, Gas/Lp Liquid Cooled

    Main brush Check for damage or wear Check brush pattern Side brush Check for damage or wear Check brush pattern Hopper dust filter Shake 50 Hours Main brush Rotate end-for-end 1-- 12 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 15 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 (--30_ F) NOTE: Also check procedures indicted (H) after the first 50 hours of operation.
  • Page 16: Maintenance Chart, Diesel

    Check brush pattern Side brush Check for damage or wear Check brush pattern Hopper dust filter Shake 50 Hours Main brush Rotate end-for-end Fuel pipes and clamps Check for tightness and wear 1-- 14 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 17 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 (--30_ F) NOTE: Also check procedures indicted (H) after the first 50 hours of operation.
  • Page 18: Pushing, Towing, And Transporting The Machine

    Turn the bypass valve 90_ from the normal position before pushing or towing the machine. The illustration shows the bypass valve in the pushing or towing position. 1-- 16 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 19: Machine

    Do not drive the machine onto the truck or trailer unless the loading surface is horizontal AND is 380 mm (15 in) or less from the ground. 6400IC MM433 (12- -01) 1-- 17 Home Find... Go To..
  • Page 20 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-- 18 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 21: Machine Jacking

    FOR SAFETY: When servicing machine, block machine tires before jacking up machine. FOR SAFETY: When servicing machine, jack up machine at designated locations only. Block machine up with jack stands. 6400IC MM433 (12- -01) 1-- 19 Home Find... Go To..
  • Page 22: Storing Machine

    5. Stop the engine and set the machine parking brake. 6. Check the hydraulic fluid level. It should be up to the FULL mark on the dipstick to prevent excessive condensation from forming in the reservoir. 1-- 20 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 23: To Store Machine 30 To 90 Days

    6. Seal the air cleaner inlet and the exhaust outlet with weatherproof masking tape. 7. Tighten the engine oil filler cap, the fuel tank cap, and the radiator cap to make certain they are securely in place. 6400IC MM433 (12- -01) 1-- 21 Home Find... Go To..
  • Page 24: Hardware Information

    They include the following: 0.75 in 215--280 313--407 (291--380) (424--552) Locktite 515 sealant -- gasket forming material. TENNANT Part No. 75567,15 oz 1.00 in 500--650 757--984 (440 ml) cartridge. (678--881) (1026--1334) NOTE: Decrease torque by 20% when using a Locktite 242 blue -- medium strength thread thread lubricant.
  • Page 25: Hydraulic Fitting Information

    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 6400IC MM433 (12- -01) 1-- 23 Home Find... Go To..
  • Page 26: Machine Troubleshooting

    Hopper lip skirts worn or damaged Replace lip skirts Hopper door partially or Open hopper door completely closed Wrong sweeping brush Contact TENNANT representative for recommendations Recirculation flap damaged Replace flap 1-- 24 6400IC MM433 (12- -96) Home Find... Go To..
  • Page 27 ......2--16 TO REPLACE REAR WHEEL HOUSING PIVOT BEARINGS . . . 2--16 2-- 1 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 28 CHASSIS 2-- 2 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 29: Introduction

    CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat, steering, brakes and tires. 2-- 3 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 30: Seat

    1. Tilt the seat shroud back against the support cable. 2. Remove the four hex nuts holding the seat brackets to the seat shroud. 3. Remove the seat assembly from the seat shroud. 2-- 4 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 31 Line up the holes and install the hardware. Tighten the hex screws to 18.5 -- 24Nm (15 -- 20 ft lb). 7. Close the seat shroud and adjust the seat to a comfortable position. 2-- 5 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 32: To Adjust Seat Position

    The static drag chain prevents build up of static electricity in the machine. The chain is attached near the rear of the brush compartment skirts. The chain should be in contact with the floor at all times. 2-- 6 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 33: Front Tires And Wheels

    2. Jack up one front corner of the machine. Place jack stands under machine frame. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 2-- 7 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 34 9. Tighten the nut with a hand wrench until the wheel binds, then back the nut off to nearest cotter pin hole. 10. Insert a new cotter pin through nut and hole. 2-- 8 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 35 CHASSIS 11. After making sure the wheel spins freely, carefully reinstall the hub cap. 12. Remove the jackstands and lower the machine. 13. Repeat the procedure on the other wheel. 2-- 9 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 36: Brakes And Tires

    2. Jack up one front corner of the machine. Place jack stands under machine frame. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 2-- 10 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 37 7. Replace the old brake shoes with new brake shoes. 8. Reinstall the one large ”C” shaped brake tension spring on the new brake shoes. 9. Slide the wheel back on the axle. 2-- 11 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 38 12. Insert a new cotter pin through nut and hole. 13. After making sure the wheel spins freely, carefully reinstall the hub cap. 14. Remove the jackstands and lower the machine. 15. Repeat the procedure on the other wheel. 2-- 12 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 39: Parking Brake

    BRAKES instructions. Adjust the parking brake so it will hold the Machine on a smooth 8 degree incline. The brake pedal should not travel more than 2 inches to fully engage the brakes. 2-- 13 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 40: To Adjust Brakes

    Jack machine up at designated locations only. Block machine up with jack stands. 3. Remove the cotter pin and the clevis pin holding the brake rod clevis to the brake assembly lever. 2-- 14 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 41 7. Repeat the procedure on both sides. 8. Drive the machine and operate the brakes. Check for equal engagement of the brakes on both wheels. 2-- 15 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 42: Rear Tire And Wheel, And Wheel Support

    The rear wheel support bearings must be lubricated every 200 hours of operation. Use Lubriplate EMB grease (TENNANT part no. 01433--1). Check the rear tire pressure every 100 hours of operation. The proper tire air pressure is 790 + 35 kPa (115 + 5 psi).
  • Page 43 NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 7. Remove the rear drive motor mounting bolts. 8. Slide the rear drive motor out of the wheel housing. 2-- 17 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 44 12. Remove the cotter pin from the large slotted nut on top of the rear housing pivot pin. Remove the slotted nut. 2-- 18 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 45 15. Replace the pressed in bearing cups. 16. Pack the new bearing cones with Lubriplate EMB grease. Coat the bearing cups with grease. 17. Position the bearings in the housing. 2-- 19 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 46 21. Thread castle nut on the pin. Tighten to 34 -- 40 Nm (25 -- 30 ft lb). Check for any play. If the pin is not seated, tap with rubber mallet and re--torque castle nut. 2-- 20 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 47 26. Re--connect the rod end of the steering cylinder to the wheel housing using the .750x3.25 hex screw, nyloc nut, and flat washers. Tighten to 270 -- 300 Nm (200 -- 220 ft lb). 2-- 21 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 48 31. Mount the hub to the tapered motor shaft. Tighten the slotted nut to (250 ft lb). Install the cotter pin. NOTE: Make sure the key is installed on the tapered shaft of the drive motor. 2-- 22 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 49 Run the propelling in both directions. Check for any leaks. 34. Remove the jack stands and lower the machine to the ground. 35. Operate the machine. Check the rear drive for proper operation. 2-- 23 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 50 CHASSIS 2-- 24 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 51 ....3--70 MACHINE TROUBLESHOOTING ..3--71 3-- 1 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 52 SWEEPING 3-- 2 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 53: Introduction

    The side brush sweeps debris in front of the machine and the main brush sweeps the debris into the hopper. The vacuum fan pulls air from the hopper and through the dust filter. 3-- 3 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 54: Debris Hopper

    Engage the support bar. 2. Remove the hopper level adjustment bolt, nut, and washers. 3. Cut the plastic ties holding the hopper harness to the main harness. 4. Disconnect the battery cables. 3-- 4 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 55 7. Disconnect the side brush lift cable at the hydraulic motor. 8. Remove the four hex screws holding the hopper bumper to the sides of the hopper. 3-- 5 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 56 12. The hopper can now be pulled away from the machine. 13. Disconnect and plug the hydraulic hoses leading to the hopper dump door cylinder. 14. The hopper can now be removed from the machine. 3-- 6 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 57: To Install Hopper

    3. Line up the holes in the hopper pivot bearing flanges with the holes in the hopper lift arms. Install the four hex screws and nyloc nuts. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 3-- 7 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 58 8. Reconnect the hopper harness to the main harness. 9. See the schematic in the ELECTRICAL section of this manual for proper harness connections. 10. Reconnect the battery cables. 3-- 8 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 59 11. Reinstall the lip height adjustment bolt on the back of the hopper. 12. Start the machine and check for proper operation of hopper vacuum fan, dump door, side brush rotation and side brush up and down. 3-- 9 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 60: To Adjust Hopper Lip Height

    2. Loosen the three hex screws holding the hopper bumper to the front of the hopper. 3. Adjust the hopper bumper so it is level with the machine frame. 4. Firmly tighten all of the hardware. 3-- 10 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 61: Hopper Lift Arm

    Brake, Turn Off Machine And Remove Key. 3. Remove the debris hopper. See TO REMOVE HOPPER FROM MACHINE instructions. 4. Remove the cotter pins from the upper, hopper lift cylinder pin. 3-- 11 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 62 8. If the large self aligning bearing needs to be changed, remove retaining rings and press the old bearing out of the lift arm. 3-- 12 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 63: To Install Hopper Lift Arm

    5. Align the hole in lift arm pin with the hole in the pin boss on the tower. Install the hex screws and tighten to 18 -- 24 Nm (13 -- 18 ft lb). 3-- 13 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 64 Reinstall the cylinder pin and cotter pins. 7. Reinstall the hopper assembly. See TO INSTALL HOPPER instructions. 3-- 14 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 65: Hopper Dump Door

    Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 4. Disconnect the rod end of dump door cylinder from the bracket on the center of the dump door. 3-- 15 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 66 7. Use a razer knife to remove the RTV from the two dump door pivot bolts on each side of the hopper. Remove the two hex screws. 8. Drop the dump door down and out of the hopper. 3-- 16 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 67: To Install Hopper Dump Door

    5. Put a small amount of RTV around the two hex screws. 6. Reinstall the seal on the front of the dump door. Hand tighten the five hex screws tight. 3-- 17 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 68 9. Start the machine and open and close hopper door a few times. Check for proper operation. NOTE: Make sure the seals on the dump door are adjusted so they contact the inside wall of the hopper. 3-- 18 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 69: Hopper Dust Filter

    Air dry the wet dust filter; do not use compressed air. NOTE: Be sure the dust filter is completely dry before reinstalling it in the machine. 3-- 19 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 70: To Replace Hopper Dust Filter

    Put the cleaned or new dust filter in the hopper insert with the arrows pointing up. 6. Lower the hopper cover support and close the hopper cover. Latch the hopper cover. 3-- 20 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 71: Main Brush

    FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Raise the main brush. 3. Open the right side main brush access door. 3-- 21 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 72 8. Slide the main brush idler plate plug in the main brush. 9. Reinstall the attachment bolt. 10. Close the right side main brush access door. Check the main brush pattern. 3-- 22 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 73: To Check And Adjust Main Brush Pattern

    A polish mark will remain on the floor. 4. Raise and stop the main brush. 5. Drive the machine off the test area. 3-- 23 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 74 A. Move the brush shaft bearing bracket up or down in the slots. B. Re- -check the main brush pattern and readjust as necessary. Then adjust the width of the main brush pattern. 3-- 24 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 75: To Replace Main Brush Idler Plug Bearing

    3. Clean the area around where the cap was mounted in the idler plug. 4. Remove the M12 flat screw, nyloc hex nut, and washer holding the idler plug to the idler arm. 3-- 25 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 76 Tighten the four hex screws to 8--10 Nm (6--8 ft lb). 10. Position the idler plug on the idler arm shaft. Reinstall the long flat screw. Tighten to 68--81 Nm (50--60 ft lb). 3-- 26 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 77 11. Put a small amount of RTV on the lip of the plastic cap and install in the end of the idler plug. 12. Reinstall the idler arm on the machine. 13. Operate the machine and check for proper operation. 3-- 27 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 78: To Replace Main Brush Shaft Bearings

    3. Remove the large hex screw and nyloc nut holding the brush arm to the pivot bearings. 4. Let the brush arm drop down and out of the way. 3-- 28 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 79 9. Reinstall the main brush motor plate and idler plate. 10. Check main brush pattern for taper and width. Adjust as necessary. See TO CHECK AND ADJUST MAIN BRUSH PATTERN. 3-- 29 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 80: Side Brush

    2. Set the machine parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Raise the side brush. 3-- 30 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 81 7. Reinstall the side brush retaining pin through the side brush hub and shaft. 8. Secure the pin by clipping the pin keeper over the end of the pin. 3-- 31 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 82 SWEEPING 9. Disengage the hopper support bar and lower the hopper. 10. Adjust the side brush pattern with the side brush down pressure lever. 3-- 32 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 83: To Adjust Side Brush Pattern

    2. Turn the side brush lever clockwise to decrease side brush pattern. Turn the side brush lever counter--clockwise to increase side brush pattern. One-half of the bristles should normally contact the floor. 3. Raise the side brush. 3-- 33 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 84: To Adjust Side Brush Tilt Pattern

    2. Raise the hopper slightly and shut off the machine. 3. Loosen the two hex screws on the back of the hopper bumper near the side brush assembly. 4. Tilt the side brush in either direction. 3-- 34 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 85 SWEEPING 5. Tighten the hardware firmly. 6. Lower the hopper. 7. Start the machine and turn on the side brush. Check the side brush pattern. 8. Raise the side brush. 3-- 35 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 86: Side Brush Guard

    3. Rotate or replace the side brush guard. 4. Reinstall the four bolts in the side brush motor and tighten to 22--27 Nm (16--20 ft lb). 3-- 36 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 87: Side Brush Pivot

    Torque the front and rear compression springs to reduce excessive movement. The side brush tilt is adjusted with the side brush cable. Turn the clevis on the cable to get the desired side brush pattern. 3-- 37 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 88: Skirts And Seals

    Engage Hopper Support Bar. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 4. Remove the hopper lip retaining strip mounting hardware. 3-- 38 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 89 7. Tighten the mounting hardware to 8--14 Nm (6--10 ft lb). 8. Start the machine and lower the hopper. 3-- 39 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 90: Brush Door Skirts

    2. Stop the machine and set the machine parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Open the right hand brush door. 3-- 40 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 91 9. Slide the brush door skirt up or down so it will clear the floor by 3--5 mm (0.12 to 0.25 in). Hand tighten the hex screws firmly. 10. Operate the machine and check the new skirt for proper operation. 3-- 41 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 92: To Replace And Adjust Left Hand Brush Door Skirt

    Brake, Turn Off Machine And Remove Key. 3. Open the left hand brush door. 4. Remove the four hex screws holding the skirt mount plate to the machine. 5. Remove the brush skirt retaining bolts. 3-- 42 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 93 11. Slide the brush door skirt up or down so it will clear the floor by 3--5 mm (0.12 to 0.25 in). Hand tighten the hex screws firmly. 12. Operate the machine and check the new skirts for proper operation. 3-- 43 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 94: Right Brush Door Seal

    The deflector blade is spring loaded. Check the skirt and blade for wear or damage and adjustment daily. NOTE: Rear tire pressure will affect skirt clearances. 3-- 44 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 95: To Replace And Adjust The Rear Skirt And Deflector Blade

    Brake, Turn Off Machine And Remove Key. 3. Open the main brush doors. 4. Remove the main brush. 5. Remove the retaining strip and floor skirt. Discard the old skirt. 3-- 45 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 96 8--14 Nm (6--10 ft lb). up to 5 mm (up to 0.25 in) 10. Remove the brush contact blade retaining strip and the brush contact blade. Discard the old blade. 3-- 46 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 97 13. Tighten the brush contact blade mounting bolts to 8--14 Nm (6--10 ft lb). 14. Reinstall the main brush. 15. Close the main brush doors. 16. Operate the machine and check for proper operation. 3-- 47 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 98: Hopper Side Seals

    Check the seal for wear or damage every 100 hours of operation. You can reach the seal by lifting the hopper and engaging the prop arm. 3-- 48 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 99: To Replace Hopper Side Seals

    5. Position the new skirt and existing retainer on the front of the machine frame. Secure with plastic push--in hardware. 6. Repeat on the other side of the main frame. 3-- 49 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 100: Hopper Inspection Door Seal

    They seal the hopper when the hopper door is closed. Tighten hardware to 3--4 Nm (2.5--3.5 ft lb). Check the seals for wear or damage every 100 hours of operation. 3-- 50 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 101: To Replace Hopper Dump Door Seals

    Discard the old seal. 5. Remove the three hex screws holding each side seal to the dump door. Discard the old seals. 3-- 51 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 102 Make sure the seals are lined up with edge of hopper when tightening. 8. Start machine and lower hopper. 9. Operate the machine and check the dump door for proper operation. 3-- 52 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 103: Vacuum Fan

    On the air cooled machine the vacuum fan is located in front of the engine. AIR COOLED On the water cooled machine the vacuum fan is located under the radiator. LIQUID COOLED 3-- 53 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 104: To Remove Vacuum Fan Assembly (Liquid Cooled)

    Brake, Turn Off Machine And Remove Key. 3. Jack up the rear of the machine and install jack stands under the machine frame. 4. Remove the rear tire and wheel assembly. 5. Open the seat shroud. 3-- 54 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 105 10. Remove the vacuum fan assembly from the bottom of the machine. NOTE: The vacuum fan assembly must be removed out the bottom of the machine. 3-- 55 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 106: To Install Vacuum Fan Assembly (Liquid Cooled)

    Brake, Turn Off Machine And Remove Key. 3. Jack up the rear of the machine and install jack stands under the machine frame. 4. Remove the rear tire and wheel assembly. 5. Open the seat shroud. 3-- 56 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 107 V--belt. The belt spec. is 20 3 lb tension. Apply 1.5 lb at the middle of the belt span to obtain .17 inch of deflection. 10. Firmly tighten the four hex screws. 3-- 57 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 108 Tighten the wheel nuts to 122 -- 150 Nm (90 -- 110 ft lb). 13. Remove the jack stands and lower the machine. 14. Start the machine and operate the vacuum fan. Check for proper operation. 3-- 58 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 109: To Remove Vacuum Fan Assembly (Air Cooled)

    Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Remove the vacuum fan belt guard. 4. Remove the vacuum hose connected to the vacuum fan assembly. 3-- 59 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 110 V--belt from the sheave. Remove the V--belt. 7. Remove the three hex screws holding the vacuum fan assembly to the machine frame. 8. Remove the vacuum fan assembly from the machine. 3-- 60 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 111: To Install Vacuum Fan Assembly (Air Cooled)

    3. Position the vacuum fan assembly in the machine. 4. Align the holes in vacuum fan mount bracket with the holes in the machine frame. Reinstall the three hex screws. Leave loose for now. 3-- 61 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 112 7. Firmly tighten the hex screws. 8. Reinstall the fan belt guard. 9. Reconnect the vacuum hose to the vacuum fan housing. 10. Start the machine and operate the vacuum fan. Check for proper operation. 3-- 62 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 113: To Replace Vacuum Fan Impeller

