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MAINTENANCE

3-33

215E MM158 (11--91)

BRAKES AND TIRES

BRAKES

The parking brake and the foot brake operate the

brake cable which controls two disc brakes.

The brakes should be adjusted after every 100

hours of operation. The brakes are properly

adjusted when the parking brake lever will travel

0.50 in (15 mm) before engaging the brakes.

To adjust the brakes, remove the clevis pin from

each brake assembly, turn the clevis ends an

equal amount, reconnect the clevis pins, and

recheck the parking brake lever travel.

03073

BRAKE ASSEMBLY

A. Right Side Tire

B. Brake Cable

C. Clevis

D. Brake Assembly

TIRES

All of the machine tires are solid and need no

regular maintenance.

Summary of Contents for 215E

Page 1: ...215E MM158 Operator and Parts Manual ...

Page 2: ...arts Options Hydraulic Components and Cross Reference sections MACHINE DATA Please fill out at time of installation for future reference Machine Model Number 215E Machine Serial Number Machine Options TENNANT Representative phone no Customer ID Number Date of Installation Manual Number MM158 Revision 11 Published 2 98 Copyright E 1986 1987 1988 1989 1990 1991 1993 1994 1998 TENNANT Printed in U S ...

Page 3: ...k 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 Slow On Grades And Slippery Surfaces Use Care When Backing Machine Move Machine With Care When Hopper Is Raised Make Sure Adequate Clearance Is Available Before Raising Hopper Do Not Carry Riders On Machine Always Follow Safety An...

Page 4: ... a new label in its place HOPPER WARNING LABEL LOCATED ON THE HOPPER SIDE OF THE FRONT SUPPORT PARTITION BATTERY CAUTION LABEL LOCATED ON THE OPERATOR SIDE OF THE FRONT SUPPORT PARTITION HOPPER SUPPORT BAR WARNING LABEL LOCATED ON THE HOPPER SUPPORT BAR HOPPER SUPPORT BAR WARNING LABEL LOCATED ON THE OPERATOR SIDE OF THE HOPPER FOR SAFETY LABEL LOCATED ON THE SEAT SHROUD 07193 ...

Page 5: ...SPECIFICATIONS 1 3 POWER TYPE 1 3 POWER TRAIN 1 3 STEERING 1 3 HYDRAULIC SYSTEM 1 3 BRAKING SYSTEM 1 3 SUSPENSION SYSTEM 1 3 SYSTEM FLUID CAPACITIES 1 3 GENERAL MACHINE DIMENSIONS CAPACITIES 1 3 MACHINE WEIGHTS 1 3 GENERAL MACHINE PERFORMANCE 1 3 MACHINE DIMENSIONS 1 4 ...

Page 6: ...SPECIFICATIONS 215E MM158 6 88 1 2 ...

Page 7: ...iameter rod 2500 psi 17 240 kPa maximum rated pressure BRAKING SYSTEM Service brakes mechanical disc brakes 2 1 per front wheel cable actuated Parking brakes utilizes service brakes cable actuated SUSPENSION SYSTEM Front 12 x 3 00 zero pressure tires 2 Rear 12 x 3 00 solid tire 1 SYSTEM FLUID CAPACITIES Hydrostatic transmission 1 6 pt 0 75 L Hydraulic system reservoir 2 qt 1 8 L Hydraulic system t...

Page 8: ...SPECIFICATIONS 215E MM158 11 91 1 4 MACHINE DIMENSIONS SIDE VIEW TOP VIEW 63 75 in 1620 mm 53 75 in 1365 mm 46 75 in 1190 mm 07194 ...

