Tennant 235E Operator'S Manual Download Page 33

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MAINTENANCE

3-1

235E MM165 (8--95)

SECTION 3

CONTENTS

Page

RECOMMENDED FIRST 50-HOUR MACHINE

INSPECTION

3-3

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

MAINTENANCE CHART

3-4

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

LUBRICATION

3-6

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

GEARBOX

3-6

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

REAR WHEEL SUPPORT BEARING

3-6

. .

SIDE BRUSH LEVER PIVOT

3-6

. . . . . . . . .

STEERING LINKAGE

3-7

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

HYDRAULICS

3-8

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

HYDRAULIC FLUID

3-8

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

HYDRAULIC FLUID RESERVOIR

3-8

. . . . .

HYDRAULIC FILTER

3-9

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

TO REPLACE FILTER ELEMENT

3-9

. .

HYDRAULIC FLUID LEAKS

3-9

. . . . . . . . . .

HYDRAULIC SCHEMATIC

3-10

. . . . . . . . . . .

HYDRAULIC SYSTEM

TROUBLESHOOTING

3-11

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

HYDRAULIC COMPONENTS

TROUBLESHOOTING

3-12

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

ELECTRICAL SYSTEM

3-13

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

BATTERIES

3-13

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

BATTERY CHARGING

3-14

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

TO CHARGE BATTERIES

3-14

. . . . . . . . .

ELECTRIC MOTORS

3-16

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

PROPELLING SYSTEM

TROUBLESHOOTING

3-17

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

PROPELLING CIRCUIT

3-18

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

TO ADJUST “NEUTRAL”POSITION 3-18

ELECTRICAL SCHEMATIC (For machine

below serial number 002205)

3-19

. . . .

ELECTRICAL SCHEMATIC (For machines

from serial number 002205

to 002310)

3-20

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

ELECTRICAL SCHEMATIC (For machines

serial number 002311 and above) 3-21

ELECTRICAL SCHEMATIC, AUXILIARY

SIDE BRUSH (For machines serial

number 002311 and above)

3-22

. . . . . . . .

BELTS AND CHAINS

3-23

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

HYDRAULIC PUMP BELT

3-23

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

TO REPLACE AND ADJUST

HYDRAULIC PUMP BELT

3-23

. . . . . .

VACUUM FAN BELT

3-24

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

TO REPLACE AND ADJUST

VACUUM FAN BELT

3-24

. . . . . . . . . . .

MAIN BRUSH BELT

3-25

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

TO REPLACE MAIN BRUSH BELT

3-25

TAPER LOCK BUSHINGS

3-26

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

TO REMOVE TAPER

LOCK BUSHING

3-26

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

TO INSTALL TAPER

LOCK BUSHING

3-26

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

STATIC DRAG CHAIN

3-26

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

Page

DEBRIS HOPPER AND DUST FILTER

3-27

. . .

DEBRIS HOPPER

3-27

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

TO CHECK AND ADJUST

HOPPER FLOOR CLEARANCE

3-27

THERMO SENTRY

3-27

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

TO CHECK THE

THERMO SENTRY

3-27

. . . . . . . . . .

HOPPER DUST FILTER

3-28

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

TO REMOVE AND REPLACE

HOPPER DUST FILTER

3-29

. . . . . . . .

BRUSHES

3-30

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

MAIN BRUSH

3-30

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

TO REMOVE MAIN BRUSH

3-30

. . . . . . .

TO INSTALL MAIN BRUSH

3-30

. . . . . . . .

TO CHECK AND ADJUST MAIN

BRUSH PATTERN

3-30

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

SIDE BRUSH

3-32

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

TO REMOVE SIDE BRUSH

3-32

. . . . . . . .

TO INSTALL SIDE BRUSH

3-32

. . . . . . . .

SKIRTS AND SEALS

3-33

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

BRUSH SKIRTS

3-33

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

TO REPLACE AND ADJUST

BRUSH SKIRTS

3-33

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

REAR SKIRTS

3-33

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

TO REPLACE AND ADJUST

REAR SKIRTS

3-33

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

HOPPER LIP SKIRT

3-34

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

TO REPLACE HOPPER LIP SKIRT

3-34

DUST SEALS

3-34

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

TO REPLACE DUST SEALS

3-34

. . . . . . .

