Tennant 6400 User manual

6400
*MM432*
www.tennantco.com
Sweeper
Operator Manual
MM432
Rev. 12 (04-2009)
North America / International
(Electric)

This manual is furnished with each new model. It provides necessary operation and maintenance instructions.
Read this manual completely and understand the machine before operating or servicing it.
This machine will provide excellent service. However, the best results will be obtained at minimum costs if:
SThe machine is operated with reasonable care.
SThe machine is maintained regularly - per the machine maintenance instructions provided.
SThe machine is maintained with manufacturer supplied or equivalent parts.
PROTECT THE ENVIRONMENT
Please dispose of packaging materials,
old machine components such as
batteries, hazardous fluids including
antifreeze and oil, in an environmentally
safe way according to local waste
disposal regulations.
Always remember to recycle.
MACHINE DATA
Please fill out at time of installation for future reference.
Model No. --
Serial No. --
Machine Options --
Sales Rep. --
Sales Rep. phone no. --
Customer Number --
Installation Date --
Tennant Company
PO Box 1452
Minneapolis, MN 55440
Phone: [phone] or (763) 513--2850
www.tennantco.com
Thermo--Sentry, Instant Access, and Perma--Filter are US registered and unregistered trademarks of Tennant Company.
Specifications and parts are subject to change without notice.
Original instructions, Copyright E1996--2000, 2001, 2002, 2004, 2006--2009 TENNANT Company, Printed in U.S.A.

CONTENTS
1
6400E MM432 (8--07)
CONTENTS
Page
SAFETY PRECAUTIONS 3...................
OPERATION 5..............................
OPERATOR RESPONSIBILITY 5.........
MACHINE COMPONENTS 6.............
SYMBOL DEFINITIONS 7................
CONTROLS AND INSTRUMENTS 9......
OPERATION OF CONTROLS 10..........
DIRECTIONAL PEDAL 10..............
BRAKE PEDAL 11....................
PARKING BRAKE PEDAL 11...........
SEAT SUPPORT RELEASE LEVER 11..
HOPPER LEVER 12...................
HOPPER DOOR LEVER 12............
MAIN BRUSH LEVER 12...............
MAIN BRUSH DOWN
PRESSURE KNOB 13..............
VACUUM AND FILTER
SHAKER LEVER 13................
POWER KILL SWITCH (OPTION) 13....
CLOGGED FILTER LIGHT (OPTION) 14.
HOPPER TEMPERATURE LIGHT --
THERMO SENTRY 14..............
HOPPER DOOR CLOSED LIGHT
(OPTION) 14......................
HYDRAULIC FILTER BYPASS LIGHT
(OPTION) 14......................
BATTERY DISCHARGE INDICATOR 15.
STEERING WHEEL 15................
HOURMETER 15.....................
STEERING WHEEL TILT HANDLE 16...
ON-OFF KEY SWITCH 16..............
HORN BUTTON 16....................
SIDE BRUSH LEVER 16...............
OPERATING LIGHTS SWITCH
(OPTION) 17......................
OPERATING/HAZARD LIGHTS
SWITCH (OPTION) 17..............
SIDE BRUSH DOWN PRESSURE
KNOB 17...........................
FUSES 18.............................
CIRCUIT BREAKERS 18...............
OPERATOR SEAT 19..................
DELUXE SUSPENSION SEAT
(OPTION) 19......................
HOPPER SUPPORT BAR 20...........
HOW THE MACHINE WORKS 21..........
PRE-OPERATION CHECKLIST 21.........
STARTING THE MACHINE 22.............
SWEEPING AND BRUSH
INFORMATION 23....................
SWEEPING 25...........................
STOP SWEEPING 26....................
EMPTYING THE HOPPER 27.............
STOP THE MACHINE 29.................
POST-OPERATION CHECKLIST 30
........
ENGAGING HOPPER SUPPORT BAR 31..
Page
DISENGAGING HOPPER SUPPORT
BAR 33..............................
OPERATION ON INCLINES 34............
OPTIONS 35.............................
VACUUM WAND 35...................
MACHINE TROUBLESHOOTING 37.......
MAINTENANCE 38.........................
MAINTENANCE CHART 38...............
LUBRICATION 40........................
PROPELLING GEARBOX 40...........
REAR WHEEL SUPPORT 40...........
STEERING LINK 41...................
FRONT WHEEL BEARINGS 41.........
HOPPER LIFT ARM PIVOTS 41........
HYDRAULICS 42........................
HYDRAULIC FLUID RESERVOIR 42....
HYDRAULIC FLUID 42................
HYDRAULIC HOSES 43...............
BATTERIES 44...........................
CHARGING THE BATTERIES 45.......
ELECTRIC MOTORS 47..................
BELTS AND CHAINS 47..................
HYDRAULIC PUMP BELT 47...........
VACUUM FAN BELT 48................
MAIN BRUSH INTERMEDIATE BELT 48.
MAIN BRUSH BELT 48................
STATIC DRAG CHAIN 48..............
DEBRIS HOPPER 49.....................
HOPPER DUST FILTER 49.............
REMOVING HOPPER DUST
FILTER 50......................
BRUSHES 51.............................
MAIN BRUSH 51......................
REPLACING MAIN BRUSH 51.......
CHECKING AND ADJUSTING
MAIN BRUSH PATTERN 52......
SIDE BRUSH 54......................
REPLACING SIDE BRUSH 54.......
SIDE BRUSH GUARD 55...........
SIDE BRUSH PIVOT 55.............
SKIRTS AND SEALS 56..................
HOPPER LIP SKIRT 56................
HOPPER SIDE SKIRT 56..............
BRUSH DOOR SKIRTS 56.............
REAR SKIRTS 57.....................
SIDE BRUSH DUST CONTROL
SKIRTS (OPTION) 57...............
BRUSH DOOR SEALS 57..............
HOPPER SEALS 57...................
HOPPER ACCESS DOOR SEAL 58.....
HOPPER DOOR SEALS 58
............
VACUUM FAN SEAL 58................
BRAKES AND TIRES 59..................
BRAKES 59...........................
TIRES 59.............................
REAR WHEEL 59.....................