Page 9: ... 8 START SWITCH 2 8 MAIN BRUSH POSITION LEVER 2 8 SIDE BRUSH POSITION LEVER 2 8 STEERING WHEEL 2 8 MAIN BRUSH HEIGHT ADJUSTMENT KNOB 2 9 CHARGER PANEL 2 9 CIRCUIT BREAKERS AND FUSES 2 9 HOPPER SUPPORT BAR 2 10 TO ENGAGE HOPPER SUPPORT BAR 2 10 TO DISENGAGE HOPPER SUPPORT BAR 2 10 Page MACHINE OPERATION 2 11 NORMAL SWEEPING OPERATION 2 11 PRE START CHECKLIST 2 11 TO START MACHINE 2 11 TO SWEEP 2 11...

Page 10: ...OPERATION 215E MM158 2 98 2 2 ...

Page 11: ...CKING BATTERY ELECTROLYTE LEVEL A Battery B Electrolyte Indicator Ring FOR SAFETY When Servicing Machine Avoid Contact With Battery Acid 5 Check the battery specific gravity to determine the state of charge as described in BATTERIES in the MAINTENANCE section Charge the batteries if necessary 6 Connect the batteries to machine connector A B 03065 CONNECTING BATTERIES TO MACHINE CONNECTOR A Machine...

Page 12: ...TION 215E MM158 11 91 2 4 OPERATION OF CONTROLS A B C D E F G H 03085 MACHINE COMPONENTS A Operator Seat E Hopper B Steering Wheel F Side Brush C Instrument Panel G Access Door D Filter Cover H Seat Support ...

Page 13: ...displays on the machine Side Brush Down Side Brush Up Main Brush Down Main Brush Up Main Brush Extra Down Pressure Hopper Door Close Hopper Door Open Hopper Up Hopper Down Filter Shaker Start Hazard Light Operational Lights Key Switch Horn Interrupt Switch Battery Charger Interrupt Battery Charger Battery ...

Page 14: ...or Switch B Directional Pedal M Hopper Switch C Parking Brake Lever N Horn Button D Charger Timer O Key Operated On off Switch E Charger Gauge P Start Switch F Circuit Breakers Q Main Brush Lever G Battery Discharge Indicator R Side Brush Lever Voltmeter S Steering Wheel H Hour Meter T Main Brush Adjustment Knob I Hazard Light Switch U Parking Brake Release Lever J Lights Switch V Charger Panel K ...

Page 15: ...of hours you wish to charge the batteries The timer will automatically stop the charger CHARGER GAUGE The charger gauge indicates the level of charge being passed to the batteries on machines below serial number 003860 The gauge needle should be in the green area when charging and in the black area when done BATTERY DISCHARGE INDICATOR The battery discharge indicator is an option on machines below...

Page 16: ...red HORN BUTTON The horn button operates the machine horn It is located on the instrument panel KEY OPERATED ON OFF SWITCH The key operated on off switch has two positions To allow the machine to operate turn the key clockwise To stop the motor turn the key counterclockwise START SWITCH The start switch controls the motor starter windings To start the motor turn the key clockwise and push the star...

Page 17: ...e circuit protection devices designed to stop the flow of current in the event of a circuit overload Once tripped circuit breakers must be manually reset If the overload which caused the circuit breaker to trip is still present in the circuit the circuit breaker will continue to stop current flow until the overload is corrected Fuses are a one time circuit protection device designed to stop the fl...

Page 18: ...he machine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing The Machine Stop On Level Surface Set Parking Brake 2 Raise the hopper to the fully raised position 3 Position the hopper support bar on the lintel A B 03068 ENGAGED HOPPER SUPPORT BAR LOW DUMP MODEL A Lintel B Support Bar A B 03069 ENGAGED HOPPER SUPPORT BAR MULTI LEVEL DUMP MODEL A Lintel B Support Bar 4 Slowly l...

Page 19: ... in the operator s seat with the directional control pedal in the neutral position and with a foot on the brake pedal or with the parking brake set FOR SAFETY Before Starting Machine Make Sure All Safety Devices Are In Place And Operate Properly 2 Turn the key operated on off switch to the right 3 Push the start switch until the motor starts 4 Release the machine parking brake 5 Drive the machine ...