HOPPER DUMP DOOR SEAL

3-35

. . . . . . . .

TO REPLACE HOPPER DUMP

DOOR SEAL

3-35

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

VACUUM FAN SEAL

3-36

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

FILTER COVER SEAL

3-36

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

BRAKES AND TIRES

3-37

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

BRAKES

3-37

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

TIRES

3-37

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

REAR WHEEL

3-37

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

Summary of Contents for 235E

Page 1: ...235E MM165 Operator Manual ...

Page 2: ...e 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 your machine model number and seria...

Page 3: ...ce 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 s...

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 235E MM165 3 91 d ...

Page 7: ... 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 And Traffic Rules 5 Before Leaving Or Servicing Machine Stop On Leve...

Page 8: ...dicated If these or any labels become damaged or illegible install a new label in its place 03402 03403 03400 03365 FOR SAFETY LABEL LOCATED ON THE SIDE OF THE CONTROL PANEL FOR SAFETY THERMO SENTRYt LABEL LOCATED ON THE LIFT ARM CROSS MEMBER EXPLOSIVE GAS CAUTION LABEL 2 LOCATED ON THE INSIDE OF THE SEAT SUPPORT ...

Page 9: ...ER SUPPORT BAR WARNING LABEL LOCATED ON THE OPERATOR SIDE OF HOPPER LIFT ARM FAN BELT DRIVE WARNING LABEL LOCATED ON THE VACUUM FAN HOPPER LIFT ARM PINCH POINT CAUTION LABEL 2 LOCATED ON THE HOPPER LIFT ARMS FALLING HOPPER WARNING LABEL LOCATED ON THE FRONT OF THE BRUSH WRAP ...

Page 10: ...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 AND FUSES 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 10 TO DUMP HOPPER 2 11 POST OPERATION CHECKLIST MOTOR OPERATING 2 11 TO STOP MACHINE 2 11 POST ...

Page 11: ...K AND ADJUST HOPPER FLOOR CLEARANCE 3 27 THERMO SENTRYt 3 27 TO CHECK THE THERMO SENTRYt 3 27 HOPPER DUST FILTER 3 28 TO REMOVE AND REPLACE HOPPER DUST FILTER 3 29 BRUSHES 3 30 MAIN BRUSH 3 30 TO REMOVE MAIN BRUSH 3 30 TO INSTALL MAIN BRUSH 3 30 TO CHECK AND ADJUST MAIN BRUSH PATTERN 3 30 SIDE BRUSH 3 32 TO REMOVE SIDE BRUSH 3 32 TO INSTALL SIDE BRUSH 3 32 Page SKIRTS AND SEALS 3 33 BRUSH SKIRTS 3...

Page 12: ...s Group 5 52 Fig 29 Labels Group 5 54 Page OPTIONS 6 1 ORDERING REPAIR PARTS 6 3 Fig 1 Cab Kit 6 4 Fig 2 Overhead Guard Kit 6 6 Fig 3 Revolving Light Kit Overhead Guard 6 7 Fig 4 Revolving Light Kit Shroud 6 8 Fig 5 Battery Kit 295 A h Wet 6 9 Fig 6 Battery Kit 295 A h Dry International Only 6 10 Fig 7 Battery Kit 306 A h Wet 6 11 Fig 8 Battery Kit 306 A h Dry International Only 6 12 Fig 9 Battery...

Page 13: ...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 14: ...SPECIFICATIONS 235E MM165 3 91 1 2 ...

Page 15: ... 30 mm diameter rod 3000 psi 20 685 kPa maximum rated pressure Filter spin on type 10 micron nominal 25 psi 170 kPa bypass pressure BRAKING SYSTEM Service brakes mechanical drum brakes 2 1 per front wheel linkage actuated Parking brakes utilizes service brakes linkage actuated SUSPENSION SYSTEM Front 15 x 3 00 solid tires 2 Rear 16 x 4 00 solid tire 1 SYSTEM FLUID CAPACITIES Hydraulic system reser...