CONTENTS
6400E MM432 (6--01)
2
Page
PUSHING, TOWING, AND
TRANSPORTING THE MACHINE 60....
PUSHING OR TOWING THE
MACHINE 60......................
TRANSPORTING THE MACHINE 60....
MACHINE JACKING 62...................
STORING MACHINE 62..................
SPECIFICATIONS 63.......................
GENERAL MACHINE PERFORMANCE 63..
POWER TYPE 64........................
STEERING 64............................
HYDRAULIC SYSTEM 64.................
BRAKING SYSTEM 64...................
TIRES 64................................
MACHINE DIMENSIONS 65...............
INDEX 66...................................

SAFETY PRECAUTIONS
3
6400E MM432 (6--08)
SAFETY PRECAUTIONS
The following symbols are used throughout this
manual as indicated in their description:
WARNING: To warn of hazards or
unsafe practices that could result in
severe personal injury or death.
FOR SAFETY: To identify actions that
must be followed for safe operation of
equipment.
The machine is suited to sweep disposable
debris. Do not use the machine other than
described in this Operator Manual. The machine
is not designed for use on public roads.
The following information signals potentially
dangerous conditions to the operator or
equipment:
WARNING: Batteries emit hydrogen gas.
Explosion or fire can result. Keep
sparks and open flame away. Keep
covers open when charging.
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.
FOR SAFETY:
1. Do not operate machine:
-- Unless trained and authorized.
-- Unless operation manual is read and
understood.
-- In flammable or explosive areas unless
designed for use in those areas.
-- In areas with possible falling objects
unless equipped with overhead guard.
2. Before starting machine:
-- Make sure all safety devices are in
place and operate properly.
-- Check brakes and steering for proper
operation.
3. When starting machine:
-- Keep foot on brake and directional
pedal in neutral.
4. When using machine:
-- Do not pick up burning or smoking
debris, such as cigarettes, matches or
hot ashes.
-- Use brakes to stop machine.
-- Go slowly on inclines and slippery
surfaces.
-- Use care when reversing machine.
-- Move machine with care if hopper is
raised.
-- Make sure adequate clearance is
available before raising hopper.
-- Do not carry riders on machine.
-- Always follow safety and traffic rules.
-- Report machine damage or faulty
operation immediately.
5. Before leaving or servicing machine:
-- Stop on level surface.
-- Set parking brake.
-- Turn off machine and remove key.
6. When servicing machine:
-- Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves when
working on machine.
-- Block machine tires before jacking up
machine.
-- Jack up machine at designated
locations only. Block machine up with
jack stands.
-- Use hoist or jack that will support the
weight of the machine.
-- Wear eye and ear protection if using
pressurized air or water.
-- Disconnect battery connections before
working on machine.
-- Avoid contact with battery acid.
-- Use cardboard to locate leaking
hydraulic fluid under pressure.
-- Use Tennant supplied or equivalent
replacement parts.
7. When loading/unloading machine
onto/off truck or trailer:
-- Turn off machine.
-- Use truck or trailer that will support
the weight of the machine.
-- Use winch. Do not drive the machine
onto/off the truck or trailer unless the
load height is 380 mm (15 in) or less
from the ground.
-- Set parking brake after machine is
loaded.
-- Block machine tires.
-- Tie machine down to truck or trailer.

