Tennant 6550 User manual

6500/6550
330275
Rev. 02 (5--02)
Service Manual
Gas/LP/Diesel
*330275*

This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT
Model 6500/6550.
The set is organized into seven major groups: General Information, Chassis, Sweeping, Electrical,
Hydraulics, Engine--G/LPG, and Engine--D.
General Information: Machine transport, machine jacking, machine storage, machine specifications, and
machine maintenance chart.
Chassis: Tire/wheel replacement, brake adjustment and replacement, seat removal and installation,
chassis lubrication, and steering adjustment and replacement.
Sweeping: Hopper repair/replacement, brush repair/replacement, skirt/seal repair/replacement, and
sweeping troubleshooting.
Electrical: Battery maintenance and replacement, instrument panel replacement, and electrical
troubleshooting.
Hydraulics: Valve replacement/repair, motor replacement/repair, cylinder replacement/repair, pump
replacement/repair, filter replacement, and hydraulics troubleshooting.
Engine -- G/LPG: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system
maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine
repairs.
Engine -- D: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system
maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine
repairs.
Manual Number -- 330275
Revision: 02
Published: 5--02
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 E1998, 2002 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
1-1
6500/6550 330275 (5--02)
CONTENTS
Page
SAFETY PRECAUTIONS 1-2.................
SPECIFICATIONS 1-6.......................
GENERAL MACHINE
DIMENSIONS/CAPACITIES 1-6.........
GENERAL MACHINE PERFORMANCE 1-6..
POWER TYPE 1-7........................
STEERING 1-8...........................
HYDRAULIC SYSTEM 1-8.................
BRAKING SYSTEM 1-8...................
TIRES 1-8...............................
MACHINE DIMENSIONS 1-9...............
MAINTENANCE 1-10........................
MAINTENANCE CHART--GAS/LP 1-10......
MAINTENANCE CHART--DIESEL 1-12......
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE 1-14....................
PUSHING OR TOWING THE
MACHINE 1-14.....................
TRANSPORTING THE MACHINE 1-14...
MACHINE JACKING 1-17..................
STORING MACHINE 1-18.................
TO STORE MACHINE UP TO
30 DAYS 1-18......................
TO STORE MACHINE 30 TO
90 DAYS 1-18......................
TO STORE MACHINE FOR MORE
THAN 90 DAYS 1-19................
HARDWARE INFORMATION 1-20..........
STANDARD BOLT TORQUE CHART 1-20
METRIC BOLT TORQUE CHART 1-20...
BOLT IDENTIFICATION 1-21............
THREAD SEALANT AND LOCKING
COMPOUNDS 1-21.................

GENERAL INFORMATION
6500/6550 330275 (5--02)
1-2
SAFETY PRECAUTIONS
The following precautions are used throughout
this manual as indicated in their description:
WARNING: To warn of hazards or
unsafe practices which could result in
severe personal injury or death.
FOR SAFETY: To identify actions which
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: Engine emits toxic gases.
Severe respiratory damage or
asphyxiation can result. Provide
adequate ventilation. Consult with your
regulatory authorities for exposure
limits. Keep engine properly tuned.
WARNING: Raised hopper may fall.
Engage hopper support bar.
WARNING: Lift arm pinch point. Stay
clear of hopper lift arms.
WARNING: Moving belt and fan. Keep
away.
FOR SAFETY:
1. Do not operate machine:
-- Unless trained and authorized.
-- Unless operator manual is read and
understood.
-- If it is not in proper operating
condition.
-- 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:
-- Check for fuel, oil, and liquid leaks.
-- Keep sparks and open flame away
from refueling area.
-- Make sure all safety devices are in
place and operate properly.
-- Check brakes and steering for proper
operation.
-- Make sure back-up alarm sounds and
lights when reversing machine.
3. When starting machine:
-- Keep foot on brake and directional
pedal in neutral.
4. When using machine:
-- Use brakes to stop machine.
-- Go slow on inclines and slippery
surfaces.
-- Use care when reversing machine.
-- Move machine with care when hopper
is raised.
-- Make sure adequate clearance is
available before raising hopper.
-- Do not carry passengers 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.

GENERAL INFORMATION
1-3
6500/6550 330275 (5--02)
6. When servicing machine:
-- Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
-- Block machine tires before jacking
machine up.
-- Jack machine up 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 when
using pressurized air or water.
-- Disconnect battery connections before
working on machine.
-- Avoid contact with battery acid.
-- Avoid contact with hot engine coolant.
-- Allow engine to cool.
-- Keep flames and sparks away from
fuel system service area. Keep area
well ventilated.
-- Use cardboard to locate leaking
hydraulic fluid under pressure.
-- Use TENNANT supplied or approved
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.

