Tennant 235 Operator'S Manual Download Page 37

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MAINTENANCE

3-1

235 MM166 (3--94)

SECTION 3

CONTENTS

Page

RECOMMENDED FIRST 50-HOUR

MACHINE INSPECTION

3-3

. . . . . . . . . . . . .

MAINTENANCE CHART

3-4

. . . . . . . . . . . . . . . .

LUBRICATION

3-6

. . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE

3-6

. . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE BRUSH LEVER PIVOT

3-6

. . . . . . . . .

REAR WHEEL SUPPORT BEARING

3-7

. .

STEERING LINKAGE

3-7

. . . . . . . . . . . . . . . .

HYDRAULICS

3-8

. . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC FLUID

3-8

. . . . . . . . . . . . . . . . .

HYDRAULIC FLUID RESERVOIR

3-8

. . . . .

HYDRAULIC FILTER

3-8

. . . . . . . . . . . . . . . .

TO REPLACE FILTER ELEMENT

3-9

. .

HYDRAULIC PUMPS

3-9

. . . . . . . . . . . . . . . .

TO START AND BREAK-IN

HYDRAULIC PUMP

3-9

. . . . . . . . . . . .

DIRECTIONAL PEDAL

3-10

. . . . . . . . . . . . . . .

TO ADJUST DIRECTIONAL

PEDAL LINKAGE

3-10

. . . . . . . . . . . . . .

LIFT ARM SPEED LIMITER

3-11

. . . . . . . . . .

HYDRAULIC FLUID LEAKS

3-12

. . . . . . . . . .

HYDRAULIC SCHEMATIC

3-13

. . . . . . . . . . .

HYDRAULIC SYSTEM

TROUBLESHOOTING

3-14

. . . . . . . . . . . .

HYDRAULIC COMPONENTS

TROUBLESHOOTING

3-15

. . . . . . . . . . . .

ENGINE

3-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE LUBRICATION

3-16

. . . . . . . . . . . . . .

COOLING SYSTEM

3-16

. . . . . . . . . . . . . . . . .

AIR INTAKE SYSTEM

3-16

. . . . . . . . . . . . . . .

AIR FILTER

3-16

. . . . . . . . . . . . . . . . . . . . . . . .

TO CLEAN OR REPLACE AIR

FILTER ELEMENT

3-16

. . . . . . . . . . . . .

FUEL SYSTEM, GASOLINE

3-17

. . . . . . . . . .

FUEL FILTER

3-17

. . . . . . . . . . . . . . . . . . . .

CARBURETOR

3-17

. . . . . . . . . . . . . . . . . .

FUEL SYSTEM -- LPG

3-18

. . . . . . . . . . . . . . .

LPG FUEL SYSTEM

3-18

. . . . . . . . . . . . . .

FUEL TANKS

3-19

. . . . . . . . . . . . . . . . . . . .

TO CHANGE AN LPG FUEL TANK

3-20

FUEL FILTER LOCK

3-21

. . . . . . . . . . . . . .

VAPORIZER-REGULATOR

3-21

. . . . . . . .

CARBURETOR

3-21

. . . . . . . . . . . . . . . . . .

OIL PRESSURE SWITCH

3-21

. . . . . . . . .

LPG FUEL TROUBLESHOOTING

3-21

. . . . .

ELECTRICAL SYSTEM

3-22

. . . . . . . . . . . . . .

SPARK PLUG

3-22

. . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM

3-22

. . . . . . . . . . . . . . .

STARTER

3-22

. . . . . . . . . . . . . . . . . . . . . . .

Page

CYLINDER HEAD

3-22

. . . . . . . . . . . . . . . . . . .

CYLINDER HEAD

3-22

. . . . . . . . . . . . . . . .

VALVE TAPPET CLEARANCE

3-23

. . . . .

CRANKCASE VENTILATION

SYSTEM

3-23

. . . . . . . . . . . . . . . . . . . . .

TUNE-UP CHART

3-23

. . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM

3-24

. . . . . . . . . . . . . . . . .

BATTERY

3-24

. . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SCHEMATIC

3-25

. . . . . . . . . . .

ELECTRICAL SCHEMATIC,

AUXILIARY SIDE BRUSH

3-26

. . . . . . . . . .

BELTS AND CHAINS

3-27

. . . . . . . . . . . . . . . . . . .

HYDRAULIC PUMP BELT

3-27

. . . . . . . . . . . .

