Tennant 6200LP User manual

330375
Rev. 00 (6–99)
Service Manual
6200G/LP

This service manual is intended to be used as an aid in the detailed service, repair, and troubleshooting of
your TENNANT Model 6200G/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: 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 –G/LP: Air filter replacement, oil changing, cooling system maintenance,
engine troubleshooting, engine removal, and engine repairs.
Manual Number – 330375
Revision: 00
Published: 6–99
Copyright 1999 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
1-1
6200G/LP330375 (6–99)
CONTENTS
Page
SAFETY PRECAUTIONS 1–3. . . . . . . . . . . . . .
SPECIFICATIONS 1–5. . . . . . . . . . . . . . . . . . . .
GENERAL MACHINE PERFORMANCE 1–5. .
POWER TYPE 1–6. . . . . . . . . . . . . . . . . . . . . . . .
STEERING 1–7. . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEM 1–7. . . . . . . . . . . . . . . . .
BRAKING SYSTEM 1–7. . . . . . . . . . . . . . . . . . .
TIRES 1–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE DIMENSIONS 1–8. . . . . . . . . . . . . . .
MAINTENANCE 1–9. . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE CHART 1–9. . . . . . . . . . . .
PUSHING, TOWING, AND
TRANSPORTING THE MACHINE 1–11. . .
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 6200G/LP330375 (6–99)

GENERAL INFORMATION
1-3
6200G/LP330375 (6–99)
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: 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.

GENERAL INFORMATION
1-4 6200G/LP330375 (6–99)
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.
HOPPER SUPPORT LABEL –LOCATED ON
INSIDE METAL PANEL ON BOTH SIDES OF
THE MACHINE.
HOPPER LIFT ARMS LABEL –
LOCATED ON BOTH LIFT ARMS.
EMISSIONS LABEL –LOCATED
BEHIND THE OPERATOR’S SEAT.

GENERAL INFORMATION
1-5
6200G/LP330375 (6–99)
SPECIFICATIONS
GENERAL MACHINE DIMENSIONS/CAPACITIES
Item Dimension/capacity
Length 1956 mm (77 in)
Width 1245 mm (49 in)
Height 1440 mm (57 in)
Height with overhead guard 2035 mm (80 in)
Track 94 mm (37 in)
Wheelbase 97 mm (38 in)
Main sweeping brush diameter 280 mm (11 in)
Main sweeping brush length 711 mm (28 in)
Side brush diameter 520 mm (20.5 in)
Sweeping path width 711 mm (28 in)
Sweeping path width with one side brush 1070 mm (42 in)
Sweeping path width with two side brushes 1400 mm (55 in)
Main sweeping brush pattern width 65 mm (2.5 in)
Hopper weight capacity 135 kg (300 lb)
Hopper volume capacity 85 L (3 cu ft)
Dust filter area 4.6 sq m (49 sq ft)
GVWR 927 kg (2700 lb)
Ceiling height minimum dumping clearance 2286 mm (90 in)
GENERAL MACHINE PERFORMANCE
Item Measure
Maximum forward speed 9.7 km/h (6 mph)
Maximum reverse speed 4.8 km/h (3 mph)
Minimum aisle turn 2095 mm (82.5 in)
Minimum turning radius, left 1400 mm (55 in)
Minimum turning radius, right 1400 mm (55 in)
Maximum rated incline with empty hopper 10/18%
Maximum rated incline with full hopper 6/11%