GENERAL INFORMATION
6500/6550 330275 (6--01)
1-4
The following safety labels are mounted on the
machine in the locations indicated. If these or any
label becomes damaged or illegible, install a new
label in its place.
HOPPER LIFT ARMS LABEL -- LOCATED
ON BOTH HOPPER LIFT ARMS.
HOPPER SUPPORT BAR LABEL -- LOCATED
ON THE HOPPER SUPPORT BAR AND ON
BOTH HOPPER LIFT ARMS.
ENGINE FAN AND BELT LABEL --
LOCATED ON THE RADIATOR SHROUD.
EMISSIONS LABEL -- LOCATED ON THE SIDE
PANEL OF THE OPERATOR COMPARTMENT.
07748
FOR SAFETY LABEL -- LOCATED ON
THE SIDE PANEL OF THE OPERATOR
COMPARTMENT.

GENERAL INFORMATION
1-5
6500/6550 330275 (6--01)
The following safety labels are mounted on the
machine in the locations indicated. If these or any
label becomes damaged or illegible, install a new
label in its place.
HOPPER LIFT ARMS LABEL --
LOCATED ON BOTH HOPPER
LIFT ARMS.
HOPPER SUPPORT BAR LABEL --
LOCATED ON THE HOPPER SUPPORT
BAR AND ON BOTH HOPPER LIFT
ARMS.
ENGINE FAN AND BELT LABEL --
LOCATED ON THE RADIATOR SHROUD.
EMISSIONS LABEL -- LOCATED
ON THE SIDE PANEL OF THE
OPERATOR COMPARTMENT.
07522
FOR SAFETY LABEL -- LOCATED
ON THE SIDE PANEL OF THE
OPERATOR COMPARTMENT.

GENERAL INFORMATION
6500/6550 330275 (3--99)
1-6
SPECIFICATIONS
GENERAL MACHINE DIMENSIONS/CAPACITIES
Item Dimension/capacity
Length 2360 mm (93 in)
Width 1590 mm (62.5 in)
Height 1475 mm (58 in)
Height with overhead guard 2080 mm (82 in)
Height with overhead guard and hazard light 2270 mm (89.5 in)
Height with cab 2100 mm (82.62 in)
Height with cab and hazard light 2285 mm (90 in)
Track 1345 mm (53 in)
Wheelbase 1135 mm (44.75 in)
Main brush diameter 355 mm (14 in)
Main brush length 1145 mm (45 in)
Side brush diameter 660 mm (26 in)
Side brush diameter (auxiliary) 585 mm (23 in)
Sweeping path width 1145 mm (45 in)
Sweeping path width with side brush 1560 mm (61.5 in)
Main brush pattern width 50 to 65 mm (2.0 to 2.5 in)
Hopper weight capacity (6500 with plastic hopper) 409 kg (900 lb)
Hopper weight capacity (6500 with metal hopper) 545 kg (1200 lb)
Hopper weight capacity (6550) 545 kg (1200 lb)
Hopper volume capacity 396 L (14 cu ft)
Dust filter area 7.2 m2(77sqft)
GVWR (6500) 1927 kg (4250 lb)
GVWR (6550) 2064 kg (4550 lb)
Sound level 80 dBa
Ceiling height minimum dumping clearance 2745 mm (9 ft)
GENERAL MACHINE PERFORMANCE
Item Measure
Maximum forward speed (6500) 13.7 kmh (8.5 mph)
Maximum forward speed (6550) 16.1 kmh (10 mph)
Maximum reverse speed 4.0 kmh (2.5 mph)
Minimum aisle turn width, left 2870 mm (113 in)
Minimum aisle turn width, right 4725 mm (186 in)
Maximum rated climb and descent angle (6500) 6_
Maximum rated climb and descent angle (6550) 10_