TO REPLACE AND ADJUST

HYDRAULIC PUMP BELT

3-27

. . . . . .

VACUUM FAN BELT

3-27

. . . . . . . . . . . . . . . . .

TO REPLACE AND ADJUST

VACUUM FAN BELT

3-27

. . . . . . . . . . .

MAIN BRUSH BELT

3-29

. . . . . . . . . . . . . . . . .

TO REPLACE MAIN BRUSH BELT

3-29

TAPER LOCK BUSHINGS

3-30

. . . . . . . . . . . .

TO REMOVE TAPER

LOCK BUSHING

3-30

. . . . . . . . . . . . . .

TO INSTALL TAPER

LOCK BUSHING

3-30

. . . . . . . . . . . . . .

STATIC DRAG CHAIN

3-30

. . . . . . . . . . . . . . .

DEBRIS HOPPER AND DUST FILTER

3-31

. . .

DEBRIS HOPPER

3-31

. . . . . . . . . . . . . . . . . . .

TO CHECK AND ADJUST HOPPER

FLOOR CLEARANCE

3-31

. . . . . . . . . .

THERMO SENTRY

3-31

. . . . . . . . . . . . . . . .

TO CHECK THE

THERMO SENTRY

3-31

. . . . . . . . . .

HOPPER DUST FILTER

3-32

. . . . . . . . . . . . .

TO REMOVE AND REPLACE

HOPPER DUST FILTER

3-33

. . . . . . . .

Summary of Contents for 235

Page 1: ...235 MM166 Operator Manual ...

Page 2: ... operated with reasonable care D The machine is maintained regularly per the maintenance instructions provided D The machine is maintained with Tennant Company supplied or equivalent parts Parts and supplies may be ordered by phone or mail from any Tennant Company parts and service center distributor or from any of the Tennant Company subsidiaries Before ordering parts or supplies be sure to have ...

Page 3: ...e of the machine This section gives you specification information on the engine electric motors brake system hydraulics fluid capacities and machine weight to mention a few The section also has a illustration of the top and side view of the machine with the height and width dimensions displayed OPERATION The Operation section of the manual contains information needed to operate the machine This se...

Page 4: ...used on all machines such as 000000 If the column lists zeros on the left of the dash and a number on the right of the dash then the part is used on machines up to and including that machine serial number such as 00000 002345 For parts that are used on machines beginning at and continuing on from a certain serial number the column would list a serial number on the left of the dash and have blank s...

Page 5: ...supplier and TENNANT parts numbers for repair parts Breakdowns for hydraulic and electrical components have TENNANT part numbers for the parts TENNANT supplies The serial numbers listed in any of the parts lists in these sections is a serial number the manufacturer uses to identify design changes in their particular component ORDERING REPAIR PARTS Once you have located a part to order there are se...

Page 6: ...ABOUT THIS MANUAL 235 MM166 5 91 d ...

Page 7: ... 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 And Traffic Rules 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 ...

Page 8: ...nted on the machine in the locations indicated If these or any labels become damaged or illegible install a new label in its place 03403 FOR SAFETY THERMO SENTRYt LABEL LOCATED ON THE LIFT ARM CROSS MEMBER 03402 FOR SAFETY LABEL LOCATED ON THE SIDE OF THE CONTROL PANEL 03486 ...

Page 9: ...ABEL LOCATED ON THE OPERATOR SIDE OF HOPPER LIFT ARM 03397 FAN BELT DRIVE WARNING LABEL LOCATED ON THE VACUUM FAN 03401 HOPPER LIFT ARM PINCH POINT CAUTION LABEL 2 LOCATED ON THE HOPPER LIFT ARMS 03399 FALLING HOPPER WARNING LABEL LOCATED ON THE FRONT OF THE BRUSH WRAP 03486 ...

Page 10: ...UT SWITCH OPTION 2 8 AUXILIARY SIDE BRUSH UP DOWN SWITCH OPTION 2 8 CIRCUIT BREAKERS 2 9 HOPPER SUPPORT BAR 2 9 Page MACHINE OPERATION 2 10 NORMAL SWEEPING OPERATION 2 10 PRE START CHECKLIST 2 10 TO START MACHINE 2 10 TO SWEEP 2 11 TO DUMP HOPPER 2 11 POST OPERATION CHECKLIST ENGINE OPERATING 2 11 TO STOP MACHINE 2 12 POST OPERATION CHECKLIST ENGINE STOPPED 2 12 TO ENGAGE HOPPER SUPPORT BAR 2 12 T...