Page 20: ...y back the machine away from the dump site or dumpster POST OPERATION CHECKLIST MOTOR OPERATING Check brush patterns for width and evenness NOTE Before leaving the machine perform the post operation checks TO STOP MACHINE 1 Return the directional pedal to the neutral position Apply the brake 2 Pull the main brush position lever into the Main Brush Up position 3 Pull the side brush position lever i...

Page 21: ...st brushes Debris caught in brush drive mechanism Free mechanism of debris Main brush drive failure Belt broken or off sheave Side brush drive failure Belt broken or off sheave Hopper not adjusted properly Adjust hopper floor clearance Hopper full Empty hopper Hopper floor skirts worn damaged Replace skirts Machine will not travel Directional control pedal linkage out of adjustment or broken Check...

Page 22: ...ng brake FOR SAFETY Before Leaving Or Servicing The Machine Stop On Level Surface Set Parking Brake 3 Block the tires which are not being jacked up in order to secure the machine position FOR SAFETY When Servicing Machine Block Machine Tires Before Jacking Machine Up 4 Use a jack of adequate capacity to raise the machine Jack up the machine only at the designated locations FOR SAFETY When Servicin...

Page 23: ...t the locations specified To tie the machine down use the holes on the front and the lower rear machine frame A 03071 REAR TIE DOWN LOCATION A Tie Down Hole When transporting the machine on a trailer or in a truck be sure to engage the machine parking brake and block the machine tires to prevent the machine from rolling ...

Page 24: ... following procedures must be followed to lessen the chance of rust sludge or other undesirable deposits from forming 1 Empty debris hopper 2 Place the main brush and side brush levers in the raised position 3 Fully charge the batteries 4 Disconnect the batteries to machine connector 5 Park the machine in a cool dry area ...

Page 25: ...AFT BELT 3 18 TO REPLACE JACKSHAFT BELT 3 18 INTERMEDIATE SIDE BRUSH BELT 3 18 TO REPLACE INTERMEDIATE SIDE BRUSH BELT 3 18 SIDE BRUSH BELT 3 19 TO REPLACE SIDE BRUSH BELT 3 19 MAIN BRUSH BELT 3 19 TO REPLACE MAIN BRUSH BELT 3 19 DRIVE CHAIN AND BELT ALIGNMENT AND TENSIONING 3 20 TO ALIGN AND TENSION DRIVE CHAINS AND BELTS 3 20 STATIC DRAG CHAIN 3 22 Page DEBRIS HOPPER AND DUST FILTER 3 23 DEBRIS ...

Page 26: ...MAINTENANCE 215E MM158 6 88 3 2 ...

Page 27: ...20 HOUR MACHINE INSPECTION After the first 20 hours of operation the following procedures are recommended 1 Check the brush pattern for correct brush adjustment 2 Check the floor skirts to floor clearance 3 Check the side brush and main brush patterns ...

Page 28: ...n 1 Daily 8 Dust filter Shake 1 3 Brush skirts Check for damage and wear 3 13 Main brush Check for damage and wear 1 13 Main brush Check floor pattern 1 11 Side brush Check for damage and wear 1 11 Side brush Check floor pattern 1 5 Hopper Check for hopper door seal for damage and wear 3 25 Hours 1 Batteries Check electrolyte level DW 6 25 Hours 16 Transmission Check oil level EO 1 2 Hydraulic res...

Page 29: ...in Brush Rotate end for end 1 8 Dust filter Clean or replace 1 100 Hours 1 Batteries Clean tops and terminals 6 100 Hours 4 Drive chains Check and adjust tension 3 4 Drive chains Lubricate EO 3 7 Brakes Adjust 2 9 Differential Apply grease to fittings SPL 2 10 Steering gear Apply grease to fitting SPL 1 5 Hopper Clean inside 1 5 Hopper Check floor clearance 1 6 Lift cylinder Apply grease to fittin...