GENERAL INFORMATION
1-7
6500/6550 330275 (5--01)
POWER TYPE
Engine
(Gas/LPG)
Type Ignition Cycle Aspiration Cylinders Bore Stroke
Ford VSG 1.3L Piston Distributor-
less-
type spark
4Natural 474 mm
(2.91 in)
75 mm
(2.97 in)
Displacement Net power, governed Net power, maximum
1300 cc (79 cu in) 23.2 kw (32 hp) @ 2400 rpm 39.5 kw (53 hp) @
4000 rpm
Fuel Cooling system Electrical system
Gasoline, 87 octane
minimum, unleaded. Fuel
tank: 36 L (9.6 gal)
Water/ethylene glycol
antifreeze
12 V nominal
LPG,
F
l
t
k
1
5
k
(
3
3
l
b
)
Total: 4.5 L (1.2 gal) 50 A alternator
Fuel tank: 15 kg (33 lb) Radiator: 3.8 L (1 gal)
Idle speed, no load (Fast 1) governed speed, under
load
(Fast 2) governed
speed, under load
1350 +250 rpm 2000 +50 rpm 2400 +50 rpm
Spark plug gap Firing order Valve clearance, cold
1 mm (0.04 in) 1--2--4--3, counterclockwise
rotation
0.20 mm (0.008 in)
intake
0.50 mm (0.020 in)
exhaust
Engine lubricating oil with filter
3.3 L (3.5 qt) 10W--30 SAE--SG/SH
Engine (Diesel) Type Ignition Cycle Aspiration Cylinders Bore Stroke
Kubota V1505--B Piston Diesel 4Natural 478 mm
(3.07 in)
78.4 mm
(3.08 in)
Displacement Net power, governed Net power, maximum
1500 cc (91.4 cu in) 24.6 kw (34 hp) @ 2400 rpm 27.2 kw (37.5 hp) @
3000 rpm
Fuel Cooling system Electrical system
Diesel
Fuel tank: 36 L (9.6 gal)
Water/ethylene glycol
antifreeze
12 V nominal
(
g
)
Total: 4.5 L (1.2 gal) 50 A alternator
Radiator: 3.8 L (1 gal)
Idle speed, no load (Fast 1) governed speed, under
load
(Fast 2) governed
speed, under load
950 +50 rpm 2000 +50 rpm 2400 +50 rpm
Engine lubricating oil without filter
6 L (6.35 qt) diesel rated engine oil above CD grade only

GENERAL INFORMATION
6500/6550 330275 (5--01)
1-8
STEERING
Type Power source Emergency steering
Rear wheel, hydraulic cylinder
and rotary valve controlled
Hydraulic accessory pump Manual
HYDRAULIC SYSTEM
System Capacity Fluid Type
Hydraulic reservoir 24.6 L (6.5 gal) TENNANT part no. 65869 -- above 7_C(45_F)
Hydraulic total N/A L (N/A gal)
p
(
)
TENNANT part no. 65870 -- below 7_C(45_F)
BRAKING SYSTEM
Type Operation
Service brakes Mechanical drum brakes (2), one per front wheel,
cable actuated
Parking brake Utilize service brakes, cable actuated
TIRES
Location Type Size Pressure
Front (2) Solid 5x18in --
Rear (1) Pneumatic 6x19in 790 + 35kPa(115+5 psi)

GENERAL INFORMATION
1-9
6500/6550 330275 (5--98)
2080 mm
(82 in)
2360 mm (93 in)
1590 mm
(62.5 in)
TOP VIEW
SIDE VIEW FRONT VIEW
1475 mm
(58 in)
1135 mm
(44.75 in)
1560 mm
(61.5 in)
350662
MACHINE DIMENSIONS

GENERAL INFORMATION
6500/6550 330275 (5--98)
1-10
MAINTENANCE
1
2
345678910
11
12
13
14
15
16 89
17
07747
MAINTENANCE CHART--GAS/LP
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 7Engine air filter Check indicator -- 1
y
g
Empty dust cap -- 1
6Engine crankcase Check oil level EO 1
8Brush compartment skirts Check for damage, wear and
adjustment
-- 5
12 Hopper lip skirts Check for damage, wear and
adjustment
-- 3
12 Hopper side skirt Check for damage and wear -- 1
13 Main brush Check for damage, wear, and
adjustment
-- 1
Check brush pattern -- 1
11 Side brush Check for damage, wear, and
adjustment
-- 1
Check brush pattern -- 1
50 Hours 13 Main brush Rotate end-for-end -- 1