    5. Hold the impeller from turning and remove the hex nut from the end of the fan impeller shaft. Pull the impeller straight off the shaft. NOTE: Make sure to retain the shaft key and spacer. 3-- 63 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 114 10. Reinstall the nine thread cutting screws in the fan housing. Hand tighten. 11. Reinstall the vacuum fan assembly in the machine. See TO INSTALL VACUUM FAN ASSEMBLY instructions in this section. 3-- 64 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 115: To Replace Vacuum Fan Impeller Bearings

    5. Hold the impeller from turning and remove the hex nut from the end of the fan impeller shaft. Pull the impeller straight off the shaft. NOTE: Make sure to retain the shaft key and spacer. 3-- 65 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 116 NOTE: Make sure to note the orientation of the bearings and impeller shaft in relation to the bearing housing. 9. Press two new bearings in the bearing housing. 3-- 66 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 117 NOTE: Place a small amount of grease on the impeller shaft to ease installation. 13. Reinstall the fan impeller housing using the nine thread cutting screws. Tighten to 223 -- 290 Ncm (20 -- 25 in lb). 3-- 67 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 118 Push the sheave all the way on and hand tighten the two set screws tight. 15. Reinstall the vacuum fan assembly in the machine. See TO INSTALL VACUUM FAN ASSEMBLY instructions in this section. 3-- 68 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 119: To Tension Vacuum Fan Belt (Liquid Cooled)

    3. Tighten the four hex screws. 4. Apply 1--1/2 lbs of force to the middle of the V--belt (1/2 way between the two sheaves). There should be approximately 5/32” of deflection. 5. Re--check belt tension. 3-- 69 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 120: To Tension Vacuum Fan Belt (Air Cooled)

    3. Tighten the hex screws. 4. Apply 1--1/2 lbs of force to the middle of the V--belt (1/2 way between the two sheaves). There should be approximately 1/4” of deflection. 3-- 70 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 121: Machine Troubleshooting

    Hopper full Empty hopper Hopper lip skirts worn or damaged Replace lip skirts Hopper door partially or Open the hopper door completely closed Wrong sweeping brush Contact TENNANT representative for recommendations 3-- 71 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 122 SWEEPING 3-- 72 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 123 ..4--34 WIRE HARNESS GROUP GAS/LP AIR COOLED ..... 4--36 6400IC MM433 (12- -01) 4-- 1 Home Find... Go To..
  • Page 124 ELECTRICAL 4-- 2 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 125: Introduction

    ELECTRICAL INTRODUCTION The machines electrical system consists of the battery, instrument panel, switches, relays, and circuit breakers. 4-- 3 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 126: Electrical System

    Keep the battery caps on the batteries always except when adding water or taking hydrometer readings. FOR SAFETY: When Servicing Machine, Avoid Contact With Battery Acid. 4-- 4 6400IC MM433 (10- -93) Home Find... Go To..
  • Page 127 (80_ F), the reading must be temperature corrected. Add or subtract to the specific gravity reading 0.004, 4 points, for each 6_ C (10_ F) above or below 27_ C (80_ F). 4-- 5 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 128: To Replace Battery

    1. Tilt the seat support. Locate the battery on the left side of the machine in front of the engine. 2. Disconnect the battery cables. 3. Remove the battery hold down strap. 4-- 6 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 129 6. Reinstall the battery hold down strap. 7. Reconnect the positive, then the negative battery cables. 8. Lower the seat support and start the machine to test the new battery. 4-- 7 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 130: Thermo Sentryt

    1. Open the hopper cover and engage prop rod. 2. Locate the Thermo Sentryton the back of the filter shaker motor bracket. Unplug the two wires leading to the Thermo Sentryt. 4-- 8 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 131 Sentryt to the bracket. Remove from the hopper. 4. Install the new Thermo Sentryton the bracket. Reinstall the hardware and tighten, 5. Reconnect the wires and close the hopper cover. 4-- 9 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 132: To Replace Thermo Sentryt Shut Off Solenoid

    2. Cut the plastic wire tie holding the Thermo Sentrytsolenoid wire to the machine. Disconnect the Thermo Sentrytsolenoid wire harness from hopper harness. 3. Remove the pin connecting the rod of the Thermo Sentrytsolenoid to the lever. 4-- 10 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 133 Thermo Sentrytsolenoid from the machine. 5. Mount the new Thermo Sentrytsolenoid on the bracket with existing hardware. 6. Reconnect the wires to the Thermo Sentryt solenoid. 7. Close the seat support. 4-- 11 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 134: Instrument Panel

    Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the hopper and engage the support bar. 2. Open the seat support and disconnect the battery. 4-- 12 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 135 8. Reconnect the wires to the new light. See schematic in this section. 9. Position the mount plate back on the instrument panel. Reinstall the two nyloc nuts and tighten. 4-- 13 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 136 ELECTRICAL 10. Reconnect the battery cable. 11. Close the seat support. 12. Start the machine and lower the hopper. Check the indicator lights for proper operation. 4-- 14 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 137: Circuit Breakers

    Circuit Breaker Rating Circuit Protected CB-1 15 A Thermo Sentryt CB-2 15 A Hourmeter, engine, fuel level CB-3 15 A Hopper, brushes CB-4 15 A Operating lights CB-5 15 A Horn 4-- 15 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 138: To Replace Circuit Breaker

    4. Use the electrical schematic in this section to locate the circuit breaker that needs to be replaced. 5. Disconnect the wires leading to the faulty circuit breaker. 4-- 16 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 139 NOTE: The circuit breaker will only fit in the hole in one direction. 9. Plug the main harness wires into the new circuit breaker. See the schematic in this section. 10. Reconnect the battery cables. 4-- 17 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 140 ELECTRICAL 11. Close the seat support. 12. Start the machine and lower the hopper. Check the new circuit breaker for proper operation. 4-- 18 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 141: To Replace Filter Shaker Motor

    1. Open the hopper cover and engage the prop rod. 2. Locate the filter shaker motor on the top side of the filter shaker assembly. 3. Unplug the filter shaker motor from the hopper harness. 4-- 19 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 142 Position the weight flush with the guard plate. 8. Install the new shaker motor on the assembly mount plate. Tighten the two hex screws to 18 -- 24 Nm (15 -- 20 ft lb). 4-- 20 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 143 18 -- 24 Nm (15 -- 20 ft lb). 10. Plug the shaker motor into the hopper harness. 11. Test the shaker motor for proper operation. 12. Disengage the hopper cover prop rod and lower the cover. 4-- 21 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 144: To Replace Machine Electrical Relay

    Brake, Turn Off Machine And Remove Key. 1. Raise the hopper and engage the support bar. 2. Open the seat support and remove the battery cables from battery. 3. Locate the relays under the circuit breakers. 4-- 22 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 145 6. Remove the hex nut holding the relay to the panel. Remove and discard the relay. 7. Position the new relay on the instrument panel. Reinstall the hex screw and nyloc nut. Hand tighten. 4-- 23 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 146 NOTE: The harness plug will only fit in the new relay in one direction. 9. Reconnect the battery cables. 10. Close the seat support. 11. Start the engine and lower the hopper. Check the new relay for proper operation. 4-- 24 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 147 ELECTRICAL 4-- 25 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 148: Electrical Schematic Gas/Lp Liquid Cooled

    ELECTRICAL ELECTRICAL SCHEMATIC GAS/LP LIQUID COOLED 4-- 26 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 149 ELECTRICAL ELECTRICAL SCHEMATIC GAS/LP LIQUID COOLED 350167 - - G, LP, LIQ 4-- 27 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 150: Electrical Schematic Diesel

    ELECTRICAL ELECTRICAL SCHEMATIC DIESEL 4-- 28 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 151 ELECTRICAL ELECTRICAL SCHEMATIC DIESEL 350169 - - D 4-- 29 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 152: Electrical Schematic Gas/Lp Air Cooled

    SU- -1 18A/ORA GAUGE 24/PUR UNIT 13U/BLK 13C/BLK TURNS ON ALT. CHARGE LIGHT AT 18C/ORA IND. LIGHT 9/BLU 13H/BLK LESS THAN CHARGE 12.3 .3 SENSE VOLTS 18J/ORA UNIT LINE GROUND LINE 4-- 30 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 153 74F/YEL 13AE/BLK HEADLIGHT EACH LAMP GROUND LINE LEGEND CB CIRCUIT BREAKER RELAY CONTACTR MTR MOTOR FUEL GAUGE PM PERMANENT MAGNET JACK SWITCH PLUG SENDING UNIT SOLENOID VALVE HOUR METER 350168 4-- 31 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 154: Wire Harness Group Gas/Lp Liquid Cooled

    ELECTRICAL WIRE HARNESS GROUP GAS/LP LIQUID COOLED 4-- 32 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 155 M2 OIL PRESSURE 85 COIL+ 86 COIL -- 30 COMMON CONTACT 18F/ORA 14/YEL 87 N.O. CONTACT 21/GRY 87A N.C. CONTACT SECTION E--E VIEW F--F 350139 - - G, LP, LIQ 4-- 33 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 156: Wire Harness Group Diesel

    ELECTRICAL WIRE HARNESS GROUP DIESEL 4-- 34 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 157 ELECTRICAL WIRE HARNESS GROUP DIESEL 4D/YEL 18C/ORA 1A/RED 1B/RED 7/GRY 12/BRN 20A/BLU 12A/BRN 20B/BLU 20B/BLU 14A/YEL 20C/BLU 14B/YEL 1B/RED STARTING 72A/GRN MODE DIODE 1 350137 - - D 4-- 35 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 158: Wire Harness Group Gas/Lp Air Cooled