Page 11: ...N BELT 3 27 TO REPLACE AND ADJUST VACUUM FAN BELT 3 27 MAIN BRUSH BELT 3 29 TO REPLACE MAIN BRUSH BELT 3 29 TAPER LOCK BUSHINGS 3 30 TO REMOVE TAPER LOCK BUSHING 3 30 TO INSTALL TAPER LOCK BUSHING 3 30 STATIC DRAG CHAIN 3 30 Page DEBRIS HOPPER AND DUST FILTER 3 29 DEBRIS HOPPER 3 29 TO CHECK AND ADJUST HOPPER FLOOR CLEARANCE 3 29 THERMO SENTRYt 3 29 TO CHECK THE THERMO SENTRYt 3 31 HOPPER DUST FIL...

Page 12: ...y and Air Intake Group 5 50 Fig 29 Control Panel Group 5 52 Fig 30 Wire Harness Group 5 54 Fig 31 Labels Group 5 56 Page LPG PARTS 6 1 ORDERING REPAIR PARTS 6 3 Fig 1 Engine and Fuel Line Group LPG 6 4 Fig 2 Control Panel Group LPG 6 6 OPTIONS 7 1 ORDERING REPAIR PARTS 7 3 Fig 1 Cab Kit 7 4 Fig 2 Overhead Guard Kit 7 5 Fig 3 Revolving Light Kit Overhead Guard 7 6 Fig 4 Revolving Light Kit Shroud 7...

Page 13: ...S Page MACHINE 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 4 GENERAL MACHINE DIMENSIONS CAPACITIES 1 4 MACHINE WEIGHTS 1 4 MACHINE DIMENSIONS 1 5 ...

Page 14: ...SPECIFICATIONS 235 MM166 5 91 1 2 ...

Page 15: ...e hopper lift side brush drive open center single spool type Pump propelling variable displacement piston type 0 85 cu in 14 cc maximum displacement per revolution 9 1 gpm 35 L min 2400 Propelling system relief pressure 2000 psi 13 790 kPa Pump accessories gear type 0 26 cu in 4 cc displacement 1 1 gpm 4 L min 1000 rpm Side brush and lift cylinder system relief pressure 1350 psi 9310 kPa Motor sid...

Page 16: ...rack front 44 in 1115 mm Wheel base 41 in 1040 mm Main brush width 36 in 915 mm Main brush outside diameter 14 in 355 mm Side brush rotary diameter 19 in 480 mm Sweeping path width total 48 in 1220 mm Hopper capacity 10 cu ft 0 28 m 650 lb 295 kg Dust filter 49 sq ft 4 5 m pleated panel filter element MACHINE WEIGHTS Net weight dry 1840 lb 835 kg GVWR 2780 lb 1260 kg GENERAL MACHINE PERFORMANCE Ma...

Page 17: ...SPECIFICATIONS 1 5 235 MM166 3 93 MACHINE DIMENSIONS SIDE VIEW TOP VIEW 77 5 in 1970 mm 48 in 1220 mm 53 in 1345 mm 03366 ...

Page 18: ...SPECIFICATIONS 235 MM166 5 91 1 6 ...

Page 19: ...EL GAUGE 2 7 FLASHER SWITCH 2 7 STEERING WHEEL 2 7 HORN BUTTON 2 7 SIDE BRUSH LEVER 2 8 SIDE BRUSH ADJUSTMENT KNOB 2 8 AUXILIARY SIDE BRUSH IN OUT SWITCH OPTION 2 8 AUXILIARY SIDE BRUSH UP DOWN SWITCH OPTION 2 8 CIRCUIT BREAKERS 2 9 HOPPER SUPPORT BAR 2 9 Page MACHINE OPERATION 2 10 NORMAL SWEEPING OPERATION 2 10 PRE START CHECKLIST 2 10 TO START MACHINE 2 10 TO SWEEP 2 11 TO DUMP HOPPER 2 11 POST...

Page 20: ...OPERATION 235 MM166 5 91 2 2 ...

Page 21: ...n Manual Is Read And Understood 3 Check the hydraulic fluid level in the hydraulic fluid reservoir See HYDRAULICS in the MAINTENANCE section 4 Check the main brush adjustment See BRUSHES in the MAINTENANCE section 5 Check the engine oil level See ENGINE in the MAINTENANCE section 6 Fill the fuel tank or install an LPG fuel tank on the machine FOR SAFETY When Servicing Machine Keep Flames And Spark...