GENERAL INFORMATION
1-11
6500/6550 330275 (5--02)
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
100 Hours 10 Hopper dust filter Check for damage, clean or re-
place
-- 1
3Radiator Clean core exterior -- 1
Check coolant level WG 1
2Hydraulic fluid reservoir Check fluid level HYDO 1
1Rear tire Check pressure -- 1
8Main brush and hopper
seals
Check for damage or wear -- 8
6Engine crankcase Change oil and filter element EO 1
200 Hours 4Engine fan belt *Check tension -- 1
3Radiator hoses and clamps Check for tightness and wear -- 2
15 Parking brake Check adjustment -- 1
14 Brake pedal Check and adjust travel -- 1
1Rear wheel support
bearings
Lubricate SPL 2
17 Hopper bearings Lubricate SPL 2
11 Side brush guard Rotate 90_-- 1
400 Hours 9Front wheel bearings Check, lubricate, and adjust SPL 2
6Engine *Check and adjust valve clear-
ance
-- 8
Check and adjust idle speed -- 1
Check and adjust carburetor idle
mixture
-- 1
Clean or replace and adjust
spark plugs
-- 4
Replace oil fill cap/PCV breather.
Clean PCV hose.
-- --
Fuel filters -- 2
800 Hours 3 Cooling system Flush WG 1
2Hydraulic fluid reservoir Replace hydraulic breather -- 1
y
Replace suction strainer -- 1
Change hydraulic fluid HYDO 1
5Hydraulic fluid filter Change filter element -- 1
2Hydraulic hoses Check for wear and damage -- 31
1Propelling motor *Torque shaft nut -- 1
1Rear wheel *Torque wheel nuts -- 1
16 Battery *Clean and tighten battery cable
connections
-- 1
LUBRICANT/FLUID
EO Engine oil, 10W30 SAE--SG/SH rated....
HYDO Tennant Company or approved hydraulic fluid.
WG Water and permanent-type ethylene glycol anti-freeze, --34_C(--30_F)...
SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)...
NOTE: Also check procedures indicted (*) after
the first 50-hours of operation.

GENERAL INFORMATION
6500/6550 330275 (5--98)
1-12
MAINTENANCE
1
2
3456 7 8910
11
1213141516 89
17
18
07747
MAINTENANCE CHART--DIESEL
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 7Engine air filter Check indicator -- 1
y
g
Empty dust cap -- 1
6Engine crankcase Check oil level EO 1
8Brush compartment skirts Check for damage, wear and
adjustment
-- 5
12 Hopper lip skirts Check for damage, wear and
adjustment
-- 3
12 Hopper side skirt Check for damage and wear -- 1
13 Main brush Check for damage, wear, and
adjustment
-- 1
Check brush pattern -- 1
11 Side brush Check for damage, wear, and
adjustment
-- 1
Check brush pattern -- 1

GENERAL INFORMATION
1-13
6500/6550 330275 (3--00)
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
50 Hours 13 Main brush Rotate end-for-end -- 1
6Fuel pipes and clamps Check for tightness and wear -- 1
100 Hours 6Engine crankcase Change oil and filter EO 1
4Engine fan belt Check tension -- 1
10 Hopper dust filter Check for damage, clean or re-
place
-- 1
3Radiator Clean core exterior -- 1
Check coolant level WG 1
2Hydraulic fluid reservoir Check fluid level HYDO 1
1Rear tire Check pressure -- 1
8Main brush and hopper
seals
Check for damage or wear -- 8
200 Hours 3Radiator hoses and clamps Check for tightness and wear -- 2
15 Parking brake Check adjustment -- 1
14 Brake pedal Check and adjust travel -- 1
1Rear wheel support bear-
ings
Lubricate SPL 2
17 Hopper bearings Lubricate SPL 2
11 Side brush guard Rotate 90_-- 1
400 Hours 9Front wheel bearings Check, lubricate, and adjust SPL 2
6Fuel filter Replace cartridge -- 1
18 Fuel tank Remove sediment -- 1
800 Hours 3 Cooling system Flush WG 1
2Hydraulic fluid reservoir Replace hydraulic breather -- 1
y
Replace suction strainer -- 1
Change hydraulic fluid HYDO 1
5Hydraulic fluid filter Change filter element -- 1
2Hydraulic hoses Check for wear and damage -- 31
1Propelling motor *Torque shaft nut -- 1
1Rear wheel *Torque wheel nuts -- 1
16 Battery *Clean and tighten battery cable
connections
-- 1
LUBRICANT/FLUID
EO Engine oil, diesel rating above CD grade only....
HYDO Tennant Company or approved hydraulic fluid.
WG Water and permanent-type ethylene glycol anti-freeze, --34_C(--30_F)...
SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)...
NOTE: Also check procedures indicted (*) after
the first 50-hours of operation.

