Tennant 6100 G/LP User manual

330235
Rev. 02 (9--01)
Service Manual
6100 G/LP

This service manual is intended to be used as an aid in the detailed service, repair, and troubleshooting of
your TENNANT Model 6100 G/LP.
The set is organized into six major groups: General Information, Chassis, Sweeping, Electrical,
Hydraulics, and Engine--G/LP.
General Information: Safety precautions, machine specifications, machine maintenance chart, machine
tieing, machine jacking, machine storing, machine pushing or towing, and hardware information.
Chassis: Tire/wheel replacement, brake adjustment and replacement, steering adjustment and
replacement.
Sweeping: Hopper repair/replacement, brush repair/replacement, skirt/seal repair/replacement, and
sweeping troubleshooting.
Electrical: Battery maintenance and replacement, electrical schematics, and electrical troubleshooting.
Hydraulics: Valve replacement, motor replacement/repair, cylinder replacement/repair, pump
replacement/repair, filter replacement, hydraulic schematic, and hydraulic troubleshooting.
Engine -- G/LP: Air filter replacement, oil changing, cooling system maintenance/repair,
engine troubleshooting, engine removal, and engine repairs.
Manual Number -- 330235
Revision: 02
Published: 9--01
Copyright E2000, 2001 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
1--1
6100 G/LP 330235 (9--01)
CONTENTS
Page
SAFETY PRECAUTIONS 1--3................
SPECIFICATIONS 1--5......................
GENERAL MACHINE
DIMENSIONS/CAPACITIES 1--5........
GENERAL MACHINE PERFORMANCE 1--5.
POWER TYPE 1--6.......................
STEERING 1--6..........................
HYDRAULIC SYSTEM 1--6................
BRAKING SYSTEM 1--6..................
TIRES 1--6..............................
MACHINE DIMENSIONS 1--7..............
MAINTENANCE 1--8........................
MAINTENANCE CHART 1--8..............
PUSHING, TOWING, AND
TRANSPORTING THE MACHINE 1--10..
PUSHING OR TOWING THE
MACHINE 1--10....................
TRANSPORTING THE MACHINE 1--10..
MACHINE JACKING 1--12.................
STORING MACHINE 1--12................
HARDWARE INFORMATION 1--13............
STANDARD BOLT TORQUE CHART 1--13..
METRIC BOLT TORQUE CHART 1--13.....
BOLT IDENTIFICATION 1--13..............
THREAD SEALANT AND LOCKING
COMPOUNDS 1--13...................
HYDRAULIC FITTING INFORMATION 1--14....
HYDRAULIC TAPERED PIPE FITTING
(NPT) TORQUE CHART 1--14..........
HYDRAULIC TAPERED SEAT FITTING
(JIC) TORQUE CHART 1--14...........
HYDRAULIC O--RING FITTING
TORQUE CHART 1--14................

GENERAL INFORMATION
1--2 6100 G/LP 330235 (9--01)

GENERAL INFORMATION
1--3
6100 G/LP 330235 (9--00)
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:
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:
-- Check for fuel 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.
3. When starting machine:
-- Keep foot on brake and directional
pedal in neutral.
4. When using machine:
-- Use brakes to stop machine.
-- Go slowly on inclines and slippery
surfaces.
-- Use care when reversing machine.
-- 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 of adequate capacity
to lift 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.
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: Brush throws debris. Stop
motor before lifting hopper.

GENERAL INFORMATION
1--4 6100 G/LP 330235 (9--00)
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.
FOR SAFETY LABEL -- LOCATED ON THE
SIDE OF THE OPERATOR COMPARTMENT.
FLYING DEBRIS LABEL -- LOCATED
ABOVE HOPPER
352182
EMISSIONS LABEL -- Located
Below The Operator’s Seat.

GENERAL INFORMATION
1--5
6100 G/LP 330235 (9--00)
SPECIFICATIONS
GENERAL MACHINE DIMENSIONS/CAPACITIES
Item Dimension/capacity
Length 1520 mm (60 in)
Width 805 mm (32 in)
Height 1180 mm (46 in)
Track 880 mm (35 in)
Wheelbase 682 mm (27 in)
Main sweeping brush diameter 280 mm (11 in)
Main sweeping brush length 560 mm (22 in)
Side brush diameter 406 mm (16 in)
Sweeping path width 560 mm (22 in)
Sweeping path width with one side brush 762 mm (30 in)
Sweeping path width with two side brushes 965 mm (38 in)
Main sweeping brush pattern width 50 mm (2 in)
Hopper weight capacity 90 kg (200 lb)
Hopper volume capacity 85 L (3 cu ft)
Dust filter area 3.2sqm (34 sq ft)
GVWR 2041 kg (1009 lb)
GENERAL MACHINE PERFORMANCE
Item Measure
Maximum forward speed 8km/h (5 mph)
Maximum reverse speed 4.8 km/h (3 mph)
Minimum aisle turn 1830 mm (72 in)
Minimum turning radius 1725 mm (68 in)
Maximum rated incline with empty hopper 10_/ 17.6%
Maximum rated incline with full hopper 8_/ 14.1%