Page 22: ...ON 235 MM166 5 91 2 4 OPERATION OF CONTROLS A B C D E H G F 03486 MACHINE COMPONENTS A Operator Seat E Hopper B Seat Support F Hopper Inspection Door C Steering Wheel G Side Brush D Filter Cover H Access Door ...

Page 23: ...al N Main Brush Lever C Parking Brake Lever O Choke Knob D Operator Seat P Side Brush Lever E Seat Support Lever Q Vacuum Lever F Side Brush and Hopper Lever R Hour Meter G Throttle Lever S Fuel Level Gauge H Temp Light T Flasher Switch I Amps Light U Steering Wheel J Oil Pressure Light V Horn Button K Hopper Door Switch W Auxiliary Side Brush Switches L Lights Switch ...

Page 24: ...d to the desired position and release the lever SEAT SUPPORT LEVER The seat support lever locks the seat support down To raise the seat support pull the lever and seat support back To lower the seat support hold on to the lever and lower the seat support Do not let the seat support drop or machine damage may occur SIDE BRUSH AND HOPPER LEVER The side brush and hopper lever controls side brush rota...

Page 25: ... into the UP position To lower the main brush push the lever forward and to the left and release it When parking the machine always raise the brush to prevent the bristles from taking a set CHOKE KNOB The choke knob is present on gasoline powered machines and controls the engine choke To engage the choke for cold starting pull the choke knob out To release the choke push the knob in VACUUM LEVER T...

Page 26: ...the right To increase the brush pattern and the side brush contact with the floor turn the knob to the left B A 03386 SIDE BRUSH ADJUSTMENT KNOB A Side Brush Adjustment Knob B Hopper AUXILIARY SIDE BRUSH IN OUT SWITCH OPTION The auxiliary side brush in out switch controls the in and out movement of the auxiliary side brush option To move the brush in press the top of the in out switch To move the ...

Page 27: ...seat support The following chart shows the various circuit breakers and the electrical components they protect PROTECTIVE CIRCUIT DEVICE RATING PROTECTED CB 1 15 A Controls CB 2 10 A Horn CB 3 10 A Filter Shaker CB 4 10 A Hopper Dump Door CB 5 7 A Hopper Dump Door Thermo Sentryt and Air Flow Solenoids CB 6 15 A Lights A B 03491 CIRCUIT BREAKERS A Instrument Panel Bracket B Circuit Breakers HOPPER ...

Page 28: ...achines Slowly open the LPG tank service valve NOTE Opening the service valve too quickly may cause the service valve check valve to stop the flow of LPG fuel If the check valve stops the flow of fuel close the service valve wait a few seconds and slowly open the valve once again 2 The machine operator must be in the operator s seat with the directional pedal in the neutral position and with a foo...

Page 29: ...en release the lever to lower the main brush 3 Move the side brush lever into the Down position 4 Push the side brush and hopper lever into the ON position 5 Press and hold the hopper door switch in the OPEN position 6 Sweep as required TO DUMP HOPPER 1 Push the main brush lever into the UP position 2 Pull the side brush lever into the Raised position 3 Move the vacuum lever to the Filter Shaker p...

Page 30: ...el Surface Set Parking Brake Turn Off Machine And Remove Key 8 LPG powered machines Close the LPG tank service valve POST OPERATION CHECKLIST ENGINE STOPPED Check the skirts for damage wear and adjustment Check for wire or string tangled on the brushes Check to make sure LPG tank service valve is closed Check for LPG odor or frost on LPG hoses and components indicating a leak Check for leaks TO EN...

Page 31: ...r TO DISENGAGE HOPPER SUPPORT BAR 1 Raise the hopper 2 Place the support bar in its storage position 3 Lower the hopper OPERATION ON GRADES Drive the machine slowly on grades Use the brake pedal to control machine speed FOR SAFETY When Using Machine Go Slow On Grades And Slippery Surfaces The maximum rated climb and descent angle is 10_ ...

Page 32: ...ve Poor sweeping performance Brush bristles worn Replace brushes Poor sweeping performance Brushes not adjusted properly Adjust brushes Debris caught in brush drive mechanism Free mechanism of debris Main brush drive failure Belt loose broken or off sheave Side brush drive failure See HYDRAULIC SYSTEM TROUBLESHOOTING Side brush turns slowly or not at all Hopper not adjusted properly Adjust hopper ...