Page 30: ...oir C Fill Cap DIFFERENTIAL The differential drives the two front wheels Two grease fittings are located on the differential housing for lubrication The differential should be lubricated by applying Lubriplate EMB grease TENNANT Part No 01433 1 to the grease fittings after every 100 hours of operation A B 01783 DIFFERENTIAL A Differential B Grease Fitting DRIVE CHAINS The two wheel drive chains an...

Page 31: ...1433 1 to the grease fitting after every 100 hours of operation A B 01786 STEERING GEAR A Steering Gear B Grease Fitting LIFT CYLINDER The lift cylinder is present on multi level dump model machines It raises the hopper to dump it The top lift cylinder bearing should be lubricated by applying Lubriplate EMB grease TENNANT Part No 01433 1 to the grease fitting after every 100 hours of operation A B...

Page 32: ...emperature ranges If a locally available hydraulic fluid is preferred or if products of only one oil company are used the hydraulic fluid used must match closely the viscosity specifications given in the chart for TENNANT Hydraulic Fluid as well as the other features described Do not substitute automatic transmission fluid for hydraulic fluid ATTENTION Hydraulic components depend on system hydraul...

Page 33: ...MAINTENANCE 3 9 215E MM158 6 88 03078 HYDRAULIC SCHEMATIC ...

Page 34: ...e level in each battery cell after every 25 hours of operation The electrolyte level must always be above the battery plates Add distilled water to maintain solution at the correct level above the plates but do not overfill Never add acid to batteries only water Keep vent plugs firmly in place at all times except when adding water or taking hydrometer readings FOR SAFETY When Servicing Machine Avo...

Page 35: ...n off switch counterclockwise FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake And Turn Off Machine 3 Open the seat support WARNING Batteries Emit Hydrogen Gas Explosion Or Fire Can Result Keep Sparks And Open Flame Away Keep Covers Open When Charging 4 Check the electrolyte level in the batteries Before charging add just enough distilled water to cover the pl...

Page 36: ...Charge Indicator Lamp C Yellow Charger On Indicator Lamp D Red Incomplete Battery Status Indicator Lamp E Yellow 80 Charge Indicator Lamp F Green Complete Charge Indicator Lamp NOTE If the red no charge indicator lamp lights when the charger is plugged into a wall outlet the charger can not charge the battery meaning there is something wrong with the battery When the lamps stop flashing the red in...

Page 37: ...0 mm above the battery plates 5 Check the specific gravity of the batteries Charge the batteries until the specific gravity is 1 26 to 1 28 6 Add battery acid if necessary to 0 38 in 10 mm above the battery plates 7 Insert battery vent caps in the vent holes 8 Clean the battery posts and cables 9 Install the batteries in the machine 10 Connect the battery cables to the batteries See the STANDARD M...

Page 38: ...MAINTENANCE 215E MM158 11 91 3 14 03089 ELECTRICAL SCHEMATIC For machines below serial number 003860 ...

Page 39: ...MAINTENANCE 3 15 215E MM158 11 91 03089 ELECTRICAL SCHEMATIC For machines serial number 003860 and above ...

Page 40: ...MAINTENANCE 215E MM158 11 91 3 16 03089 ELECTRICAL SCHEMATIC For machines serial number 003860 and above ...

Page 41: ...heaves 7 Pull the fan bracket backward snug the belt and tighten the bracket mounting bolts 8 Replace the transmission belt and the jackshaft belt 9 Check the alignment and tension of the belt as described in DRIVE CHAIN AND BELT ALIGNMENT AND TENSIONING 10 Close seat support TRANSMISSION BELT The transmission belt transfers power from the motor sheave to the transmission Check the belt condition ...

Page 42: ...otor to relieve belt tension A B 03552 BELT ADJUSTMENT BOLT A Adjustment Bolt B Jam Nut 4 Remove the belt A B C 03081 JACKSHAFT BELT A Jackshaft Belt B Motor Sheave C Jackshaft 5 Position the new belt on the sheaves 6 Tighten the adjustment bolt until the belt snugs 7 Check the alignment and tension the belt as described in DRIVE CHAIN AND BELT ALIGNMENT AND TENSIONING 8 Close the seat support INT...