GENERAL INFORMATION
1--6 6100 G/LP 330235 (9--00)
POWER TYPE
Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke
Robin Piston Breakerless-
type spark
4Natural 184 mm
(3.31 in)
61 mm
(2.40 in)
Displacement Net power, governed Net power, maximum
338 cc (20.63 cu in) 5.4 kw (7.5 hp) @ 2200 rpm 8.2 kw (11 hp) @
3600 rpm
Fuel Cooling system Electrical system
Gasoline, 87 octane
minimum, unleaded. Fuel
tank: 6 L (1.5 gal)
Air cooled 12 V nominal
LPG,
F
u
e
l
t
a
n
k
:
9
k
g
(
2
0
l
b
)
12.5 A alternator
F
ue
l
t
an
k
:
9
k
g
(
2
0
l
b
)
Vapor
Idle speed (Fast) governed speed Firing order
2200 rpm (gov) 2200 rpm (gov)
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
0.0072 in) intake and exhaust
1.20 L (1.27 qt) 10W30
SAE--SG/SH
STEERING
Type Power source Emergency steering
Front wheel, manual controlled Manual steering Manual
HYDRAULIC SYSTEM
System Capacity Fluid Type
Hydraulic reservoir TENNANT part no. 65869--above 7°C(45°F)
Hydraulic total TENNANT part no. 65870--above 7°C(45°F)
BRAKING SYSTEM
Type Operation
Service brakes Mechanical disc brake (1), one front wheel, cable
actuated
Parking brake Utilizes service brakes, cable actuated
TIRES
Location Type Size
Front (1) Solid 90 x 305 mm (3.5 in x12 in OD)
Rear (2) Solid 76 x 305 mm (3 in x 12 in OD)

GENERAL INFORMATION
1--7
6100 G/LP 330235 (9--01)
TOP VIEW
SIDE VIEW
1524 mm (60 in)
813 mm
(32 in)
1270 mm
(50 in)
FRONT VIEW
352185
MACHINE DIMENSIONS

GENERAL INFORMATION
1--8 6100 G/LP 330235 (2--99)
MAINTENANCE
8
10
11
6
4
9
5
12
2
3
7
1
13
8
14
15
MAINTENANCE CHART
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 3Engine Check oil level EO 1
y
g
Check air intake and cooling
areas for debris
-- 1
6Brush compartment skirts
and seals
Check for damage, wear, and
adjustment
-- 6
4Main brush Check for damage or wear -- 1
5Side brush(es) Check for damage or wear -- 1(2)
(
)
Check brush pattern -- 1(2)
7Hopper dust filter Shake -- 1
25 Hours 3Engine Clean air filter element -- 1
50 Hours 3Engine oil Change EO 2
3Engine air filter Replace -- 2
2Vacuum fan belt Check tension and wear -- 2
4Main brush Rotate end-for-end -- 1
Check brush pattern -- 1
15 QuickMoptbroom (Option) Rotate or wash sweep heads -- 2

GENERAL INFORMATION
1--9
6100 G/LP 330235 (2--99)
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
100 Hours 3Engine Change oil and filter element EO 1
g
Clean or replace spark plugs -- 1
Clean or replace air filter element -- 1
Clean cooling fins -- 1
-- Battery HCheck electrolyte DW 1
7Hopper dust filter Check for damage, clean or
replace
-- 1
8Tires Check for damage or wear -- 3
9Large Debris Trap Flap Check for damage or wear -- 1
10 Propelling chain Lubricate and check tension EO 1
12 Hopper Seal Check for damage or wear -- 4
200 Hours 1Engine Clean or replace spark plugs -- 1
1Engine Clean fuel filter/ sediment bowl -- 1
11 Brake Check adjustment -- 1
13 Side brush(es) Check pivot adjustment -- 1(2)
2Vacuum fan belt Check tension and wear -- 1
3Main brush belt Check for wear -- 1
300 Hours 13 Side brush motor(s) Check motor brushes -- 1
800 Hours Hydraulic fluid reservoir Replace filler cap. -- 3
y
Replace suction strainer -- 3
Change hydraulic fluid HYDO 3
Hydraulic fluid filter HChange filter element -- 3
-- Hydraulic hoses Check for wear and damage -- 3
1Propelling motor HTorque shaft nut -- 3
1
E
n
g
i
n
e
R
e
p
l
a
c
e
f
u
e
l
f
i
l
t
e
r
3
1
E
ng
i
ne
R
ep
l
ace
f
ue
l
f
i
l
t
er. --
3
-- Battery HClean and tighten battery cable
connections
-- 3
LUBRICANT/FLUID
DW Distilled water....
EO SAE 10W--30 Engine oil....
HYDO TENNANT or approved hydraulic fluid.
NOTE: More frequent intervals may be required
in extremely dusty conditions.
NOTE: Also check procedures indicated (H) after
the first 50 hours of operation.