    ELECTRICAL WIRE HARNESS GROUP GAS/LP AIR COOLED FUEL GAUGE 4-- 36 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 159 86 COIL -- 30 COMMON CONTACT 18M/ORA 18N/ORA 14/YEL 13L/BLK 87 N.O. CONTACT 21/GRY 87A N.C. CONTACT SECTION G--G VIEW H--H VIEW J--J NOTE: 1. ALL PART NUMBERS ARE FOR REFERENCE ONLY. 4-- 37 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 160 ELECTRICAL 4-- 38 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 161: 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-- 39 6400IC MM433 (10- -93) Home Find... Go To..
  • Page 162: Liquid Cooled Gas/Lp Engine Will Not Start

    COIL COIL WIRE SPARK PLUGS PRESSURE RELAY 14/YEL 20A/BLU LOW OIL PRESSURE CB- -2 18C/ORA 18E/ORA 21/GRY 13D/BLK 15 AMP 18F/ORA 23/YEL GRND 21/GRY OIL PRESSURE SWITCH GROUND LINE LINE 4-- 40 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 163 OR REPLACE DEFECTIVE PARTS STILL WILL NOT START CHECK THE IGNITION COIL AND DISTRIBUTOR- -- -REPLACE DEFECTIVE COMPONENT CHECK FOR FUEL FLOW OUTPUT FROM THE FUEL PUMP REPLACE IF NECESSARY 4-- 41 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 164: Liquid Cooled Gas/Lp Engine Starts But Will Not Stay Running

    COIL COIL WIRE SPARK PLUGS PRESSURE RELAY 14/YEL 20A/BLU LOW OIL PRESSURE CB- -2 18C/ORA 18E/ORA 21/GRY 13D/BLK 15 AMP 18F/ORA 23/YEL GRND 21/GRY OIL PRESSURE SWITCH GROUND LINE LINE 4-- 42 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 165 IS THERE BATTERY VOLTAGE BETWEEN 14/YEL AND GROUND DURING ENGINE CRANKING AFTER THE OIL PRESSURE LIGHT HAS GONE OUT ? REPLACE M2 RELAY CHECK FUEL FILTER AND REPLACE IF DEFECTIVE 4-- 43 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 166: Diesel Engine Will Not Start

    21/GRY 13D/BLK 15 AMP 18E/ORA 23/YEL GRND OIL PRESSURE LINE SWITCH GROUND LINE LEGEND SYMBOL DESCRIPTION CIRCUIT BREAKER DIODE LAMP RELAY OR CONTACTOR COIL MOTOR SOLENOID, ELECTROMECHANICAL SOLENOID VALVE SWITCH 4-- 44 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 167 PLACE IF NECESSARY CHECK OUTPUT OF FUEL PUMP FOR FUEL FLOW CHECK WIRING TO GLOW PLUGS MEASURE THE RESISTANCE OF EACH GLOW PLUG EACH PLUG SHOULD BE ABOUT .5 OHMS 4-- 45 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 168: Diesel Engine Starts But Will Not Stay Running

    21/GRY 13D/BLK 15 AMP 18E/ORA 23/YEL GRND OIL PRESSURE LINE SWITCH GROUND LINE LEGEND SYMBOL DESCRIPTION CIRCUIT BREAKER DIODE LAMP RELAY OR CONTACTOR COIL MOTOR SOLENOID, ELECTROMECHANICAL SOLENOID VALVE SWITCH 4-- 46 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 169 IS THERE BATTERY VOLTAGE BETWEEN 14/YEL AND GROUND DURING ENGINE CRANKING AFTER THE OIL PRESSURE LIGHT HAS GONE OUT ? REPLACE M2 RELAY CHECK FUEL FILTER AND REPLACE IF DEFECTIVE 4-- 47 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 170: Air Cooled Gas/Lp Engine Will Not Start

    (FLYWHEEL RELAY 1F/RED ALTERNATOR) 40 AMPS MAX RECTIFIER- - 13Q/BLK ALT. OUTPUT REGULATOR AT 2500 RPM SPARK PLUG ENGINESHUT- -DOWN RELAY 13K/BLK 17/PUR NOT USED 18N/ORA 13L/BLK GROUND LINE LINE 4-- 48 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 171 AT TERMINAL 30 ON THE KEY SWITCH TO GROUND REPLACE THE ENGINE IGNITION COIL REPLACE THE KEY IGNITION SWITCH REPLACE THE ENGINE SHUTDOWN RELAY CHECK THE CONNECTIONS BETWEEN THE BATTERY AND THE KEY IGNITION SWITCH 4-- 49 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 172: Air Cooled Gas/Lp Engine Starts But Will Not Stay Running

    (FLYWHEEL RELAY 1F/RED ALTERNATOR) 40 AMPS MAX RECTIFIER- - 13Q/BLK ALT. OUTPUT REGULATOR AT 2500 RPM SPARK PLUG ENGINESHUT- -DOWN RELAY 13K/BLK 17/PUR NOT USED 18N/ORA 13L/BLK LINE GROUND LINE 4-- 50 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 173 THE BATTERY CHECK TO SEE IF THE OIL PRESSURE SWITCH IS CLOSED WITH THE KEY ON AND THE ENGINE STOPPED REPLACE THE OIL PRESSURE SWITCH REPLACE THE OIL PRESSURE RELAY M2 4-- 51 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 174 ELECTRICAL 4-- 52 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 175 ....5--85 HYDRAULIC HOSE GROUP ... . 5--87 5-- 1 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 176: Hydraulics

    HYDRAULICS 5-- 2 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 177 HYDRAULICS INTRODUCTION The hydraulic system consists of the propel pump, accessory pump, control valve, and drive motors. 5-- 3 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 178: Hydraulic Fluid Reservoir

    800 hours of operation. The reservoir has a built-in strainer outlet that filters hydraulic fluid before it enters the system. Replace the strainer every 800 hours of operation. 5-- 4 6400IC MM433 (3- -96) Home Find... Go To..
  • Page 179: Hydraulic Fluid

    The quality and condition of the hydraulic fluid play a very important role in how well the machine operates. Tennant’s hydraulic fluid is specially selected to meet the needs of Tennant machines. Tennant’s hydraulic fluids provide a longer life for the hydraulic components. There are two fluids...
  • Page 180: To Drain Hydraulic Fluid Reservoir And Replace Filter Element

    NOTE: Be aware the hydraulic filter is lower than the reservoir. All fluid will drain from the reservoir. Discard all hydraulic fluid drained from the system. The fluid may contain foreign material harmful to the hydraulic system. 5-- 6 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 181 6. Apply a thin coat of hydraulic fluid to the seal of the new hydraulic fluid filter element. 7. Thread and hand tighten the new hydraulic fluid filter element on the filter head. AIR COOLED 8. Refill the hydraulic reservoir. 5-- 7 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 182: To Fill Hydraulic Fluid Reservoir

    6. Put the reservoir breather-filler cap on the reservoir. 7. Start engine and operate all the hydraulic components. 8. Recheck the hydraulic fluid level. 9. Check for any leaks. 5-- 8 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 183: Hydraulic Pumps

    The machine accessory pump is a hydraulic gear pump. After repairing or replacing a hydraulic pump, or when system contamination is likely, change the hydraulic fluid in the reservoir and the hydraulic fluid filter. LIQUID COOLED 5-- 9 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 184: To Replace Propel Pump (Liquid Cooled)

    Brake, Turn Off Machine And Remove Key. 2. Open the seat support and disconnect the battery cables. 3. Remove the hose leading from the air cleaner to the machine lintel. 5-- 10 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 185 Move the directional spring assembly out of the way. NOTE: Do not disconnect the hydraulic hoses leading to the accessory pump. 5-- 11 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 186 11. Remove the hydraulic fittings from the old pump and install in the new pump in the same orientation. 5-- 12 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 187 15. Position the accessory pump in the back of the new propel pump. Make sure the O--ring is in place on the accessory pump. 5-- 13 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 188 18. Reconnect the charge line to the propel pump. 19. Reinstall the directional arm to the propel pump. Leave the three hex screws loose for now. 20. Reinstall the hose to the air cleaner and machine lintel. 5-- 14 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 189 22. Raise the rear drive tire off the floor. Place jack stands under the frame. 23. Adjust the neutral centering of the new propel pump. See TO ADJUST DIRECTIONAL SPRING instructions. 5-- 15 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 190: To Replace Accessary Pump (Liquid Cooled)

    Brake, Turn Off Machine And Remove Key. 2. Open the seat support and disconnect the battery cables. 3. Remove the hose leading from the air cleaner to the machine lintel. 5-- 16 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 191 7. Remove the two hex screws holding the accessory pump and directional bracket to the propel pump. Move the directional spring assembly out of the way. 5-- 17 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 192 Make sure the O--ring is in place on the accessory pump. 11. Position the directional spring mount bracket over the mounting flange on the new accessory pump. 5-- 18 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 193 NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 14. Reinstall the hose to the air cleaner and machine lintel. 15. Reconnect the battery cables. Reinstall the front rubber firewall. 5-- 19 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 194 16. Raise the rear drive tire off the floor. Place jack stands under the frame. 17. Adjust the neutral centering of the new propel pump. See TO ADJUST DIRECTIONAL SPRING instructions. 5-- 20 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 195: To Replace Propel Pump (Air Cooled)

    3. Disconnect and plug the hydraulic charge line leading to the back of the propel pump. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-- 21 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 196 7. Remove the two hex screws holding the propel pump to the bellhousing. Pull the propel pump out of the bellhousing and remove it from the machine. 5-- 22 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 197 See the hose pictorial in this section. NOTE: Do not reconnect the charge line to the propel pump until after the accessory pump and directional spring mount bracket are installed. 5-- 23 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 198 15. Reconnect the charge line to the propel pump. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 16. Reinstall the directional arm to the propel pump. Leave the three hex screws loose for now. 5-- 24 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 199 18. Raise the rear drive tire off the floor. Place jack stands under the frame. 19. Adjust the neutral centering of the new propel pump. See TO ADJUST DIRECTIONAL SPRING instructions. 5-- 25 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 200: To Replace Accessary Pump (Air Cooled)

    NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 3. Disconnect and plug the hydraulic hoses leading to the accessory pump. 5-- 26 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 201 7. Position the new accessory pump in the back of the propel pump. Make sure the O--ring is in place on the accessory pump. 5-- 27 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 202 12. Raise the rear drive tire off the floor. Place jack stands under the frame. 13. Adjust the neutral centering of the new propel pump. See TO ADJUST DIRECTIONAL SPRING instructions. 5-- 28 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 203: Directional Pedal

    Brake, Turn Off Machine And Remove Key. 1. Open the seat support and disconnect the battery cables. 2. Remove the lower hose from the air cleaner assembly for better access to the directional spring. 5-- 29 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 204 Pull the directional spring up out of the slot. NOTE: Mark the directional cable before removing the directional spring to make sure the new spring is install in the same location. 5-- 30 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 205 2nd jam nut, and ball end. Tighten the jam nuts in the same location as they were removed. 11. Install a new plastic wire tie around the cable bracket. 5-- 31 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 206 Tighten the hex screw to 11 -- 14 Nm (7 -- 10 ft lb). 13. Reinstall the lower hose on the air cleaner assembly. 14. See TO ADJUST DIRECTIONAL SPRING instructions. 5-- 32 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 207: To Replace Directional Cable (Liquid Cooled)

    2. Open the seat support and disconnect the battery cables. 3. Remove the two hydraulic tank straps. Lift the tank up far enough to access the cable. Do not disconnect the hydraulic hoses. 5-- 33 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 208 7. Remove the ball end, 1st jam nut, washer, propel cable bracket, and 2nd jam nut from the end of the directional cable. NOTE: Make note of the location of the 2nd jam nut for proper re- -assembly. 5-- 34 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 209 10. Push the directional cable through the large cable clamp under the hydraulic accessory pump. 11. Go to the operators compartment and remove the floor plate access panel. 5-- 35 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 210 16. Carefully route the new directional cable in the machine. Follow the same path as the old cable. 17. Reinstall the clamp on the new directional cable at the operator compartment side panel. 5-- 36 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 211 11 -- 14 Nm (7 -- 10 ft lb). 20. Reinstall the floor access plate. 21. Position the hydraulic tank back down on the frame. Reinstall the two tank straps. 5-- 37 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 212 Tighten the hex screw to 11 -- 14 Nm (7 -- 10 ft lb). NOTE: Make sure the spacers are in place under the ball end. 27. See TO ADJUST DIRECTIONAL SPRING instructions. 5-- 38 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 213: To Adjust Directional Spring (Liquid Cooled)

    2. Open the seat support. 3. Start the machine and check the rear tire for any rotation. If the tire is rotating in either direction the centering spring needs to be adjusted. 5-- 39 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 214 Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 7. Remove the jack stands and lower the machine. Check to make sure the machine does not creep. 5-- 40 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 215: To Replace Directional Spring (Air Cooled)

    2. Remove the hex screw and nyloc nut holding the directional spring ball end to the propel pump arm. Retain the two spacers. 3. Cut the plastic tie from around the propel cable bracket. 5-- 41 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 216 Position the new spring in the same location on the cable as the old one. 8. Place the new directional spring in the mount slot. Tighten the large jam nut firmly. 5-- 42 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 217 11. Reconnect the cable ball end to the propel pump arm. Tighten the hex screw to 11 -- 14 Nm (7 -- 10 ft lb). 12. See TO ADJUST DIRECTIONAL SPRING instructions. 5-- 43 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 218: To Replace Directional Cable (Air Cooled)

    Retain the two spacers. 3. Remove the two hydraulic tank straps. Lift the tank up far enough to access the cable. Do not disconnect the hydraulic hoses. 5-- 44 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 219 NOTE: Mark the directional cable before removing the directional spring to make sure the new spring is install in the same location. 7. Un--screw the directional spring from the directional cable. 5-- 45 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 220 11. Remove the old directional cable from the machine. Remove the clevis from the old cable and install on the new cable in the same location. 5-- 46 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 221 14. Reconnect the cable clevis to the directional pedal. Tighten the hex screw and nyloc to 11 -- 14 Nm (7 -- 10 ft lb). 15. Reinstall the floor access plate. 5-- 47 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 222 Tighten the large jam nut firmly. 19. Reinstall the 1st jam nut, cable bracket, 2nd jam nut, and ball end. Tighten the jam nuts in the same location as they were removed. 5-- 48 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 223 Tighten the hex screw to 11 -- 14 Nm (7 -- 10 ft lb). NOTE: Make sure the spacer in place under the ball end. 22. See TO ADJUST DIRECTIONAL SPRING instructions. 5-- 49 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 224: To Adjust Directional Spring (Air Cooled)

    2. Open the seat support. 3. Start the machine and check the rear tire for any rotation. If the tire is rotating in either direction the centering spring needs to be adjusted. 5-- 50 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 225 Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 7. Remove the jack stands and lower the machine. Check to make sure the machine does not creep. 5-- 51 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 226: To Replace Hopper Lift Cylinder

    NOTE: Always observe hydraulic cleanliness requirements when opening hydraulic lines. 5. Remove the inside cotter pin from the upper clevis pin on the upper end of the hopper lift cylinder. Remove the clevis pin. 5-- 52 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 227 10. Align the bottom of the lift cylinder with the hole in the frame mount lug. Reinstall the clevis pin and cotter pin. 5-- 53 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 228 12. Reconnect the hydraulic hoses to the new cylinder. See schematic in this section. 13. Start the machine and operate the hopper. Check for any leaks and proper operation. Reinstall the front rubber firewall. 5-- 54 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 229: To Replace Hopper Dump Door Cylinder

    5. Remove the cotter pin and clevis pin from the top of the dump door cylinder were it attaches to the center/rear of the debris hopper. 5-- 55 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 230 8. Remove the fittings from the old cylinder and install in the new cylinder in the same orientation. 9. Position the new cylinder in the machine with the rod end pointing to the center of the dump door. 5-- 56 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 231 See the schematic in this section. 13. Start the machine and open and close the hopper dump door. Check for any leaks and proper operation. Reinstall the front rubber firewall. 5-- 57 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 232: To Replace Steering Cylinder

    2. Open the seat support. 3. Turn the steering wheel to the left so the rear drive casting can be accessed from the fuel tank area of the machine. 5-- 58 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 233 7. Disconnect and cap the two hydraulic hoses leading to the steering cylinder. NOTE: Always observe hydraulic cleanliness requirements when opening hydraulic lines. 5-- 59 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 234 18.75 in. 11. Position the new steering cylinder and balljoint assembly in the machine with the rod part of the cylinder toward the rear of the machine. 5-- 60 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 235 15. Remove the jack stands from machine and lower. 16. Start machine and turn steering wheel in both directions. Observe the steering cylinder for any leaks. 5-- 61 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 236: To Replace Steering Valve

    2. Turn off the engine and engage the parking brake. Open the seat support. 3. Remove battery cables from battery. 4. Remove the rubber cap in the center of the steering wheel. 5-- 62 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 237 7. Remove and plug the five hydraulic hoses on the steering control motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 8. Remove the hex screws holding the hydraulic steering valve to the steering column. 5-- 63 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 238 Reinstall the hex screws and tighten to 31 -- 40 Nm (27 -- 35 ft lb). 12. Reconnect the hydraulic hoses to hydraulic steering valve. See the schematic in this section. 5-- 64 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 239 14. Reinstall the rubber steering wheel cover. 15. Reconnect the battery cables and start engine. Turn the steering wheel and check for any leaks and proper operation. Reinstall the front rubber firewall. 5-- 65 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 240: Hydraulic Control Valve

    Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the seat support. 2. Remove the hair pins, C pins, and tension spring holding the valve handles to the valve. 5-- 66 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 241 6. Install the new valve back on the valve mount bracket. Reinstall the two M6 hex screws and nyloc nuts. Tighten to 115 -- 225 Ncm (10 -- 20 in lb). 5-- 67 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 242 8. Reinstall the two valve handles, C pins, and hair pins on the new valves. 9. Reconnect the tension spring to the left handle. 10. Start the machine and check the control valve for proper operation. 5-- 68 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 243: Hydraulic Solenoid Valve

    Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the hopper and engage the support bar. Remove the front rubber firewall. 2. Open the seat support. 5-- 69 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 244 6. Go in front of the machine and down under the brush wrap. Locate the two hex screws holding the solenoid valve to the machine frame. Remove the valve from the machine. 5-- 70 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 245 18 -- 24 Nm (15 -- 20 ft lb). 9. Reconnect the hydraulic hoses. See schematic in this section. 10. Reconnect the two electrical coils to the main harness. 5-- 71 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 246 HYDRAULICS 11. Reinstall the battery and connect the battery cables. 12. Start the machine and check the new valve for any leak and proper operation. Reinstall the front rubber firewall. 5-- 72 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 247: To Replace Main Brush Motor

    Remove the skirt assembly from the machine. 4. Remove and plug the hydraulic hoses leading to the main brush motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-- 73 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 248 Remove the motor from the machine. 9. Remove the hydraulic fittings from old motor and install in the new motor in the same orientation. 5-- 74 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 249 13. Reinstall the castle nut and tighten to 40 -- 54 Nm (30 -- 40 ft lb). Continue to tighten castle nut until it lines up with hole in brush motor shaft. Install a new cotter pin. 5-- 75 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 250 14. Reinstall the dust skirt assembly on the machine. Tighten the hex screws to 18 -- 24 Nm (15 -- 20 ft lb). 15. Reinstall the main brush. Operate the machine and check for proper operation. 5-- 76 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 251: To Replace Side Brush Motor