SAFETY PRECAUTIONS
6400E MM432 (12--96)
4
The following safety labels are mounted on the
machine in the locations indicated. If these or any
labels become damaged or illegible, install a new
label in its place.
BATTERY CHARGING LABEL -- LOCATED ON
THE CONTROL BOX.
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.
FAN AND BELT LABEL -- LOCATED ON THE
VACUUM FAN PLATE AND BELT SHROUD.
350159

OPERATION
5
6400E MM432 (9--96)
OPERATION
OPERATOR RESPONSIBILITY
-The operator’s responsibility is to take care
of the daily maintenance and checkups of
the machine to keep it in good working
condition. The operator must inform the
service mechanic or supervisor when the
maintenance intervals are required as stated
in the MAINTENANCE section of this
manual.
-Read this manual carefully before operating
the machine. View the operation video
supplied with the machine.
FOR SAFETY: Do not operate machine,
unless operation manual is read and
understood.
-Check the machine for shipping damage.
Check to make sure the machine is
complete per shipping instructions.
-Keep your machine regularly maintained by
following the maintenance information in this
manual. We recommend taking advantage
of a regularly scheduled service contract
from your Tennant representative.
-Order parts and supplies directly from your
authorized Tennant representative. Use the
parts manual provided when ordering parts.
-After the first 50 hours of operation, follow
the recommended procedures stated in the
MAINTENANCE CHART.
07324

OPERATION
6400E MM432 (9--96)
6
MACHINE COMPONENTS
A
B
C
D
E
F
G
H
350159
A. Operator seat
B. Steering wheel
C. Instrument panel
D. Hopper cover
E. Side brush
F. Hopper access door
G. Brush door
H. Seat support

OPERATION
7
6400E MM432 (8--07)
SYMBOL DEFINITIONS
These symbols identify controls, displays, and
features on the machine:
Filter shaker Hourmeter
Vacuum fan on Steering wheel tilt
Vacuum fan off Off
Hopper down On
Hopper up Start
Hopper door open Horn
Hopper door close Side brush down and on
Main brush down and on Side brush up and off
Main brush up and off Operating lights
Battery charging system Hazard light
Clogged dust filter Variable pressure
Thermo Sentry Side brush pressure
Hopper door closed
Hydraulic filter clogged

OPERATION
6400E MM432 (9--96)
8
Circuit breaker #1
Circuit breaker #2
Circuit breaker #3
Circuit breaker #4

OPERATION
9
6400E MM432 (8--07)
CONTROLS AND INSTRUMENTS
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
RS
T
U
V
W
X
350014
A. Brake pedal
B. Parking brake pedal
C. Directional pedal
D. Seat support release lever
E. Hopper lever
F. Hopper door lever
G. Main brush lever
H. Main brush down pressure knob
I. Vacuum and filter shaker lever
J. Power kill switch (option)
K. Clogged filter light (option)
L. Hopper temperature light -- Thermo Sentry
M. Hopper door closed light (option)
N. Hydraulic filter bypass light (option)
O. Battery discharge indicator
P. Steering wheel
Q. Hourmeter
R. Steering wheel tilt handle
S. On-off key switch
T. Horn button
U. Side brush lever
V. Operating/hazard light switch (option)
W. Side brush down pressure knob
X. Circuit breakers

OPERATION
6400E MM432 (9--96)
10
OPERATION OF CONTROLS
DIRECTIONAL PEDAL
The directional pedal controls the direction of
travel and the propelling speed of the machine.
You change the speed of the machine with the
pressure of your foot on the pedal; the harder you
press the faster the machine travels.
The machine will coast for a short distance before
changing direction when the directional pedal is
reversed. Use the brake pedal to stop the
machine.
Forward: Press the top of the directional pedal
with the toe of your foot.
Reverse: Press the bottom of the directional
pedal with the heel of your foot.
Neutral: Take your foot off the directional pedal
and it will return to the Neutral position.