GENERAL INFORMATION
6500/6550 330275 (5--01)
1-14
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE
PUSHING OR TOWING THE MACHINE
If the machine becomes disabled, it can be
pushed from the front or rear, but towed only from
the rear.
The propelling pump has a bypass valve to
prevent damage to the hydraulic system when the
machine is being pushed or towed. This valve
allows a disabled machine to be moved for a very
short distance and at a speed to not exceed 1.6
kp/h (1 mph). The machine is NOT intended to be
pushed or towed a long distance or at a high
speed.
ATTENTION! Do not push or tow
machine for a long distance and without
using the bypass valve, or the machine
hydraulic system may be damaged.
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.
TRANSPORTING THE MACHINE
1. Position the rear of the machine at the
loading edge of the truck or trailer.
FOR SAFETY: Use truck or trailer that
will support the weight of the machine.
NOTE: Empty the hopper before transporting the
machine.

GENERAL INFORMATION
1-15
6500/6550 330275 (5--01)
2. If the loading surface is not horizontal or is
higher than 380 mm (15 in) from the ground,
use a winch to load machine.
If the loading surface is horizontal AND is
380 mm (15 in) or less from the ground, the
machine may be driven onto the truck or
trailer.
3. To winch the machine onto the truck or
trailer, attach the winching chains in the
holes at the bottom of the rear bumper.
If the machine has the optional rear tie down
brackets, attach the winching chains to
them.
4. Turn the bypass valve 90_from the normal
position before winching the machine onto
the truck or trailer. See PUSHING OR
TOWING THE MACHINE section of this
manual. Make sure the machine is centered.
FOR SAFETY: When loading machine
onto truck or trailer, use winch. Do not
drive the machine onto the truck or
trailer unless the loading surface is
horizontal AND is 380 mm (15 in) or less
from the ground.
08151

GENERAL INFORMATION
6500/6550 330275 (3--00)
1-16
5. Position the machine onto the truck or trailer
as far as possible. If the machine starts to
veer off the centerline of the truck or trailer,
stop and turn the steering wheel to center
the machine.
6. Set the parking brake and block the machine
tires. Tie down the machine to the truck or
trailer before transporting.
The front tie down locations are the holes in
the wheel pockets at the front of the
machine frame.
If the machine has the optional front tie
down brackets above the front tires, attach
the winching chains to them.
The rear tie down locations are in the holes
at the bottom of the rear bumper. If the
machine has the optional rear tie down
brackets, use them to tie down the machine.
7. If the loading surface is not horizontal or is
higher than 380 mm (15 in) from the ground,
use a winch to unload machine.
If the loading surface is horizontal AND is
380 mm (15 in) or less from the ground, the
machine may be driven off the truck or
trailer.
FOR SAFETY: When unloading machine
off truck or trailer, use winch. Do not
drive the machine off the truck or trailer
unless the loading surface is horizontal
AND 380 mm (15 in) or less from the
ground.
08152
08151

GENERAL INFORMATION
1-17
6500/6550 330275 (5--01)
MACHINE JACKING
Empty the hopper before jacking the machine.
You can jack up the machine for service at the
designated locations. Use a hoist or jack that will
support the wieght of the machine. Always stop
the machine on a flat, level surface and block the
tires before jacking the machine up.
The front jacking locations are on the flat bottom
edge of the front of the machine frame next to the
front tires.
The rear jacking location is the middle flat bottom
edge of the rear bumper between the taillights.
FOR SAFETY: When servicing machine,
block machine tires before jacking
machine up.
FOR SAFETY: When servicing machine,
jack machine up at designated locations
only. Block machine up with jack
stands.
08029
08030

GENERAL INFORMATION
6500/6550 330275 (8--94)
1-18
STORING MACHINE
Before storing the machine for an extended period
of time, the machine needs to be prepped to
lessen the chance of rust, sludge, and other
undesirable deposits from forming. Contact
TENNANT service personnel.
TO STORE MACHINE UP TO 30 DAYS
1. Dump the debris hopper.
2. Change engine oil.
3. Raise the main brush and side brush.
4. Park the machine on a level surface in a
cool, dry area.
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.
TO STORE MACHINE 30 TO 90 DAYS
1. All of the above plus the following:
2. Remove the spark plugs.
3. Pour 90 cc (3 oz) of clean engine oil into
each spark plug hole.
4. Remove the ignition coil high tension wire.
Operate the engine starter motor for at least
a dozen revolutions. This distributes the oil
over the cylinder walls.
NOTE: Before preparing the engine for storage,
allow it to cool down to the surrounding
temperature. Oil adheres to cold metal surfaces
much better than hot surfaces.
5. Replace the high tension coil wire and spark
plugs.
6. Drain the gasoline from the carburetor.