Page 43: ...ng Or Servicing Machine Stop On Level Surface Set Parking Brake And Turn Off Machine 2 Place the side brush position lever in the Side Brush Up position 3 Open the seat support 4 Remove the front right machine frame end cap 5 Remove the front side brush sheave retaining bolt A B C 01794 SIDE BRUSH BELT A Sheave Retaining Bolt B Front Sheave C Side Brush Belt 6 Remove the existing belt 7 Position t...

Page 44: ...f alignment do not stay on sheaves and wear or break more frequently Sheave alignment can be checked as described by placing a straightedge across the sheave faces Be sure to align and tension the belts in the order given TO ALIGN AND TENSION DRIVE CHAINS AND BELTS 1 Stop the motor and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake And ...

Page 45: ... If they are not lined up loosen the sheave set screws align the sheave and retighten the set screws The belt is automatically tensioned by an idler spring assembly C E A B D 03090 DRIVE BELTS A Transmission Sheave B Transmission Belt Spring C Vacuum Fan Belt D Motor Sheave E Jackshaft Belt 8 Check the alignment of the motor sheave with the jackshaft sheave If they are not lined up loosen the jack...

Page 46: ...eave D Belt Idler Spring 13 Check the alignment of the small jackshaft sheave to the main brush sheave If they are not lined up loosen the jackshaft bearing locking collars align the sheaves and tighten the locking collars The belt is automatically tensioned by an idler spring assembly 14 Measure the length of the jackshaft belt tension spring It should be 6 5 in 165 mm To adjust the spring length...

Page 47: ...30 mm from their mounting position A B 03084 HOPPER STOP BOLTS A Hopper B Stop Bolts HOPPER DUST FILTER The hopper dust filter filters the air which is drawn up from the main brush compartment by the vacuum fan It is located inside the dust filter compartment Shake the excess dust from the filter daily Inspect and clean or replace the dust filter after every 50 hours of operation To clean the dust...

Page 48: ...RONT FILTER COVER A Filter Cover B Filter Cover Screw 3 Unplug the shaker motor leads and remove the shaker motor and springs assembly Remove the dust filter A B 03083 DUST FILTER A Dust Filter B Shaker Motor Assembly 4 Inspect and clean or replace the dust filter 5 Position the dust filter in the filter frame with the arrows pointing toward the machine 6 Secure the filter with the shaker motor an...

Page 49: ...adjust the skirt height and retighten the retaining strip 8 Check the skirt clearance 9 Reinstall the right side access door TO REPLACE BRUSH SKIRTS 1 Park the machine on a smooth level floor 2 Stop the motor and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake And Turn Off Machine 3 Unlatch and open the left side access door 4 Remove the...

Page 50: ...o the machine with the retaining strip removed earlier 8 Raise the hopper disengage the hopper support bar and lower the hopper HOPPER DUMP DOOR SEAL The hopper dump door seal is present on multi level dump model machines It allows the hopper to be high dumped without scattering debris Check the seal for damage daily TO REPLACE HOPPER DUMP DOOR SEAL 1 Empty the debris hopper 2 Raise the hopper 3 E...

Page 51: ...Slide the vertical rear skirt up or down so it is 0 to 0 12 in 0 to 5 mm above the floor 8 Retighten the retaining strip bolts HOPPER LIP SKIRT The hopper lip skirt floats over debris and helps deflect that debris into the hopper It is located on the bottom rear of the hopper The hopper lip skirt should be inspected for wear or damage daily TO REPLACE HOPPER LIP SKIRT 1 Empty the machine debris ho...

