Tennant 6200D User manual

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

This service manual is intended to be used as an aid in the detailed service, repair, and troubleshooting of
your TENNANT Model 6200D.
The set is organized into six major groups: General Information, Chassis, Sweeping, Electrical,
Hydraulics, and Engine--D.
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: V--belt replacement, brush replacement, bearing replacement, skirt/seal repair/replacement,
and sweeping troubleshooting.
Electrical: Battery maintenance and replacement, electrical schematics, and electrical troubleshooting.
Hydraulics: Cylinder replacement, pump (s) replacement, hydraulic motor replacement, hydraulic
schematic, and hydraulic troubleshooting.
Engine -- D: Air filter replacement, oil changing, cooling system maintenance,
engine troubleshooting, engine removal, and engine repairs.
Manual Number -- 330395
Revision: 01
Published: 6--02
Copyright E1999, 2002 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
1-1
6200D 330395 (6--02)
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 SYSTEMS 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..............
MACHINE TROUBLESHOOTING 1-15...

GENERAL INFORMATION
1-2 6200D 330395 (8--99)

GENERAL INFORMATION
1-3
6200D 330395 (6--02)
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: 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: Lift arm pinch point. Stay
clear of hopper lift arms.
WARNING: Moving belt and fan. Keep
away.
WARNING: Raised hopper may fall.
Engage hopper support bar.
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 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.

GENERAL INFORMATION
1-4 6200D 330395 (6--02)
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.
HOPPER SUPPORT LABEL -- LOCATED ON
BOTH LIFT ARMS AND THE HOPPER
SUPPORT BAR.
HOPPER LIFT ARMS LABEL --
LOCATEDONBOTHLIFTARMS.
EMISSIONS LABEL -- LOCATED BEHIND
THE OPERATOR’S SEAT.
FOR SAFETY LABEL --
LOCATED ON THE SIDE OF THE
OPERATOR COMPARTMENT.
MOVING BELT AND FAN LABEL -- LOCATED
ON TOP OF THE RADIATOR SHROUD.

GENERAL INFORMATION
1-5
6200D 330395 (6--02)
SPECIFICATIONS
GENERAL MACHINE DIMENSIONS/CAPACITIES
Item Dimension/capacity
Length 1956 mm
Width 1070 mm
Widthw/sidebrush 1120 mm
Height 1440 mm
Height with overhead guard 2045 mm
Track 94 mm
Wheelbase 97 mm
Main sweeping brush diameter 280 mm
Main sweeping brush length 711 mm
Side brush diameter 520 mm
Sweeping path width 711 mm
Sweeping path width with one side brush 1070 mm
Sweeping path width with two side brushes 1400 mm
Main sweeping brush pattern width 65 mm
Hopper weight capacity 135 kg
Hopper volume capacity 125 L
Dust filter area 4.6sqm
GVWR 927 kg
Ceiling height minimum dumping clearance 2286 mm
Sound level -- continuous 81±dB(A)
Sound level -- peak 81±dB(A)
Vibration level does not exceed 2.5 m/s@
GENERAL MACHINE PERFORMANCE
Item Measure
Maximum forward speed 8.1 km/h
Maximum reverse speed 4.8 km/h
Minimum aisle turn 2095 mm
Minimum turning radius, left 1400 mm
Minimum turning radius, right 1400 mm
Maximum rated incline with empty hopper 10_/18%
Maximum rated incline with full hopper 6_/11%

