Tennant 6400 User manual

6400
*MM431*
www.tennantco.com
Sweeper
Operator Manual
MM431
Rev. 12 (04-2009)
North America / International
(Diesel)

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
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.
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 insructions, Copyright E1996--2000, 2001, 2002, 2004, 2006--2009 TENNANT Company, Printed in U.S.A.

CONTENTS
1
6400D MM431 (8--07)
CONTENTS
Page
CONTENTS 1...............................
SAFETY PRECAUTIONS 3...................
OPERATION 6..............................
OPERATOR RESPONSIBILITY 6...........
MACHINE COMPONENTS 7...............
SYMBOL DEFINITIONS 8..................
CONTROLS AND INSTRUMENTS 10.......
OPERATION OF CONTROLS 11...........
DIRECTIONAL PEDAL 11...............
BRAKE PEDAL 12.....................
PARKING BRAKE PEDAL 12............
SEAT SUPPORT RELEASE LEVER 12...
THROTTLE LEVER 13..................
HOPPER LEVER 13....................
HOPPER DOOR LEVER 13.............
MAIN BRUSH LEVER 14................
MAIN BRUSH DOWN
PRESSURE KNOB 14...............
VACUUM AND FILTER
SHAKER LEVER 14.................
CHARGING SYSTEM LIGHT 15.........
ENGINE OIL PRESSURE LIGHT 15......
ENGINE TEMPERATURE LIGHT 15......
HOPPER TEMPERATURE LIGHT --
THERMO SENTRY 16...............
GLOW PLUG LIGHT 16.................
CLOGGED FILTER LIGHT (OPTION) 17..
HOPPER DOOR CLOSED
LIGHT (OPTION) 17.................
HYDRAULIC FILTER BYPASS
LIGHT (OPTION) 18.................
FUEL LEVEL GAUGE 18................
STEERING WHEEL 18.................
HOURMETER 18......................
STEERING WHEEL TILT HANDLE 19....
IGNITION SWITCH 19..................
HORN BUTTON 19.....................
SIDE BRUSH LEVER 20................
OPERATING LIGHTS SWITCH 20.......
OPERATING/HAZARD LIGHTS
SWITCH (OPTION) 20...............
SIDE BRUSH DOWN
PRESSURE KNOB 21...............
FUSES 21.............................
CIRCUIT BREAKERS 21................
OPERATOR SEAT 22...................
DELUXE SUSPENSION
SEAT (OPTION) 22..................
HOPPER SUPPORT BAR 23............
HOW THE MACHINE WORKS 24...........
PRE-OPERATION CHECKLIST 24..........
STARTING THE MACHINE 25..............
Page
SWEEPING AND BRUSH INFORMATION 27.
SWEEPING 28...........................
STOP SWEEPING 30.....................
EMPTYING THE HOPPER 31..............
STOP THE MACHINE 33..................
POST-OPERATION CHECKLIST 35.........
ENGAGING HOPPER SUPPORT BAR 36...
DISENGAGING HOPPER
SUPPORT BAR 38.....................
OPERATION ON INCLINES 39.............
OPTIONS 40.............................
VACUUM WAND 40....................
MACHINE TROUBLESHOOTING 42........
MAINTENANCE 44..........................
MAINTENANCE CHART 44................
LUBRICATION 46.........................
ENGINE 46............................
REAR WHEEL SUPPORT 46............
STEERING CYLINDER 46..............
FRONT WHEEL BEARINGS 47..........
HOPPER LIFT ARM PIVOTS 47.........
HYDRAULICS 48.........................
HYDRAULIC FLUID RESERVOIR 48.....
HYDRAULIC FLUID 48.................
HYDRAULIC HOSES 49................
PROPELLING MOTOR 49...............
ENGINE 50..............................
COOLING SYSTEM 50.................
AIR FILTER INDICATOR (OPTION) 50....
AIR FILTER 51.........................
FUEL FILTERS 52......................
FUEL LINES 52........................
PRIMING THE FUEL SYSTEM 53........
VALVE CLEARANCE 53................
ELECTRICAL 54..........................
BATTERY 54..........................
BELTS AND CHAINS 55...................
ENGINE BELT 55......................
VACUUM FAN BELT 55.................
STATIC DRAG CHAIN 55...............
DEBRIS HOPPER 56......................
HOPPER DUST FILTER 56..............
REMOVING HOPPER DUST FILTER 56..
BRUSHES 58.............................
MAIN BRUSH 58.......................
REPLACING MAIN BRUSH 58........
CHECKING AND ADJUSTING
MAIN BRUSH PATTERN 59.......
SIDE BRUSH 61.......................
REPLACING SIDE BRUSH 61........
SIDE BRUSH GUARD 62............
SIDE BRUSH PIVOT 62..............