OPERATION
11
6400E MM432 (9--96)
BRAKE PEDAL
The brake pedal stops the machine.
Stop: Take your foot off the directional pedal and
let it return to the Neutral position. Step on the
brake pedal.
PARKING BRAKE PEDAL
The parking brake pedal sets and releases the
front wheel brakes.
Set: Press on the brake pedal as far as possible,
then press on the parking brake pedal with the toe
portion of your foot to lock the parking brake pedal
in place.
FOR SAFETY: Before leaving or
servicing machine, stop on level
surface, set parking brake, turn off
machine, and remove key.
Release: Press on the brake pedal to unlock the
parking brake pedal.
SEAT SUPPORT RELEASE LEVER
The seat support lever releases and locks the
seat support.
Release: Pull the release lever back and lift the
seat support.
Lock: Close the seat support and release the
lever to lock the support in place.

OPERATION
6400E MM432 (9--96)
12
HOPPER LEVER
The hopper lever raises and lowers the hopper.
Hopper up: Pull the hopper lever into the Hopper
up position.
Hold: Release the hopper lever into the middle
position.
Hopper down: Push the hopper lever into the
Hopper down position.
HOPPER DOOR LEVER
The hopper door lever opens and closes the
hopper door. Open the hopper door before
sweeping. Close the hopper door when emptying
the hopper to control debris and dust.
Hopper door open: Push the hopper door lever
forward into the Hopper door open position.
Hopper door close: Pull the hopper door lever
back into the Hopper door close position for a
few seconds until the hopper door is closed.
NOTE: If the machine is equipped with the hopper
door closed light option, the light will come on
when the hopper door is closed.
MAIN BRUSH LEVER
The main brush lever controls the position and
rotation of the main brush.
Main brush down and on: Pull the lever back and
to the right into the Main brush down and on
position against the main brush down pressure
knob. The brush will automatically start rotating.
Main brush up and off: Pull the lever back and to
the left into the Main brush up and off position.

OPERATION
13
6400E MM432 (6--99)
MAIN BRUSH DOWN PRESSURE KNOB
The main brush down pressure knob changes the
amount of contact the main brush has with the
surface being swept.
Increase: Loosen the main brush down pressure
knob. Move the knob forward, away from the
operator, and retighten it.
Decrease: Loosen the main brush down pressure
knob. Move the knob back, towards the operator,
and retighten it.
VACUUM AND FILTER SHAKER LEVER
The vacuum and filter shaker lever controls the
vacuum fan duct and the filter shaker. The
vacuum fan duct should be on when sweeping dry
debris. The vacuum fan duct should be off when
sweeping wet debris.
Vacuum Fan on: Turn the lever to the left into the
Vacuum Fan on position.
Vacuum Fan off: Turn the lever to the right into
the Vacuum Fan off position.
Start filter shaker: Place the lever in the Filter
shaker position for 30 seconds.
Note: Excessive heat in the hopper will cause the
Thermo Sentrytto move the vacuum and filter
shaker lever to the Vacuum fan off position. It will
also make the hopper temperature light come on.
If this happens, stop the machine, eliminate the
source of the heat, and return the lever to the
Vacuum fan on position.
POWER KILL SWITCH (OPTION)
The power kill switch halts all power to the
machine.
Halt: Push the power kill switch in.
Restart: Turn off the machine power. Turn the
power kill switch to the right to release the switch.
Turn on the machine power.

OPERATION
6400E MM432 (8--07)
14
CLOGGED FILTER LIGHT (OPTION)
The clogged filter light comes on when the hopper
dust filter is clogged.
To clean the filter, hold the vacuum and filter
shaker lever in the Filter shaker position. If the
clogged filter light remains lit, manually clean the
hopper dust filter. See HOPPER DUST FILTER in
the MAINTENANCE section of this manual.
NOTE: The clogged filter light also comes on
when the hopper door is closed and the vacuum
fan is on.
HOPPER TEMPERATURE LIGHT -- THERMO
SENTRY
The hopper temperature light comes on when the
Thermo Sentry senses that there is excessive
heat in the hopper, possibly from a fire. The
Thermo Sentry will also move the vacuum and
filter shaker lever to the Vacuum fan off position.
If this happens, stop the machine, eliminate the
source of the heat, and return the lever to the
Vacuum fan on position.
HOPPER DOOR CLOSED LIGHT (OPTION)
The hopper door closed light comes on when the
hopper door is closed.
Make sure the hopper door is open all the way
and the hopper door closed light is off, before
sweeping.
HYDRAULIC FILTER BYPASS LIGHT (OPTION)
The hydraulic filter bypass light comes on when
the hydraulic filter is clogged. If this light comes
on, have the hydraulic filter and hydraulic fluid
changed as soon as possible.