Page 52: ...p On Level Surface Set Parking Brake And Turn Off Machine 2 Place the main brush position lever in the Main Brush Down position 3 Open the left side access door 4 Remove the brush idler arm retaining bolts from the arm hub A B C 01128 REMOVING MAIN BRUSH IDLER ARM A Brush Idler Arm B Arm Retaining Bolt C Access Door 5 Pull the brush idler arm off the arm hub 6 Grasp the main brush pull it off the ...

Page 53: ... the following leveling procedure A Park the sweeper on a level surface raise the main brush stop the motor and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake And Turn Off Machine B Open the left side access door C Remove the main brush D Reinstall the idler arm Let the front of the arm drop to take up the slack in the holes Retighten t...

Page 54: ...should be replaced when the remaining brush bristle measures 2 5 in 65 mm in length TO REMOVE SIDE BRUSH 1 Stop the motor and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake And Turn Off Machine 2 Place the side brush position lever in the Side Brush Up position 3 Remove the side brush retaining bolt from the side brush hub and s...

Page 55: ...s of power If contaminants are observed on the reservoir screen remove wash and clean it If the reservoir screen has been pierced internal failure may occur The damaged reservoir should be replaced If the transmission oil color has changed to black or milky overheating and or water contamination is indicated The oil should be drained and replaced with new oil NOTE The threads connecting the plasti...

Page 56: ...pintle arm should be adjusted so that the full stroke of the transmission may be obtained without interference from anything other than the stop bolts The forward stop bolt should be adjusted so that the threaded end of the bolt is 0 06 to 0 12 in 2 to 5 mm from the bracket The rear stop bolt should be adjusted so that the threaded end of the bolt is 1 in 25 mm from the bracket The centering sprin...

Page 57: ...roperly adjusted when the parking brake lever will travel 0 50 in 15 mm before engaging the brakes To adjust the brakes remove the clevis pin from each brake assembly turn the clevis ends an equal amount reconnect the clevis pins and recheck the parking brake lever travel A B C D 03073 BRAKE ASSEMBLY A Right Side Tire B Brake Cable C Clevis D Brake Assembly TIRES All of the machine tires are solid...

Page 58: ...MAINTENANCE 215E MM158 11 91 3 34 ...

Page 59: ... TORQUE CHART 4 3 METRIC BOLT TORQUE CHART 4 3 BOLT IDENTIFICATION 4 3 THREAD SEALANT AND LOCKING COMPOUNDS 4 3 HYDRAULIC FITTING INFORMATION 4 4 HYDRAULIC TAPERED PIPE FITTING NPT TORQUE CHART 4 4 HYDRAULIC TAPERED SEAT FITTING JIC TORQUE CHART 4 4 HYDRAULIC O RING FITTING TORQUE CHART 4 4 ...

Page 60: ...APPENDIX 140 MM130 6 88 4 2 ...

Page 61: ... 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 Main brush drive plug nut 30 ft lb 40 Nm then tighten to next slot Brake unit to hub socket head screw 9 to 12 ft lb 12 to 16 Nm with Locktite 242 blue Front wheel nut 10 to 12 ft lb 14 to 16 Nm while turning wheel tighten to spec then backoff ...

Page 62: ...2 Nm 0 38 Nm 0 56 18 20 ft lb 27 0 50 Nm 0 75 16 30 ft lb 41 0 62 Nm 0 88 14 40 ft lb 54 0 75 Nm 1 12 12 70 ft lb 95 1 0 Nm 1 31 12 90 ft lb 122 HYDRAULIC O RING FITTING TORQUE CHART Tube O D in Thread Size Minimum Torque Maximum Torque 0 25 Nm 0 44 20 6 ft lb 8 Nm 9 ft lb 12 0 38 27 Nm 0 56 18 13 ft lb 18 Nm 20 ft lb 16 Nm 10 ft lb 14 Nm 12 ft lb 0 50 41 Nm 0 75 16 20 ft lb 27 Nm 30 ft lb 33 Nm 2...

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Tennant 215E, Operator'S Manual

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