CONTENTS
6400D MM431 (6--00)
2
Page
SKIRTS AND SEALS 63...................
HOPPER LIP SKIRT 63.................
HOPPER SIDE SKIRT 63...............
BRUSH DOOR SKIRTS 63..............
REAR SKIRTS 64......................
SIDE BRUSH DUST CONTROL
SKIRTS (OPTION) 64................
BRUSH DOOR SEALS 64...............
HOPPER SEALS 64....................
HOPPER ACCESS DOOR SEAL 65......
HOPPER DOOR SEALS 65.............
VACUUM FAN SEAL 65.................
BRAKES AND TIRES 66...................
BRAKES 66...........................
TIRES 66.............................
REAR WHEEL 66......................
PUSHING, TOWING, AND
TRANSPORTING THE MACHINE 67....
PUSHING OR TOWING THE MACHINE 67
TRANSPORTING THE MACHINE 68....
MACHINE JACKING 70....................
STORING MACHINE 70...................
SPECIFICATIONS 71........................
GENERAL MACHINE PERFORMANCE 71...
POWER TYPE 72.........................
STEERING 72............................
HYDRAULIC SYSTEM 72..................
MACHINE DIMENSIONS 73................
INDEX 74...................................

SAFETY PRECAUTIONS
3
6400D MM431 (6--08)
SAFETY PRECAUTIONS
The following precautions 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: 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:
-- 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:
-- 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 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.
6. When servicing machine:
-- Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
-- 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.
-- 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.

SAFETY PRECAUTIONS
6400D MM431 (9--02)
4
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
5
6400D MM431 (12--96)
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.
EMISSIONS LABEL -- LOCATED ON THE SIDE
OF THE OPERATOR COMPARTMENT.
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 SIDES OF THE RADIATOR SHROUD.
350159

OPERATION
6400D MM431 (9--96)
6
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
required maintenance intervals occur 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
7
6400D MM431 (8--07)
MACHINE COMPONENTS
A
B
C
D
E
F
G
H
I
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
I. Fuel tank

OPERATION
6400D MM431 (8--07)
8
SYMBOL DEFINITIONS
These symbols identify controls, displays, and
features on the machine:
Filter shaker Thermo Sentry
Vacuum fan on Glow plugs
Vacuum fan off Clogged dust filter
Fast engine speed Hopper door closed
Idle engine speed Hydraulic filter clogged
Hopper down Hourmeter
Hopper up Steering wheel tilt
Hopper door open Off
Hopper door close On
Main brush down and on Start
Main brush up and off Horn
Battery charging system Operating lights
Engine oil pressure Hazard light
Engine water temperature Side brush down and on

OPERATION
9
6400D MM431 (4--09)
Side brush up and off Circuit breaker #3
Variable pressure Circuit breaker #4
Side brush pressure Circuit breaker #5
Circuit breaker #1 Diesel fuel only
Circuit breaker #2

OPERATION
6400D MM431 (8--07)
10
CONTROLS AND INSTRUMENTS
A
B
C
D
E
F
G
H
I
JK
L
M
N
OP
Q
R
S
T
U
VW
X
Y
Z
AA
BB
350013
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. Throttle lever
J. Vacuum and filter shaker lever
K. Charging system light
L. Engine oil pressure light
M. Engine temperature light
N. Hopper temperature light -- Thermo Sentry
O. Glow plug light
P. Clogged filter light (option)
Q. Hopper door closed light (option)
R. Hydraulic filter bypass light (option)
S. Fuel level gauge
T. Steering wheel
U. Hourmeter
V. Steering wheel tilt handle
W. Ignition switch
X. Horn button
Y. Side brush lever
Z. Operating light switch (Operating/hazard light switch option)
AA.Side brush down pressure knob
BB.Circuit breakers

OPERATION
11
6400D MM431 (9--96)
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.
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.
07790
07791
07792

OPERATION
6400D MM431 (9--96)
12
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 lever back and lift the seat
support.
Lock: Close the seat support and release the lever
to lock the support in place.

OPERATION
13
6400D MM431 (12--96)
THROTTLE LEVER
The throttle lever controls the engine speed.
Fast: Push the throttle lever all the way forward.
Idle: Pull the throttle lever all the way back.
NOTE: Only operate the throttle all the way open
in the Fast engine speed position when
sweeping. Operating the throttle at any other
position will reduce performance. Pull the throttle
lever all the way back before turning the machine
off.
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 before 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.

OPERATION
6400D MM431 (6--99)
14
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.
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.

OPERATION
15
6400D MM431 (9--96)
CHARGING SYSTEM LIGHT
The charging system light comes on when the
alternator is not operating within normal range;
13.5 to 14.5 V. If the light comes on, stop operating
the machine. Locate the problem and have it
corrected.
ENGINE OIL PRESSURE LIGHT
The engine oil pressure light comes on when the
engine oil pressure falls below 40 kPa (5 psi). If the
light comes on, stop operating the machine. Locate
the problem and have it corrected.
ENGINE TEMPERATURE LIGHT
The engine water temperature light comes on
when the temperature of the engine coolant is
more than 107_C (225_F). If the light comes on,
stop operating the machine. Locate the problem
and have it corrected.

OPERATION
6400D MM431 (8--07)
16
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.
GLOW PLUG LIGHT
The glow plug light comes on when the ignition
switch is turned counterclockwise to the Glow
plugs position. The light will go out when the
engine is ready to start.

OPERATION
17
6400D MM431 (6--00)
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 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.

OPERATION
6400D MM431 (9--96)
18
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.
FUEL LEVEL GAUGE
The fuel level gauge indicates how much fuel is in
the fuel tank.
NOTE: Do not let the fuel tank empty completely.
Air can enter the fuel system and it may need
bleeding before the next engine start.
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.