GENERAL INFORMATION
1-6 6200D 330395 (8--99)
POWER TYPE
Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke
Kubota Z482 Piston Diesel 4Natural 267 mm 68 mm
Displacement Net power, governed Net power, maximum
479 cc 8 kw @ 2500 rpm 10.5 kw @
3600 rpm
Fuel Cooling system Electrical system
Diesel
Fuel tank: 7.2 L
Water/ethylene glycol
atifreeze
12 V nominal
Radiator: 0.95 L
Total: 2.84 L
12.5 A alternator
Idle speed (Fast) governed speed Engine lubricating oil
with filter
2
5
0
0
±
5
0
r
p
m
(
g
o
v
)
2
5
0
0
±
5
0
r
p
m
(
g
o
v
)
2
5
L
S
A
E
1
0
W
--
3
0
2
5
0
0
±
5
0
r
p
m
(
g
o
v
)
2
5
0
0
±
5
0
r
p
m
(
g
o
v
)
2
.
5
L
S
A
E
1
0
W
--
3
0
C
D
/
C
E
r
a
t
e
d
C
D
/
C
E
ra
t
e
d
STEERING
Type Power source Emergency steering
Front wheel, manual controlled Manual steering Manual
HYDRAULIC SYSTEMS
System Capacity Fluid Type
Main hydraulic reservoir 7.58 L TENNANT part no. 65869--above 7°C
Main hydraulic total 9.48 L TENNANT part no. 65870--below 7°C
Hydraulic lift reservoir 0.53 L TENNANT part no. 65870 (Hydraulic lift res. only)
Hydraulic lift total 1.4 L
BRAKING SYSTEM
Type Operation
Service brakes 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
Rear (2) Solid 76 x 305 mm

GENERAL INFORMATION
1-7
6200D 330395 (6--02)
TOP VIEW
SIDE VIEW
1783 mm
1067 mm
2035 mm
FRONT VIEW
1435 mm
1397 mm
352945
MACHINE DIMENSIONS

GENERAL INFORMATION
1-8 6200D 330395 (6--02)
MAINTENANCE
13
13
12
14 7
2
14
15
12
2
7
4
5
6
8
9
10
11 2
7
3
3
16
MAINTENANCE CHART
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 1Engine Check oil level EO 1
y
2Brush compartment skirts Check for damage, wear and
adjustment
-- 5
3 Side skirts Check for damage, wear and
adjustment
-- 2
9Main brush Check for damage, wear and
adjustment
-- 1
6Side brush(es) Check for damage, wear and
adjustment
-- 1(2)
Check brush pattern -- 1(2)
13 Hopper dust filter Shake -- 1
50 Hours 9Main brush Rotate end-for-end -- 1
Check brush pattern -- 1
1Fuel lines Check for damage and wear -- All
100 Hours 1Engine Change oil and filter element EO 1
g
Replace air filter element -- 1
Check air filter housing dust cap -- 1
16 Radiator Check core exterior for debris -- 1
Check coolant level WG 1

GENERAL INFORMATION
1-9
6200D 330395 (6--02)
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
100 Hours 13 Hopper dust filter Check for damage, clean or
replace
-- 1
4Steering castor pivot
bearing
Lubricate SPL 1
13 Hopper seals Check for damage or wear -- 6
13 Hopper filter seals Check for damage or wear -- 2
13 Vacuum seal Check for damage or wear -- 1
11 Vacuum fan belt Check tension and wear -- 1
10 Main brush belt Check tension and wear -- 1
14 Hydraulic pump belt Check tension and wear -- 1
15 Jackshaft belt Check tension and wear -- 1
14 Hydraulic fluid reservoirs Check fluid levels -- 2
7Tires Check for damage or wear -- 3
200 Hours 5 Brake Check adjustment -- 1
4Steering gear chain Lubricate EO 1
6Side brush(es) guard Check for damage or wear -- 1(2)
16 Radiator hoses and clamps Check tension and wear -- 2
400 Hours 1Fuel filter cartridge Replace element -- 1
800 Hours 14 Hydraulic fluid reservoirs Change hydraulic fluid HYDO 2
14 Hydraulic hoses Check for wear and damage -- All
14 Hydraulic fluid filter Replace filter element -- 1
14 Main hydraulic reservoir
cap
Replace cap -- 1
14 Main hydraulic reservoir
strainer
Replace strainer -- 1
7Wheels Check rear wheel axle torque -- 2
8Battery HClean and tighten battery cable
connections
-- 2
16 Cooling system Flush WG 1
LUBRICANT/FLUID
EO Engine oil, SAE 10W--30, CD/CE rated....
HYDO Tennant or approved hydraulic fluid.
SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)...
WG Water and permanent--type ethylene glycol anti--freeze, --34°C....
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 6200D 330395 (6--02)
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
6200D 330395 (6--02)
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 6200D 330395 (6--02)
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 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
6200D 330395 (8--99)
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 6200D 330395 (8--99)
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