Page 33: ...ower the debris hopper 2 Stop the engine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 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 r...

Page 34: ...ack stands from under the machine 11 Lower the machine 12 Remove the blocks from the tires MACHINE TIE DOWNS The machine may be tied down at each corner of the main frame using the tie down brackets supplied in the tie down kit A 03372 FRONT TIE DOWN LOCATION A Tie Down Bracket When transporting the machine on a trailer or in a truck be sure to set the machine parking brake and block the machine t...

Page 35: ... 30 to 90 days A Remove the spark plugs B Pour 3 oz 90 cc of clean engine oil into each spark plug hole C Remove the ignition coil high tension wire Operate the engine starter motor for ten seconds This distributes the oil over the cylinder walls NOTE Before preparing the engine for storage allow it to cool down to the surrounding temperature Oil adheres to cold metal surfaces much better than hot...

Page 36: ...OPERATION 235 MM166 5 91 2 18 ...

Page 37: ... 18 LPG FUEL SYSTEM 3 18 FUEL TANKS 3 19 TO CHANGE AN LPG FUEL TANK 3 20 FUEL FILTER LOCK 3 21 VAPORIZER REGULATOR 3 21 CARBURETOR 3 21 OIL PRESSURE SWITCH 3 21 LPG FUEL TROUBLESHOOTING 3 21 ELECTRICAL SYSTEM 3 22 SPARK PLUG 3 22 IGNITION SYSTEM 3 22 STARTER 3 22 Page CYLINDER HEAD 3 22 CYLINDER HEAD 3 22 VALVE TAPPET CLEARANCE 3 23 CRANKCASE VENTILATION SYSTEM 3 23 TUNE UP CHART 3 23 ELECTRICAL S...

Page 38: ...IDE BRUSH 3 36 SKIRTS AND SEALS 3 37 BRUSH SKIRTS 3 37 TO REPLACE AND ADJUST BRUSH SKIRTS 3 37 REAR SKIRTS 3 37 TO REPLACE AND ADJUST REAR SKIRTS 3 37 HOPPER LIP SKIRT 3 38 TO REPLACE HOPPER LIP SKIRT 3 38 DUST SEALS 3 38 TO REPLACE DUST SEALS 3 38 HOPPER DUMP DOOR SEAL 3 39 TO REPLACE HOPPER DUMP DOOR SEAL 3 39 VACUUM FAN SEAL 3 40 FILTER COVER SEAL 3 40 BRAKES AND TIRES 3 41 BRAKES 3 41 TIRES 3 ...

Page 39: ...Check the floor skirts to floor clearance See SKIRTS AND SEALS 2 Check the side brush and main brush patterns See BRUSHES 3 Replace hydraulic fluid filter element 4 Torque the rear wheel nuts in a star pattern to 122 to 150 Nm 90 to 110 ft lb See REAR WHEEL 5 Perform all 50 hour interval lubrication and maintenance procedures listed in the MAINTENANCE CHART ...

Page 40: ...Points Daily 1 Engine Check oil level EO 1 4 Brush and rear skirts Check for damage and wear 4 18 Hopper lip skirt Check for damage and wear 1 5 Main brush Check for damage and wear 1 11 Side brush Check for damage and wear 1 25 Hours 1 Engine Clean air filter precleaner 1 Change oil and oil filter EO 1 Clean cooling fins 1 50 Hours 5 Main brush Rotate end for end 1 ...

Page 41: ...6 Vacuum fan belt Check tension 1 2 Hydraulic pump belt Check tension 1 12 Side brush lever pivot Lubricate SPL 1 14 Parking brake Check adjustment 1 16 Rear wheel support Lubricate SPL 1 bearing 13 Steering linkage Lubricate SPL 2 400 Hours 1 Engine Check and adjust idle speed 1 Clean carbon deposits 2 Check valve clearance 4 Check starter motor brushes 1 15 Hydraulic fluid reservoir Change hydra...

Page 42: ...bustion deposits will increase Using other than API class SF oil or extending oil change intervals could cause engine damage not covered by the engine warranty The engine oil capacity is 1 7 qt 1 6 L SIDE BRUSH LEVER PIVOT The side brush lever pivot allows the side brush lever to move freely Lubricate the pivot with Lubriplate EMB grease TENNANT part number 01433 1 after every 200 hours of operati...