    5. Remove the side brush from the side brush motor. 6. Remove and plug the hydraulic hoses leading to the side brush motor. Note: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-- 77 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 252 Tighten the four hex screws to (27 -- 35 ft lb). 10. Reconnect the hydraulic hoses to the side brush motor. See schematic in this section. 5-- 78 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 253 13. Secure the pin by clipping the pin keeper over the end of the pin. 14. Disengage the hopper support bar and lower the hopper. 15. Adjust the side brush pattern with the side brush down pressure lever. 5-- 79 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 254: To Replace Rear Drive Motor

    Block machine up with jack stands. 3. Remove the rear tire and wheel assembly from the drive motor hub. 4. Remove the cotter pin and slotted nut from drive wheel shaft. 5-- 80 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 255 7. Remove the four motor mounting bolts. 8. Slide the motor out of the rear wheel housing. 9. Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation. 5-- 81 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 256 13. Mount the drive hub to the tapered motor shaft. Tighten the castle nut to 270 Nm (200 ft lb) and put new 0.125 x 2.50 cotter pin through slotted nut. 5-- 82 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 257 HYDRAULICS 14. Install the rear tire. Tighten the nuts to 122--150 Nm (90--110 ft lb). 15. Remove the jack stands and lower the machine. 5-- 83 6400IC MM433 (8- -94) Home Find... Go To..
  • Page 258 HYDRAULICS Fig. 1 - - Hydraulic Schematic, Liquid cooled 350156 - - LIQ 5-- 84 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 259 HYDRAULICS Hydraulic Schematic, Liquid cooled Fig. 1 - - 350156 - - LIQ 5-- 85 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 260 HYDRAULICS Fig. 2 - - Hydraulic Schematic, Air Cooled 5-- 86 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 261 HYDRAULICS Fig. 2 - - Hydraulic Schematic, Air Cooled 350157 - - AIR 5-- 87 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 262 BRUSH CYLINDER MOTOR STEERING ACCESSORY VALVE PUMP MAIN CONTROL VALVE PROPEL PUMP MAIN BRUSH MOTOR HOPPER LIFT CYLINDER REAR DRIVE MOTOR STEERING SOLENOID CYLINDER CONTROL HYDRAULIC VALVE FILTER HYDRAULIC RESERVOIR 5-- 88 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 263 SIDE BRUSH CYLINDER MOTOR STEERING HOPPER VALVE LIFT CYLINDER MAIN CONTROL VALVE SOLENOID CONTROL VALVE MAIN BRUSH MOTOR ACCESSORY PUMP REAR DRIVE MOTOR PROPEL STEERING PUMP CYLINDER HYDRAULIC FILTER HYDRAULIC RESERVOIR 5-- 89 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 264: 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. 5-- 90 6400IC MM433 (4- -94) Home Find... Go To..
  • Page 265: Main Brush On Circuit

    MAIN BRUSH ON CIRCUIT 2150 MAIN BRUSH SIDE BRUSH 400 +/- - 20 RPM FILTER PRESSURE SUCTION RETURN PUMP CASE DRAIN RV3 (IN PROPEL PUMP) PRESSURE READINGS BASED ON 150 F STRAINER 5-- 91 6400IC MM433 (4- -94) Home Find... Go To..
  • Page 266: Main Brush Does Not Turn On

    FLOW OK? STEM CARTRIDGE REPAIR OR PLUMBING OK? REPLACE MOTOR PUMP OUTLET REPAIR OR FLOW OK? REPLACE PLUMBING REPAIR OR RV RELIEF REPLACE CARTRIDGE OK? PUMP REPAIR OR REPLACE RV RELIEF CARTRIDGE 5-- 92 6400IC MM433 (NIL) Home Find... Go To..
  • Page 267: Main Brush Does Not Turn Off

    MAIN BRUSH DOES NOT TURN OFF BRUSH SPEED LESS THAN 10 RPM? SV1 STEM SYSTEM OK MAGNETIZED? SV1 STEM CHECK CARTRIDGE ELECTRICAL SYSTEM SHIFTING OK? REPAIR OR REPLACE SV1 STEM CARTRIDGE 5-- 93 6400IC MM433 (NIL) Home Find... Go To..
  • Page 268: Main Brush & Side Brush On Circuit

    SIDE BRUSH 400 +/- - 20 RPM 90 +/- - 5 RPM FILTER PRESSURE SUCTION RETURN PUMP CASE DRAIN RV3 ( IN PROPEL PUMP) PRESSURE READINGS BASED ON 150 F STRAINER 5-- 94 6400IC MM433 (4- -94) Home Find... Go To..
  • Page 269: Side Brush Does Not Turn On

    FLOW OK? STEM CARTRIDGE REPAIR OR PLUMBING OK? REPLACE MOTOR PUMP OUTLET REPAIR OR FLOW OK? REPLACE PLUMBING REPAIR OR RV RELIEF REPLACE CARTRIDGE OK? PUMP REPAIR OR REPLACE RV RELIEF CARTRIDGE 5-- 95 6400IC MM433 (NIL) Home Find... Go To..
  • Page 270: Side Brush Does Not Turn Off

    HYDRAULICS SIDE BRUSH DOES NOT TURN OFF BRUSH SPEED < 10 RPM? SYSTEM SV2 STEM NORMAL MAGNETIZED? SV2 STEM CHECK CARTRIDGE ELECTRICAL SYSTEM SHIFTING OK? REPAIR OR REPLACE SV2 STEM CARTRIDGE 5-- 96 6400IC MM433 (NIL) Home Find... Go To..
  • Page 271: Steering Circuit

    300 PSI (STATIONARY) 650 PSI (TURNING) 1500 PSI (HELD AT STOP ON STEERING WHEEL ) PRESSURE SUCTION RETURN CASE DRAIN PUMP RV3 (IN PROPEL PUMP) PRESSURE READINGS BASED ON 150 F STRAINER 5-- 97 6400IC MM433 (4- -94) Home Find... Go To..
  • Page 272: Steering Circuit

    300 PSI (STATIONARY) 650 PSI (TURNING) 1500 PSI (HELD AT STOP ON STEERING WHEEL ) PRESSURE SUCTION RETURN CASE DRAIN PUMP RV3 (IN PROPEL PUMP) PRESSURE READINGS BASED ON 150 F STRAINER 5-- 98 6400IC MM433 (4- -94) Home Find... Go To..
  • Page 273: Power Steering Is Not Normal

    REPAIR OR PLUMBING OK? REPLACE STEER CYLINDER OR ROD ENDS PUMP OUTLET REPAIR OR FLOW OK? REPLACE PLUMBING STEERING INLET REPAIR OR PRESSURE OK? REPLACE PUMP REPAIR OR REPLACE STEERING CONTROL 5-- 99 6400IC MM433 (NIL) Home Find... Go To..
  • Page 274: Hopper Door Circuit

    LIFT DOOR CLOSE 1500 PSI (DOOR HELD CLOSED) RV5 (IN STEERING CIRCUIT) 1500 PRESSURE SUCTION RETURN CASE DRAIN PUMP RV3 (IN PROPEL PUMP) PRESSURE READINGS BASED ON 150 F STRAINER 5-- 100 6400IC MM433 (4- -94) Home Find... Go To..
  • Page 275: Hopper Door Does Not Open

    SHIFTING OK? REPAIR OR PLUMBING OK? REPLACE MANUAL CONTROL VALVE PUMP OUTLET REPAIR OR FLOW OK? REPLACE PLUMBING REPAIR OR STEERING INLET REPLACE PUMP PRESSURE OK? REPAIR OR REPLACE STEERING CONTROL 5-- 101 6400IC MM433 (NIL) Home Find... Go To..
  • Page 276: Hopper Door Does Not Close

    SHIFTING OK? REPAIR OR PLUMBING OK? REPLACE MANUAL CONTROL VALVE PUMP OUTLET REPAIR OR FLOW OK? REPLACE PLUMBING REPAIR OR STEERING INLET REPLACE PUMP PRESSURE OK? REPAIR OR REPLACE STEERING CONTROL 5-- 102 6400IC MM433 (NIL) Home Find... Go To..
  • Page 277: Hopper Door Does Not Stay Closed

    DOOR CYLINDER CLEVIS PINS & SEALS OK? REPLACE DOOR MANUAL CONTROL CYLINDER OR CLEVIS VALVE SPOOL PINS SHIFTING OK? REPAIR OR PLUMBING OK? REPLACE MANUAL CONTROL VALVE REPAIR OR REPLACE PLUMBING 5-- 103 6400IC MM433 (NIL) Home Find... Go To..
  • Page 278: Hopper Lift Circuit

    LIFT DOOR CLOSE 1500 PSI (HOPPER UP FULL) RV5 (IN STEERING CIRCUIT) 1500 PRESSURE SUCTION RETURN CASE DRAIN PUMP RV3 (IN PROPEL PUMP) PRESSURE READINGS BASED ON 150 F STRAINER 5-- 104 6400IC MM433 (4- -94) Home Find... Go To..
  • Page 279: Hopper Does Not Raise

    & PLUMBING OK? REPLACE MANUAL CONTROL VALVE PUMP OUTLET REPAIR OR FLOW OK? REPLACE CYLINDER ORIFICE OR PLUMBING REPAIR OR STEERING INLET REPLACE PUMP PRESSURE OK? REPAIR OR REPLACE STEERING CONTROL 5-- 105 6400IC MM433 (NIL) Home Find... Go To..
  • Page 280 REPAIR OR MANUAL CONTROL REPLACE LIFT VALVE SPOOL CYLINDER OR CLEVIS SHIFTING OK? PINS CYLINDER ORIFICE REPAIR OR & PLUMBING OK? REPLACE MANUAL CONTROL VALVE REPAIR OR REPLACE CYLINDER ORIFICE OR PLUMBING 5-- 106 6400IC MM433 (NIL) Home Find... Go To..
  • Page 281: Hopper Does Not Hold Up Position