GENERAL INFORMATION
1-15
6200D 330395 (6--02)
MACHINE TROUBLESHOOTING
Problem Cause Remedy
Excessive dusting Vacuum fan damper closed Press the vacuum fan / filter
shaker switch to the on position
Brush skirts and dust seals worn,
damaged, out of adjustment
Replace or adjust brush skirts or
dust seals
Hopper dust filter clogged Shake and/or clean or replace
dust filter
Hopper full Empty hopper
Vacuum fan failure Contact Tennant service person-
nel
Poor sweeping performance Brush bristles worn Replace brushes
Main and side brushes not
adjusted properly
Adjust main and side brushes
Debris caught in main brush drive
mechanism
Remove debris from drive
mechanism
Main brush drive failure Contact Tennant service
personnel
Side brush drive failure Contact Tennant service
personnel
Hopper full Empty hopper
Hopper lip skirts worn or damaged Replace lip skirts
Wrong sweeping brush Contact Tennant representative
for recommendations
Large debris trap damaged Repair or replace large debris trap
Hopper dust filter clogged Shake and/or clean or replace
dust filter
Machine will not start Engine oil level low Check and fill
Fuel tank valve closed Open valve beneath fuel tank
Fuel tank empty Fill fuel tank

GENERAL INFORMATION
1-16 6200D 330395 (8--99)

CHASSIS
2-1
6200D 330395 (8--99)
CONTENTS
Page
INTRODUCTION 2--3......................
OPERATOR SEAT 2--4....................
ADJUSTABLE OPERATOR SEAT
(OPTION) 2--4......................
DELUXE SUSPENSION SEAT
(OPTION) 2--4......................
STATIC DRAG CHAIN 2--6.................
BRAKES AND TIRES 2--6..................
SERVICE BRAKES 2--6.................
PARKING BRAKE 2--6..................
TO ADJUST SERVICE BRAKES 2--7.....
TO ADJUST PARKING BRAKE 2--8......
TO REPLACE DRIVE ASSEMBLY
BRAKE SHOES 2--9.................
REAR TIRES AND WHEELS 2--13..........
TO REMOVE REAR TIRE 2--13..........
TO INSTALL REAR TIRE 2--14...........
TO REPLACE REAR WHEEL
BEARINGS 2--15....................
FRONT TIRE AND WHEEL, AND WHEEL
DRIVE SUPPORT 2--17.................
FRONT WHEEL SUPPORT CASTER
BEARING ASSEMBLY 2--17..........
TO REMOVE FRONT DRIVE
ASSEMBLY 2--18....................
TO INSTALL FRONT DRIVE
ASSEMBLY 2--20....................
TO REPLACE DRIVE ASSEMBLY
CASTER BEARING AND
THRUST WASHERS 2--22.........
TO REPLACE DRIVE ASSEMBLY
PIVOT CONE BEARING 2--27........
TO REPLACE FRONT TIRE AND
WHEEL ASSEMBLY 2--30............
TO REPLACE FRONT DRIVE
ASSEMBLY OUTER WHEEL
BEARING 2--34..................
TO REPLACE FRONT DRIVE
ASSEMBLY INNER WHEEL
BEARING 2--36..................
Page
STEERING 2--40..........................
TO ADJUST STEERING CHAIN 2--40....
TO REPLACE STEERING CHAIN 2--41...
TO REPLACE LARGE STEERING
SPROCKET 2--42...................
TO REPLACE SMALL STEERING
SPROCKET 2--44...................
TO REPLACE STEERING HOUSING
BEARINGS 2--46....................
TO REPLACE STEERING U--JOINT 2--50.
DIRECTIONAL PEDAL 2--52...............
TO REMOVE DIRECTIONAL PEDAL
ASSEMBLY 2--52....................
TO INSTALL DIRECTIONAL PEDAL
ASSEMBLY 2--54....................

CHASSIS
2-2 6200D 330395 (8--99)