Page 43: ...on A B C 03501 REAR WHEEL SUPPORT BEARING A Rear Wheel Support B Support Grease Fitting C Rear Steering Link Grease Fitting STEERING LINKAGE The steering linkage controls machine steering A grease fitting is located on each of the two linkage ball joints for lubrication The linkage should be lubricated by applying Lubriplate EMB grease TENNANT part number 01433 1 to the grease fittings after every...

Page 44: ...OIR Hydraulic fluid is stored in the hydraulic fluid reservoir It holds 3 9 gal 14 8 L of hydraulic fluid The reservoir is located under the seat support The fluid level is checked by looking at the dipstick on the breather filler cap with the hopper in the sweeping position The reservoir is full when the fluid level is above the ADD mark on the dipstick A B 03502 HYDRAULIC FLUID RESERVOIR A Reser...

Page 45: ...n the reservoir and the hydraulic fluid filter Then the proper start and break in procedure must be followed to prevent possible damage to the pump Replace the hydraulic fluid filter after the first hour of operation TO START AND BREAK IN HYDRAULIC PUMP outlines the procedure TO START AND BREAK IN HYDRAULIC PUMP 1 Stop the engine set the machine parking brake and block the front tires of the machi...

Page 46: ...ch the propelling pump sends no hydraulic fluid to the propelling motor The machine should not creep when the neutral position is correctly adjusted Adjust the pedal linkages as described in TO ADJUST DIRECTIONAL PEDAL LINKAGE whenever the machine creeps or after replacing the hydraulic propelling pump or pump linkages The pedal linkages should also be adjusted whenever the reverse speed is excess...

Page 47: ...d The backward travel should be restricted so the machine will not travel faster than 3 mph 5 km h in reverse 11 Tighten the directional pedal ball joints and jam nuts LIFT ARM SPEED LIMITER The lift arm speed limiter limits the forward speed the machine can travel when the hopper is raised The speed limiter should be adjusted whenever the pump control linkage is adjusted The machine should travel...

Page 48: ...to search for suspected leaks A B C 00002 HYDRAULIC PINHOLE LEAK A Cardboard B Pinhole Leak C Magnifying Glass If injured by escaping hydraulic fluid see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately FOR SAFETY When Servicing Machine Use Cardboard To Locate Leaking Hydraulic Fluid Under Pressure ...

Page 49: ...MAINTENANCE 3 13 235 MM166 3 94 03460 HYDRAULIC SCHEMATIC ...

Page 50: ...ilure Hydraulic motor failure See HYDRAULIC COMPONENTS TROUBLESHOOTING Hydraulic motor failure Relief valve in control valve sticking Clean or replace relief valve Gear pump failure See HYDRAULIC COMPONENTS TROUBLESHOOTING Hydraulic gear pump failure Hopper will not lift Hydraulic control valve failure See HYDRAULIC COMPONENTS TROUBLESHOOTING Hydraulic control valve failure Hydraulic orifice at li...

Page 51: ...it Hydraulic motor failure Drive link failure Replace drive link Gerotor worn Replace gerotor set Output shaft failure Replace output shaft and bearings Hydraulic gear pump failure Pump leaking Install seal kit Hydraulic gear pump failure Gear set failure Replace gear set Shaft failure Replace gear set Hydraulic piston pump failure Pump leaking Install seal kit Hydraulic piston pump failure Relief...

Page 52: ... installed improperly serviced or inadequate air filter elements wears out more engines than long hours of operation Even a small amount of dirt will wear out a set of piston rings in just a few hours Operating with a clogged air filter element also causes the fuel mixture to be richer which can lead to formation of harmful sludge deposits in the engine Always cover the air intake when the air cle...

Page 53: ...cleaner with 1 oz 30 cc of clean engine oil Squeeze the precleaner to distribute the oil evenly throughout the foam 16 Slide the foam precleaner over the dry cartridge type filter 17 Position the air filter cover over the air filter assembly Tighten the wing nut on the air filter stud FUEL SYSTEM GASOLINE FUEL FILTER An in line fuel filter has been provided to filter the fuel The filter is located...

Page 54: ...the fuel pressure exceeds system limits From the pressure relief valve the LPG fuel is piped to the fuel filter lock The fuel filter lock filters unwanted tank scale and deposits out of the LPG fuel The fuel filter lock also stops the flow of LPG fuel when the engine is not operating The oil pressure switch controls the fuel filter lock When the engine oil pressure is 4 psi 30 kPa or greater the o...