    HOLD UP POSITION CAN SAFETY LEG BE PUT IN PLACE? LIFT CYLINDER SYSTEM OK SEALS OK? MANUAL CONTROL REPAIR OR VALVE SPOOL REPLACE LIFT SHIFTING OK? CYLINDER REPAIR OR REPLACE MANUAL CONTROL VALVE 5-- 107 6400IC MM433 (NIL) Home Find... Go To..
  • Page 282: Propel Circuit

    HYDRAULICS PROPEL CIRCUIT PROPEL MOTOR 2000 2000 9 GPM (FULL FWD) STRAINER LEVEL 400 PSI 8 RAMP 1800 PSI PRESSURE SUCTION RETURN CASE DRAIN PRESSURE READINGS BASED ON 150 F 5-- 108 6400IC MM433 (4- -94) Home Find... Go To..
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  • Page 331 ....6--18 TO INSTALL ENGINE ....6--22 6400IC MM433 (12- -01) 6-- 1 Home Find... Go To..
  • Page 332 ENG/AIR COOLED 6-- 2 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 333 ENG/AIR COOLED INTRODUCTION This section includes repair information on the engine and related systems, such as fuel, electrical, and engine removal. 6-- 3 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 334: Lubrication

    The flywheel mounted fan blows air over the engine cylinders and head to remove engine heat. The cooling fins should be cleaned every 100 hours by blowing compressed air across them. 6-- 4 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 335: Air Intake System

    They should be flexible and undamaged. Oil the precleaner element with 30 cc (1 oz) of clean engine oil. Squeeze precleaner element to distribute the oil evenly throughout the foam. 6-- 5 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 336: Fuel System -- Gasoline

    Increase the engine speed by turning the screw clockwise. Decrease the engine speed by turning the screw counter--clockwise. Idle speed is 1200 RPM + or -- 50 RPM. 6-- 6 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 337: Fuel System -- Lpg

    Check for frosting. If frosting occurs on or near any LPG component, there is a possible LPG fuel leak or malfunctioning component. 6-- 7 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 338 Check routings of all LPG hoses. Keep them away from sharp edges, exhaust manifolds, or other hot surfaces. Check for signs of abrasion or deterioration. Replace worn or damaged hoses. 6-- 8 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 339: Lp Fuel Tank

    The valve must be closed except when in service. Tank Service Valve Coupling -- Check for proper functioning, thread condition, and damaged or missing washers or o-rings. 6-- 9 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 340 Do not tamper with the relief valve setting. Magnetic Liquid Level Gauge -- Check the operation against the maximum filling point as determined by weight. 6-- 10 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 341 Changing the tank is a chance for the machine operator to carefully check over the tank, fittings, and the fuel lines and fittings. If abnormal wear is detected, report the findings to the appropriate personnel. 6-- 11 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 342: To Change An Lpg Fuel Tank

    Close the service valve immediately if an LPG leak is found, and tell the appropriate personnel. 14. If no leaks are found, the engine is ready to start. 6-- 12 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 343: Regulator

    If any malfunction is found, completely disassemble the carburetor. Clean all the parts in alcohol. Inspect all the parts and replace where needed. Carefully reassemble the carburetor with the seal repair kit. 6-- 13 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 344: Lpg Fuel Troubleshooting

    Clean the crankcase ventilation hoses, tubes, and fittings and replace the PCV valve every 400 hours of operation. GOVERNOR The mechanical governor controls engine speed. The governor should never need to be adjusted. 6-- 14 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 345: Ignition System

    Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. The alternator on this engine is located internally. The engine flywheel must be removed for access to the alternator. 6-- 15 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 346: To Replace Starter

    Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the seat support. 2. Disconnect the battery cables. 3. Disconnect the wires leading to the back of the starter. 6-- 16 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 347 7. Reconnect the wires to the back of the starter. See the schematic in the ELECTRICAL section. 8. Reconnect the battery cables and start the engine. Check the starter for proper operation. 6-- 17 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 348: To Remove Engine

    Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Open the seat support. 2. Disconnect the battery cables. 3. Remove the belt guard on the out side of the engine. 6-- 18 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 349 Slip the pipe down off the manifold. 7. Disconnect the wire harness from the starter and engine. Move the wires out of the way for engine removal. 6-- 19 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 350 11. Remove the clamp holding the propel hoses to the back of the engine. 12. Remove the four hex screws holding the engine to the engine mount plate. 6-- 20 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 351 14. The engine can now be carefully removed from the machine. NOTE: Make sure the engine is clear of any wires or hoses before you lift it out of the machine. 6-- 21 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 352: To Install Engine

    NOTE: Make sure the splines on pump line up with splines in coupler when installing pump. 3. Carefully align the mount holes in the engine block with the mount holes in the engine mount plate. 6-- 22 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 353 8. Reconnect the LPG line to the fuel lock--off. 9. Reconnect the throttle cable and choke cable. 10. Reinstall the clamp with the propel hoses on the back of the engine. 6-- 23 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 354 13. Reinstall the belt guard on the out side of the engine. 14. Reconnect the battery cables to the battery. 6-- 24 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 355 FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 16. Start the engine and check for any leaks and proper operation. 6-- 25 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 356 ENG/AIR COOLED 6-- 26 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 357 ....7--26 TO INSTALL ENGINE ....7--31 6400IC MM433 (12- -01) 7-- 1 Home Find... Go To..
  • Page 358 ENG/LIQUID COOLED 7-- 2 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 359: Introduction

    ENG/LIQUID COOLED INTRODUCTION This section includes repair information on the engine and related systems, such as fuel, electrical, and engine removal. 6400IC MM433 (7- -99) 7-- 3 Home Find... Go To..
  • Page 360: Lubrication

    FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. Flush the radiator and the cooling system every 400 hours of operation, using a dependable cleaning compound. 7-- 4 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 361: Engine Fan Belt

    Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element. 6400IC MM433 (7- -99) 7-- 5 Home Find... Go To..
  • Page 362: To Replace Air Filter Element

    Parking Brake, Turn Off Machine And Remove Key. 1. Start the engine and raise the debris hopper. Engage the support bar. 2. Unscrew the clamp ring on the filter. 3. Remove the dust cap. 7-- 6 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 363 Do not rap, tap, or pound dust out of the element. FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. 6400IC MM433 (7- -99) 7-- 7 Home Find... Go To..
  • Page 364 Tighten the clamp ring to hold it in place. Check all intake hose connections for leaks or abrasions. 12. Reset the air filter restriction indicator. 13. Lower the debris hopper. 7-- 8 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 365: Fuel System -- Gasoline

    Keep area well ventilated. If the engine is hard-starting or runs roughly or stalls at low idle speed, it may be necessary to adjust or service the carburetor. 6400IC MM433 (7- -99) 7-- 9 Home Find... Go To..
  • Page 366: Fuel System -- Lpg

    Never operate an LPG powered machine if the LPG fuel system is leaking, or if any component in the fuel system is malfunctioning. Operating the machine under either of these conditions may cause a fire or explosion. 7-- 10 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 367 Check routings of all LPG hoses. Keep them away from sharp edges, exhaust manifolds, or other hot surfaces. Check for signs of abrasion or deterioration. Replace worn or damaged hoses. 6400IC MM433 (7- -99) 7-- 11 Home Find... Go To..
  • Page 368: Lp Fuel Tanks

    The valve must be closed except when in service. Tank Service Valve Coupling -- Check for proper functioning, thread condition, and damaged or missing washers or o-rings. 7-- 12 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 369 Do not tamper with the relief valve setting. Magnetic Liquid Level Gauge -- Check the operation against the maximum filling point as determined by weight. 6400IC MM433 (7- -99) 7-- 13 Home Find... Go To..
  • Page 370 Changing the tank is a chance for the machine operator to carefully check over the tank, fittings, and the fuel lines and fittings. If abnormal wear is detected, report the findings to the appropriate personnel. 7-- 14 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 371: To Change An Lpg Fuel Tank

    Close the service valve immediately if an LPG leak is found, and tell the appropriate personnel. 14. If no leaks are found, the engine is ready to start. 6400IC MM433 (7- -99) 7-- 15 Home Find... Go To..
  • Page 372: Fuel Filter Lock

    If any malfunction is found, completely disassemble the carburetor. Clean all the parts in alcohol. Inspect all the parts and replace where needed. Carefully reassemble the carburetor with the seal repair kit. 7-- 16 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 373: Governor

    ENG/LIQUID COOLED GOVERNOR The mechanical governor controls engine speed. The governor is factory set and is not user serviceable. 6400IC MM433 (7- -99) 7-- 17 Home Find... Go To..
  • Page 374: Lpg Fuel Troubleshooting

    See Kubota engine service manual at the end of this section. CRANKCASE VENTILATION SYSTEM Clean the crankcase ventilation hoses, tubes, and fittings and replace the PCV valve every 400 hours of operation. 7-- 18 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 375: Ignition System

    4. Clean the spark plug seat in the cylinder head. 5. Use a new seat gasket and screw the plug in by hand. 6. Tighten the spark plugs with a socket wrench of the correct size. 6400IC MM433 (7- -99) 7-- 19 Home Find... Go To..
  • Page 376: To Replace Alternator