GENERAL INFORMATION
1--10 6100 G/LP 330235 (9--01)
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE
PUSHING OR TOWING THE MACHINE
If the machine becomes disabled, it can be
pushed or towed from the front or rear, but it is
easier and more stable to tow from the front end.
Only push or tow the machine for a very short
distance and do not exceed 1.6 kp/h
(1 mph). It 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 or damage
may occur to the propelling system.
TRANSPORTING THE MACHINE
1. Position the front 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.
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 to the
front tie down located in the front of the
machine frame.
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.

GENERAL INFORMATION
1--11
6100 G/LP 330235 (9--01)
4. 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.
5. 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 front of the machine frame.
The rear tie-down locations are the holes in
the sides of the machine frame near the rear
bumper.
6. 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.

GENERAL INFORMATION
1--12 6100 G/LP 330235 (9--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 weight of the machine. Always stop
the machine on a flat, level surface and block the
tires before jacking up the machine.
FOR SAFETY: Before leaving or
servicing machine, stop on level
surface, set parking brake, turn off
machine, and remove key.
The front jacking locations are on the flat bottom
edge of the front of the machine frame.
The rear jacking locations are on the corners of
the rear frame.
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.
STORING MACHINE
Before storing the machine for an extended time,
the machine needs to be serviced to lessen the
chance of rust, sludge, and other undesirable
deposits from forming.

GENERAL INFORMATION
1--13
6100 G/LP 330235 (3--97)
HARDWARE INFORMATION
The following charts state standard plated
hardware tightening ranges for normal assembly
applications. Decrease the specified torque by
20% when using a thread lubricant. Do not
substitute lower grade hardware for higher grade
hardware. If higher grade hardware than specified
is substituted, tighten only to the specified
hardware torque value to avoid damaging the
threads of the part being threaded into, as when
threading into speed nuts or weldments.
STANDARD BOLT TORQUE CHART
Thread
Size
SAE Grade 5
Torque ft lb
(Nm)
SAE Grade 8
Torque ft lb
(Nm)
0.25 in 7--10 (9--14) 10--13 (14--38)
0.31 in 15--20 (20--27) 20--26 (27--35)
0.38 in 27--35 (37--47) 36--47 (49--64)
0.44 in 43--56 (58--76) 53--76 (72--103)
0.50 in 65--85 (88--115) 89--116
(121--157)
0.62 in 130--170
(176--231)
117--265
(159--359)
0.75 in 215--280
(291--380)
313--407
(424--552)
1.00 in 500--650
(678--881)
757--984
(1026--1334)
NOTE: Decrease torque by 20% when using a
thread lubricant.
METRIC BOLT TORQUE CHART
Thread
Size
Class 8.8
Torque ft lb
_Nm)
Class 10.9
Torque ft lb
(Nm)
M4 2(3) 3(4)
M5 4(5) 6(8)
M6 7(9) 10 (14)
M8 18 (24) 25 (34)
M10 32 (43) 47 (64)
M12 58 (79) 83 (112)
M14 94 (127) 133 (180)
M16 144 (195) 196 (265)
M20 260 (352) 336 (455)
M24 470 (637) 664 (900)
NOTE: Decrease torque by 20% when using a
thread lubricant.
Exceptions to the above chart:
Check the machine for exceptions!
BOLT IDENTIFICATION
Identification
Grade Marking
Specification and
Grade
SAE--Grade 5
SAE--Grade 8
ISO--Grade 8.8
ISO--Grade 10.9
01395
THREAD SEALANT AND LOCKING
COMPOUNDS
Thread sealants and locking compounds may be
used on this machine. They include the following:
Locktite 515 sealant -- gasket forming
material. TENNANT Part No. 75567,15 oz
(440 ml) cartridge.
Locktite 242 blue -- medium strength thread
locking compound. TENNANT Part No.
32676, 0.5 ml tube.
Locktite 271 red -- high strength thread
locking compound. TENNANT Part No.
19857, 0.5 ml tube.