Page 55: ...are refilled All tank valves must be inspected for leaks using a soap solution Valves must also be checked for dirt paint or other debris in the valve openings The following specific checks must also be made Filler Valve Check for proper functioning and the presence of the handwheel Valve must be closed except during filling Vapor and Liquid Service Valves Check for proper functioning and presence...

Page 56: ...eport the findings to the appropriate personnel TO CHANGE AN LPG FUEL TANK 1 Park the machine in a designated safe area Set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Close the tank service valve 3 Operate the engine until it stops from lack of fuel FOR SAFETY When Servicing Machine Keep Flames ...

Page 57: ...it OIL PRESSURE SWITCH The engine oil pressure switch requires no regular maintenance Never bypass the oil pressure switch as this is a safety feature which prevents LPG fuel from flowing when the engine is not operating properly LPG FUEL TROUBLESHOOTING Problem Cause Remedy Engine will not start Out of fuel Replace fuel tank with full one Engine will not start Service valve opened too quickly eng...

Page 58: ...18 in 0 4 mm for LPG engines IGNITION SYSTEM The engine ignition system is the breakerless type The ignition system needs no regular maintenance The only adjustment is the ignition air module gap which should be set at 0 008 to 0 012 in 0 2 to 0 3 mm STARTER The starter motor brushes must be inspected after every 400 hours of operation CYLINDER HEAD CYLINDER HEAD The cylinder head may develop carb...

Page 59: ... of the valve stem to obtain the proper clearance CRANKCASE VENTILATION SYSTEM Clean the crankcase ventilation hoses tubes and fittings after every 200 hours of operation TUNE UP CHART Idle speed 1000 rpm Maximum governed speed 2200 rpm Spark plug gap gasoline 0 025 in 0 6 mm Spark plug gap LPG 0 018 in 0 4 mm Valve clearances cold intake 0 003 to 0 006 in 0 07 to 0 15 mm Valve clearances cold exh...

Page 60: ...t 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 Avoid Contact With Battery Acid If when checking battery specific gravity one or more battery cells tests lower than the other battery cells 0 050 or more the cell is dam...

Page 61: ...MAINTENANCE 3 25 235 MM166 3 94 03489 ELECTRICAL SCHEMATIC ...

Page 62: ...MAINTENANCE 235 MM166 3 94 3 26 03489 ELECTRICAL SCHEMATIC AUXILIARY SIDE BRUSH ...

Page 63: ...djustment Bolts D Mounting Bolts 5 Slide the pump assembly backward to remove the belt Position the new pump belt on the sheaves 6 Push the pump forward keeping the sheaves aligned and snug the mounting bolts 7 Check belt tension If it meets specification tighten the bolts If not repeat the steps A 04233 CHECKING BELT TENSION A Hydraulic Pump Belt 8 Replace belt guards 9 Lower the seat support VAC...

Page 64: ... Bolts 5 Slide the pump assembly backward to remove the belts 6 Replace the existing vacuum fan belt with a new belt A B 03499 BELTS A Vacuum Fan Belt B Pump Belt 7 Position the pump belt on the sheaves 8 Push the pump forward keeping the sheaves aligned and snug the mounting bolts 9 Tighten the pump belt as described in TO REPLACE AND ADJUST HYDRAULIC PUMP BELT 10 Turn the turnbuckle to tighten t...

Page 65: ...move Key 2 Raise the main brush 3 Open the seat support 4 Remove the vacuum fan belt guard 5 Remove the left side access door 6 Hold the idler spring arm back and remove the belt A C B 03377 MAIN BRUSH BELT A Idler Spring Arm B Main Brush Belt C Stop Bolt 7 Position the new belt on the belt sheaves 8 Replace the vacuum fan belt guard 9 Lower the seat support 10 Start the machine and lower the main...

Page 66: ...dirt 2 Insert bushing into hub be aware of sheave alignment Match hole pattern not threaded holes Each hole will be threaded on one side only 3 Oil set screws Thread them into the half threaded holes 4 Alternately tighten the set screws to 175 in lb 20 Nm 5 Using a block sleeve or drift hammer the end of the bushing Do not hammer bushing directly 6 Repeat steps 4 and 5 until torque wrench reading ...

Page 67: ...top Bolt 5 Check the distance between the floor and the bottom metal edge of the hopper The floor clearance should be 1 in 25 mm across the width of the machine To adjust the hopper floor clearance unlatch and remove the filter cover and adjust the hopper stop bolt B A C 03387 HOPPER STOP BOLT A Hopper B Stop Bolt C Lintel 6 Replace the filter cover and check the hopper cover seal It should be sli...