GENERAL INFORMATION
1-6 6200G/LP330375 (6–99)
POWER TYPE
Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke
Robin Piston Breakerless-
type spark 4 Natural 1 84 mm (3.31 in) 61 mm (2.40 in)
Displacement Net power, governed Net power, maximum
338 cc (20.6 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, 12.5 A alternator
Fuel tank: 9 kg ( 20 lb)
Vapor
Idle speed (Fast) governed speed Firing order
2200 rpm (gov) 2200 rpm (gov) 1
Spark plug gap Valve clearance, cold Engine lubricating oil
.6 mm (0.024 in)
Gasoline and LPG 0.145 to 0.185 mm (0.0057 to 0.0072 in) intake and exhaust 1.20 L (1.3 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 7.58 L (2 gal) TENNANT part no. 65869–above 7°C (45°F)
Hydraulic total 9.48 L (2.5 gal) TENNANT part no. 65870–below 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
6200G/LP330375 (6–99)
TOP VIEW
SIDE VIEW
1956 mm (77 in)
1245 mm
(49 in)
1440 mm
(57 in)
FRONT VIEW
352185
MACHINE DIMENSIONS

GENERAL INFORMATION
1-8 6200G/LP330375 (6–99)
MAINTENANCE
10
12
2
1
8
2
3
4
5
6
7
9
11
5
5
13
13
14 15
MAINTENANCE CHART
Interval Key Description Procedure Lubricant/
Fluid
No. of
Service
Points
Daily 3 Engine Check oil level –1
Check air intake and cooling
areas for debris –1
6Brush compartment skirts 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 3 Engine Check air filter element for
damage –1
50 Hours 4Main brush Rotate end-for-end –1
Check brush pattern –1
15 QuickMopbroom (Option) Rotate or wash sweep heads –2

GENERAL INFORMATION
1-9
6200G/LP330375 (6–99)
Interval Key Description Procedure Lubricant/
Fluid
No. of
Service
Points
100 Hours 3 Engine Change oil and filter element EO 1
Clean or replace spark plugs –1
Replace air filter element –1
Clean cooling fins –1
–Battery Check electrolyte DW 1
7Hopper dust filter Check for damage, clean or
replace –1
8 Tires 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 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
800 Hours 1 Engine Replace fuel filter. –3
–Battery Clean and tighten battery cable
connections –3
LUBRICANT/FLUID
DW Distilled water. . . .
EO SAE 30 Engine oil. . . .
NOTE: More frequent intervals may be required in extremely dusty conditions.

GENERAL INFORMATION
1-10 6200G/LP330375 (6–99)

GENERAL INFORMATION
1-11
6200G/LP330375 (6–99)
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE
You can push the machine from the front or rear,
but it is easier and more stable to tow from the
front end.
Unplug the drive motor from the electrical harness
before attempting to push the machine. The
machine will become much easier to maneuver
when it is unplugged.
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.
When transporting the machine on a trailer or in a
truck, be sure to set the parking brake and block
the tires to prevent the machine from rolling.

GENERAL INFORMATION
1-12 6200G/LP330375 (6–99)
MACHINE JACKING
You can jack up the machine for service at the
designated locations. Use a jack of adequate
capacity and good working condition. 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
6200G/LP330375 (6–99)
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 6200G/LP330375 (6–99)
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 9 ft lb (12 Nm)
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 6 ft lb (8 Nm) 9 ft lb
(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
6200G/LP330375 (6–99)
MACHINE TROUBLESHOOTING
Problem Cause Remedy
Excessive dusting Vacuum an damper closed Press the vacuum an / ilter
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 ilter clogged Shake and/or clean or replace
dust ilter
Hopper ull Empty hopper
Vacuum an ailure Contact Tennant service
personnel
Poor sweeping per ormance 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 rom drive
mechanism
Main brush drive ailure Contact Tennant service
personnel
Side brush drive ailure Contact Tennant service
personnel
Hopper ull 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 ilter clogged Shake and/or clean or replace
dust ilter
Machine will not start Engine oil level low Check and fill
Fuel tank valve closed Open valve –LPG tank valve or
valve below gasoline tank

GENERAL INFORMATION
1-16 6200G/LP330375 (6–99)

CHASSIS
2-1
6200G/LP 330375 (6–99)
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 6200G/LP 330375 (6–99)