    Brake, Turn Off Machine And Remove Key. 1. Open the seat support. 2. Disconnect the battery cables from the battery. 3. Cut any plastic wire ties holding the wire harness to the alternator bracket. 7-- 20 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 377 7. Remove the hex screw and nyloc nut holding the bottom of the alternator to the lower mount bracket. 8. The alternator can now be removed from the machine. 6400IC MM433 (7- -99) 7-- 21 Home Find... Go To..
  • Page 378 Leave it loose for now. 12. Reconnect the wires to the back of alternator. See the schematic in the ELECTRICAL section. 13. Place the V--belt back on the alternator pulley. 7-- 22 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 379 15. Tighten the bottom hex screw to 18 -- 24 Nm (15 -- 20 ft lb). 16. Reconnect the battery cables and start the engine. Check the new alternator for proper operation. 6400IC MM433 (7- -99) 7-- 23 Home Find... Go To..
  • Page 380: To Replace Starter

    Brake, Turn Off Machine And Remove Key. 1. Open the seat support. 2. Disconnect the battery cables from the battery. 3. Disconnect the wires leading to the back of the starter. 7-- 24 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 381 (15 -- 20 ft lb). 7. Reconnect the wires to the back of the starter. See the schematic in the ELECTRICAL section. 8. Reconnect the battery cables and check the starter for proper operation. 6400IC MM433 (7- -99) 7-- 25 Home Find... Go To..
  • Page 382: To Remove Engine

    Brake., Turn Off Machine And Remove Key. 1. Open the seat support. 2. Disconnect the battery cables from the battery. 3. Remove the large hose leading from the vacuum fan to the shut--off assembly. 7-- 26 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 383 On an LPG machine, disconnect the line leading from the tank to the fuel lockoff / vaporizer. 7. Drain the coolant from the radiator. 6400IC MM433 (7- -99) 7-- 27 Home Find... Go To..
  • Page 384 11. Remove the two hex screws holding the radiator assembly to the machine frame. 12. Remove the radiator assembly from the machine. 13. Remove the hex screws holding the exhaust pipe to the engine manifold. 7-- 28 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 385 Put a slight amount of tension on the chain. 17. Remove the two hex screws and nyloc nuts holding the rear motor mounts to the rubber isolators on the frame brackets. 6400IC MM433 (7- -99) 7-- 29 Home Find... Go To..
  • Page 386 22. The engine can now be carefully lifted out. NOTE: Make sure the engine is clear of any wires or hoses before you lift it out of the frame. 7-- 30 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 387: To Install Engine

    3. Reinstall the hex screws in the front motor mount plate and bellhousing. Use a small amount of blue loctite 242 on the threads. Leave loose for now. 6400IC MM433 (7- -99) 7-- 31 Home Find... Go To..
  • Page 388 Tighten to 13 -- 18 Nm (10 -- 13 ft lb). 7. Tighten the hex screws holding the rear rubber isolators to the frame mount brackets. Hand tighten tight. 8. Remove the hoist from the engine. 7-- 32 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 389 10W--30 SAE--SG/SH with a new filter. 12. Reconnect the wire harness to the engine components; alternator, starter, oil switch, temperature sender, ect. See schematic in the ELECTRICAL section of this manual. 6400IC MM433 (7- -99) 7-- 33 Home Find... Go To..
  • Page 390 11 -- 13 Nm (7 -- 10 ft lb). On filter with indicator tighten to 31 -- 40 Nm (37 -- 35 ft lb). 17. Reconnect fuel line on the Gas machine. 7-- 34 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 391 Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 21. Reinstall the large hose to the vacuum fan and shut--off assembly. 22. Reconnect the battery cables to the battery. 6400IC MM433 (7- -99) 7-- 35 Home Find... Go To..
  • Page 392 Jack machine up at designated locations only. Block machine up with jack stands. 24. Start the engine and check for any leaks and proper operation. Reinstall the front rubber firewall. 7-- 36 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 393 ....8--18 TO INSTALL ENGINE ....8--23 8-- 1 6400IC MM433 (12- -01) Home Find... Go To..
  • Page 394 ENGINE- -DIESEL 8-- 2 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 395: Introduction

    ENGINE- -DIESEL INTRODUCTION This section includes repair information on the engine and related systems, such as fuel, electrical, and engine removal. 6400IC MM433 (7- -99) 8-- 3 Home Find... Go To..
  • Page 396: Lubrication

    FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. Flush the radiator and the cooling system every 400 hours of operation, using a dependable cleaning compound. 8-- 4 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 397: Engine Fan Belt

    Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element. 6400IC MM433 (7- -99) 8-- 5 Home Find... Go To..
  • Page 398: To Replace Air Filter Element

    Parking Brake, Turn Off Machine And Remove Key. 1. Start the engine and raise the debris hopper. Engage the support bar. 2. Unscrew the clamp ring on the filter. 3. Remove the dust cap. 8-- 6 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 399 Do not rap, tap, or pound dust out of the element. FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. 6400IC MM433 (7- -99) 8-- 7 Home Find... Go To..
  • Page 400 Tighten the clamp ring to hold it in place. Check all intake hose connections for leaks or abrasions. 12. Reset the air filter restriction indicator. 13. Lower the debris hopper. 8-- 8 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 401: Fuel System -- Diesel

    3. Lubricate the o-ring of the new filter cartridge and spin it onto the filter head. 4. Bleed the fuel lines of air as described in TO PRIME FUEL SYSTEM instructions. 6400IC MM433 (7- -99) 8-- 9 Home Find... Go To..
  • Page 402: Fuel Lines

    4. Close the air vent and shut off the engine. 5. Clean up any fuel that was spilled during the bleeding process. 8-- 10 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 403: Governor

    400 hours of operation. See Kubota Diesel Engine Workshop Manual for 78.4 mm Stroke Series. CRANKCASE VENTILATION SYSTEM See Kubota Diesel Engine Workshop Manual for 78.4 mm Stroke Series. 6400IC MM433 (7- -99) 8-- 11 Home Find... Go To..
  • Page 404: To Replace Alternator

    Brake, Turn Off Machine And Remove Key. 1. Open the seat support. 2. Disconnect the battery cables from the battery. 3. Cut any plastic wire ties holding the wire harness to the alternator bracket. 8-- 12 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 405 7. Remove the hex screw and nyloc nut holding the bottom of the alternator to the lower mount bracket. 8. The alternator can now be removed from the machine. 6400IC MM433 (7- -99) 8-- 13 Home Find... Go To..
  • Page 406 Leave it loose for now. 12. Reconnect the wires to the back of alternator. See the schematic in the ELECTRICAL section. 13. Place the V--belt back on the alternator pulley. 8-- 14 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 407 15. Tighten the bottom hex screw to 18 -- 24 Nm (15 -- 20 ft lb). 16. Reconnect the battery cables and start the engine. Check the new alternator for proper operation. 6400IC MM433 (7- -99) 8-- 15 Home Find... Go To..
  • Page 408: To Replace Starter

    Brake, Turn Off Machine And Remove Key. 1. Open the seat support. 2. Disconnect the battery cables from the battery. 3. Disconnect the wires leading to the back of the starter. 8-- 16 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 409 (15 -- 20 ft lb). 7. Reconnect the wires to the back of the starter. See the schematic in the ELECTRICAL section. 8. Reconnect the battery cables and check the starter for proper operation. 6400IC MM433 (7- -99) 8-- 17 Home Find... Go To..
  • Page 410: To Remove Engine

    Brake., Turn Off Machine And Remove Key. 1. Open the seat support. 2. Disconnect the battery cables from the battery. 3. Remove the large hose leading from the vacuum fan to the shut--off assembly. 8-- 18 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 411 6. Disconnect the fuel line at the injector pump. Remove the fuel line were it goes through the radiator mount. 7. Drain the coolant from the radiator. 6400IC MM433 (7- -99) 8-- 19 Home Find... Go To..
  • Page 412 11. Remove the two hex screws holding the radiator assembly to the machine frame. 12. Remove the radiator assembly from the machine. 13. Remove the hex screws holding the exhaust pipe to the engine manifold. 8-- 20 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 413 Put a slight amount of tension on the chain. 17. Remove the two hex screws and nyloc nuts holding the rear motor mounts to the rubber isolators on the frame brackets. 6400IC MM433 (7- -99) 8-- 21 Home Find... Go To..
  • Page 414 22. The engine can now be carefully lifted out. NOTE: Make sure the engine is clear of any wires or hoses before you lift it out of the frame. 8-- 22 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 415: To Install Engine

    3. Reinstall the hex screws in the front motor mount plate and bellhousing. Use a small amount of blue loctite 242 on the threads. Leave loose for now. 6400IC MM433 (7- -99) 8-- 23 Home Find... Go To..
  • Page 416 Tighten to 13 -- 18 Nm (10 -- 13 ft lb). 7. Tighten the hex screws holding the rear rubber isolators to the frame mount brackets. Hand tighten tight. 8. Remove the hoist from the engine. 8-- 24 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 417 12. Install a new engine oil filter and fill the engine with the proper grade of oil. On the Diesel engine, use 5.1 L (5.4 qt) 10W--30 SAE--CC/CD with a new filter. 6400IC MM433 (7- -99) 8-- 25 Home Find... Go To..
  • Page 418 On the standard filter tighten to 11 -- 13 Nm (7 -- 10 ft lb). On filter with indicator tighten to 31 -- 40 Nm (37 -- 35 ft lb). 8-- 26 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 419 Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 20. Reinstall the large hose to the vacuum fan and shut--off assembly. 21. Reconnect the battery cables to the battery. 6400IC MM433 (7- -99) 8-- 27 Home Find... Go To..
  • Page 420 23. Start the engine and check for any leaks and proper operation. See TO BLEED FUEL SYSTEM instructions if needed. 24. Start the engine and check for any leaks and proper operation. Reinstall the front rubber firewall. 8-- 28 6400IC MM433 (7- -99) Home Find... Go To..
  • Page 421 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 422 Home Find... Go To..
  • Page 423 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 424 Home Find... Go To..

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