Page 68: ...ilter daily Inspect and clean or replace the dust filter after every 100 hours of operation To clean the dust filter use one of the following methods D TAPPING Tap the filter gently on a flat surface with the dirty side down Do not damage the edges of the filter element or the filter will not seat properly in the filter frame D AIR Blow compressed air 35 psi 240 kPa maximum through the dust filter...

Page 69: ...he filter and slide the assembly back Remove the dust filter A B D C 03389 DUST FILTER A Dust Filter B Shaker Motor Assembly C Hold Down Screws D Assembly Bolts 4 Inspect and clean or replace the dust filter 5 Position the dust filter in the filter frame with the arrows on the label pointing up 6 Secure the filter with the shaker motor assembly 7 Check the two filter hold down screws They should c...

Page 70: ...ing bolt into the threaded hole on the arm Tighten the bolt until it is tight against the backing plate Push on the brush end of the arm and retighten the bolt Repeat until the arm is loose 6 Grasp the main brush pull it off the brush drive plug and out of the main brush compartment TO INSTALL MAIN BRUSH 1 Push the main brush lever into the UP position 2 Slide the main brush into the main brush co...

Page 71: ...l number 002594 and above A Brush Limiter Nut B Main Brush Lever Slot To decrease the width of the brush pattern move the limiter nut forward and tighten the nut To increase the brush pattern width move the limiter nut back and tighten the nut If the main brush pattern is tapered wider on one side by 0 50 in 15 mm or more than the other side perform the following leveling procedure 00601 TAPERED M...

Page 72: ...ob on the front bumper The side brush should be replaced when the remaining brush bristle measures 2 5 in 65 mm in length TO REMOVE SIDE BRUSH 1 Raise the hopper 2 Engage the hopper support bar WARNING Falling Hopper Engage Hopper Support Bar Read Manual 3 Stop the engine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn O...

Page 73: ... RIGHT SIDE BRUSH SKIRT A Retaining Strip B Brush Skirt 5 Replace the doors 6 Check the skirt clearance REAR SKIRTS The rear skirts seal the brush compartment They are located on the bottom rear of the brush compartment The seals should be inspected for wear or damage daily TO REPLACE AND ADJUST REAR SKIRTS 1 Park the machine on a smooth level surface 2 Stop the engine and set the machine parking ...

Page 74: ...skirt retaining strip and the skirt A B C 03384 HOPPER LIP SKIRT A Hopper B Lip Skirt C Retaining Strip 6 Position the new skirt on the hopper Secure it with the retaining strip 7 Raise the hopper position the hopper support bar in its storage location and lower the hopper DUST SEALS Three seals control hopper dusting They are the top left and right side hopper seals They should be inspected for w...

Page 75: ...Check the seal for damage after every 100 hours of operation TO REPLACE HOPPER DUMP DOOR SEAL 1 Empty the debris hopper 2 Raise the hopper 3 Engage the hopper support bar WARNING Falling Hopper Engage HopperSupport Bar Read Manual 4 Stop the engine and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Ke...

Page 76: ...r cover Check the seal for damage after every 100 hours of operation A 03387 VACUUM FAN SEAL A Vacuum Fan Seal FILTER COVER SEAL The filter cover seal seals the filter box to the filter cover Check the seal for damage after every 100 hours of operation A B 03375 FILTER COVER SEAL A Filter Cover B Seal ...

Page 77: ...e parking brake clockwise If the knob adjustment is inadequate remove the clevis pin from each brake assembly turn the clevis ends an equal amount reconnect the clevis pins and readjust the parking brake B A 03369 BRAKE ASSEMBLY A Clevis B Brake Rod TIRES The front machine tires are solid The rear tire is pneumatic Proper air pressure is 90 psi 620 kPa They should be inspected for wear after every...

Page 78: ...MAINTENANCE 235 MM166 3 94 3 42 ...

Page 79: ... 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 80: ...APPENDIX 235 MM166 5 91 4 2 ...

Page 81: ...t lb Nm 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 Main brush drive plug nut 30 ft lb 40 Nm then tighten to next slot Brake unit to hub sockethead screw 9 to 12 ft lb 12 to 16 Nm...

Page 82: ...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 Thread Minimum Maximum O D in Size Torque 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 ...

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Tennant 235, Operator'S Manual

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