GENERAL INFORMATION
1--14 6100 G/LP 330235 (3--97)
HYDRAULIC FITTING INFORMATION
HYDRAULIC TAPERED PIPE FITTING (NPT)
TORQUE CHART
NOTE: Ratings listed are when using teflon
thread seal.
Size Minimum
Torque
Maximum
Torque
1/4 NPT 10 ft lb (14 Nm) 30 ft lb (41 Nm)
1/2 NPT 25 ft lb (34 Nm) 50 ft lb (68 Nm)
3/4 NPT 50 ft lb (68 Nm) 100 ft lb (136
Nm)
HYDRAULIC TAPERED SEAT FITTING (JIC)
TORQUE CHART
Tube O.D.
(in)
Thread Size Maximum
Torque
0.25 0.44--20 9ftlb(12Nm)
0.38 0.56--18 20 ft lb (27 Nm)
0.50 0.75--16 30 ft lb (41 Nm)
0.62 0.88--14 40 ft lb (54 Nm)
0.75 1.12--12 70 ft lb (95 Nm)
1.0 1.31--12 90 ft lb (122 Nm)
HYDRAULIC O--RING FITTING TORQUE
CHART
Tube
O.D.
(in)
Thread
Size
Minimum
Torque
Maximum
Torque
0.25 0.44--20 6ftlb(8Nm) 9ftlb
(12 Nm)
0.38 0.56--18 13 ft lb
(18 Nm)
20 ft lb
(27 Nm)
*10 ft lb
(14 Nm)
12 ft lb
(16 Nm)
0.50 0.75--16 20 ft lb
(27 Nm)
30 ft lb
(41 Nm)
*21 ft lb
(28 Nm)
24 ft lb
(33 Nm)
0.62 0.88--14 25 ft lb
(34 Nm)
40 ft lb
(54 Nm)
0.75 1.12--12 45 ft lb
(61 Nm)
70 ft lb
(95 Nm)
1.0 1.31--12 60 ft lb
(81 Nm)
90 ft lb
(122 Nm)
NOTE: Do not use sealant on o--ring threads.
*Aluminum bodied components

CHASSIS
2--1
6100 G/LP 330235 (9--00)
CONTENTS
Page
INTRODUCTION 2--3......................
BRAKES AND TIRES 2--4..................
SERVICE BRAKES 2--4.................
TO ADJUST SERVICE BRAKE 2--4....
TO ADJUST PARKING BRAKE 2--5...
TO REPLACE BRAKE PADS 2--6.....
REAR TIRES AND WHEELS 2--9...........
TO REMOVE REAR TIRE ASSEMBLY 2--9
TO INSTALL REAR TIRE ASSEMBLY 2--12
FRONT DRIVE WHEEL, AND WHEEL
HOUSING SUPPORT 2--14..............
TO REMOVE FRONT TIRE AND
WHEEL 2--14.......................
TO INSTALL FRONT TIRE AND
WHEEL 2--17.......................
TO REPLACE FRONT WHEEL DRIVE
CHAIN 2--20........................
TO REPLACE FRONT WHEEL HUB
BEARINGS 2--23....................
TO ADJUST STEERING CHAIN 2--24....
TO REPLACE STEERING CHAIN 2--26...
TO REPLACE STEERING HOUSING
BEARINGS 2--29....................
TO REPLACE STEERING U--JOINT 2--35.
TO REPLACE SMALL STEERING
SPROCKET 2--37...................
TO REPLACE LARGE STEERING
SPROCKET 2--40...................
TO REPLACE FRONT WHEEL
HOUSING NEEDLE BEARING/
THRUST WASHERS 2--44.........
TO REPLACE FRONT WHEEL
HOUSING CONE BEARING 2--50.....
PROPEL ASSEMBLY 2--55.................
DIRECTIONAL PEDAL 2--55.............
TO ADJUST DIRECTIONAL
PEDAL LINKAGE 2--55............

CHASSIS
2--2 6100 G/LP 330235 (9--00)

CHASSIS
2--3
6100 G/LP 330235 (9--00)
INTRODUCTION
This section includes information on the main
chassis related components for example the seat,
steering, brakes, and tires.

CHASSIS
2--4 6100 G/LP 330235 (9--00)
BRAKES AND TIRES
SERVICE BRAKES
The service brakes on the model 6100G consists
of a single disc and caliper located on the front
tire and wheel assembly. The parking brake uses
the same disc and caliper. The service brake and
parking brake are each actuated with a foot pedal.
TO ADJUST SERVICE BRAKE
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, place blocks in front and back
of back wheels.
1. If the service brake pedal has excessive
movement before the brake is activated, the
service brake needs to be adjusted.
2. Go under the front of the machine and
locate the disc brake caliper assembly.
3. Remove the small cotter pin from the caliper
lever pin.