OPERATION
15
6400E MM432 (9--96)
BATTERY DISCHARGE INDICATOR
The battery discharge indicator shows the charge
level of the batteries. It displays the charge level
when the machine is operating.
When the batteries are fully charged, the indicator
on the far right is lit. As the batteries discharge,
the indicator will move along the display to the
left. Recharge the batteries when the indicator
flashes.
NOTE: The reading on the battery discharge
indicator is not accurate when the machine is first
powered on. Operate the machine a few minutes
before reading the charge level of the batteries.
NOTE: The battery discharge indicator will not
reset from the flashing indicator unless the
batteries have been fully charged.
STEERING WHEEL
The steering wheel controls the machine’s
direction. The machine is very responsive to the
steering wheel movements.
Left: Turn the steering wheel to the left.
Right: Turn the steering wheel to the right.
HOURMETER
The hourmeter records the number of hours the
machine has been operated. The hourmeter
displays the number of hours in tenths of an hour.
Use this information to determine machine
maintenance intervals.

OPERATION
6400E MM432 (9--96)
16
STEERING WHEEL TILT HANDLE
The steering wheel tilt handle controls the angle of
the steering wheel.
Adjust: Pull out the tilt handle, move the steering
wheel up or down, and release the tilt handle.
ON-OFF KEY SWITCH
The on-off key switch controls machine power
with a key.
On: Turn the key clockwise all the way.
Off: Turn the key counterclockwise.
HORN BUTTON
The horn button operates the horn.
Sound: Press the button.
SIDE BRUSH LEVER
The side brush lever controls the position and
rotation of the side brush.
Side brush down and on: Pull the lever back and
to the left into the Side brush down and on
position. The brush will automatically start
rotating.
Side brush up and off: Pull the lever back and to
the right into the Side brush up and off position.

OPERATION
17
6400E MM432 (9--96)
OPERATING LIGHTS SWITCH (OPTION)
The operating lights switch powers on and off the
headlights and taillights option.
On: Press the top of the operating lights switch.
Off: Press the bottom of the operating lights
switch.
OPERATING/HAZARD LIGHTS SWITCH
(OPTION)
The operating/hazard lights switch powers on and
off the headlights and taillights option and the
hazard light option.
Operating lights on: Press the top of the
operating/hazard lights switch.
Operating/Hazard lights on: Press the bottom of
the operating/hazard lights switch.
Off: Place operating/hazard lights switch in the
middle position.
SIDE BRUSH DOWN PRESSURE KNOB
The side brush down pressure knob changes the
side brush contact with the sweeping surface.
Increase: Turn the side brush down pressure
knob counter-clockwise.
Decrease: Turn the side brush down pressure
knob clockwise.

OPERATION
6400E MM432 (12--96)
18
FUSES
Fuses are one-time protection devices designed
to stop the flow of current in the event of a circuit
overload. Never substitute higher value fuses than
specified.
The fuses are located in the control box.
Fuse Rating Circuit Protected
FU-1 100 A Hydraulic pump motor
FU-2 80 A Propelling
CIRCUIT BREAKERS
The circuit breakers are resetable electrical circuit
protection devices. Their design stops the flow of
current in the event of a circuit overload. Once a
circuit breaker is tripped, it must be reset
manually. Press the reset button after the breaker
has cooled down.
If the overload that caused the circuit breaker to
trip is still there, the circuit breaker will continue to
stop current flow until the problem is corrected.
The circuit breakers are located in the operator
compartment.
The chart lists the circuit breakers and the
electrical components they protect.
Circuit Breaker Rating Circuit Protected
CB-1 15 A Thermo Sentryt
CB-2 15 A Instrument panel,
seat switch
CB-3 15 A Operating lights
CB-4 15 A Horn