Page 16: ...SPECIFICATIONS 235E MM165 3 91 1 4 MACHINE DIMENSIONS SIDE VIEW TOP VIEW 77 5 in 1970 mm 48 in 1220 mm 53 in 1345 mm 03366 ...

Page 17: ...EERING 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 AND FUSES 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 10 TO DUMP HOPPER 2 11 POST OPERATION CHECKLIST MOT...

Page 18: ...OPERATION 235E MM165 3 91 2 2 ...

Page 19: ... A 00879 CHECKING 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 battery connector to the machine connector A B 03367 BATTERY CONNECTOR A Machine...

Page 20: ...ON 235E MM165 3 91 2 4 OPERATION OF CONTROLS C A B H D F E G 03365 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 21: ...tch B Directional Pedal K Main Brush Lever C Parking Brake Lever L Vacuum Lever D Operator Seat M Hour Meter E Seat Support Lever N Battery Condition Gauge F Side Brush and Hopper Lever O Flasher Switch G Hopper Door Switch P Steering Wheel H Accessory Switch Q Horn Button I Light Switch R Side Brush Lever S Auxiliary Side Brush Switches ...

Page 22: ...tighten the bolts The seat support has a cutout switch that stops the machine whenever the seat support is not down ADJUSTABLE SEAT LEVER OPTION The adjustable seat lever option controls the front to rear position of the seat Pull the lever out slide the seat backward or forward to the desired position and release the lever SEAT SUPPORT LEVER The seat support lever locks the seat support down To r...

Page 23: ...er of hours the machine has operated This information is useful in determining when to service the machine BATTERY CONDITION GAUGE The battery condition gauge indicates the present state of charge of the batteries The display should be on the F mark of the gauge when the batteries are fully charged As the batteries discharge the display will move down near the E mark and start to blink The batteri...

Page 24: ... 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 25: ... under the seat support The fuses are located in the speed controller box The following chart shows the various circuit breakers and fuses and the electrical components they protect PROTECTIVE CIRCUIT DEVICE RATING PROTECTED CB 1 10 A Battery gauge Accessories CB 2 10 A Horn CB 3 10 A Filter Shaker CB 4 10 A Hopper Dump Door CB 5 2 5 A Hopper Dump Door Thermo Sentryt and Air Flow Solenoids CB 6 15...

Page 26: ... Starting Machine Make Sure All Safety Devices Are In Place And Operate Properly 2 Turn the key operated on off switch key to the ON position 3 Release the machine parking brake 4 Drive the machine to the area to be swept TO SWEEP Plan the sweeping in advance Try to arrange long runs with minimum stopping and starting Sweep debris from very narrow aisles into main aisles ahead of time Do an entire...

Page 27: ...d hopper lever to the LOWER position to lower the hopper 11 Press and hold the hopper door switch in the OPEN position to open the hopper door POST OPERATION CHECKLIST MOTOR OPERATING Check the brush patterns for width and evenness TO STOP MACHINE 1 Return the directional pedal to the neutral position Apply the brake 2 Push the main brush lever into the UP position 3 Pull the side brush lever back...

Page 28: ...pport bar on the bar stand B A 03369 HOPPER SUPPORT BAR STAND A Bar Stand B Support Bar 4 Slowly lower the hopper so the bar is secure A B 03370 ENGAGED HOPPER SUPPORT BAR A Lift Arm B Support Bar 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...

Page 29: ...ism 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 floor clearance Hopper dump door closed Open dump door Hopper full Empty hopper Hopper floor skirts worn damaged Replace skirts Machine moves with jerky motion like runnin...

Page 30: ... bumper TO JACK UP MACHINE 1 Empty and lower the debris hopper 2 Stop the motor 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...

Page 31: ...jack 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 ...

Page 32: ...ods of time the following procedures must be followed to lessen the chance of rust sludge or other undesirable deposits from forming 1 Empty the debris hopper 2 Raise the main brush and side brush 3 Park the machine in a cool dry area 4 Remove or charge the batteries for four hours once every three months ...

Page 33: ...nd above 3 22 BELTS AND CHAINS 3 23 HYDRAULIC PUMP BELT 3 23 TO REPLACE AND ADJUST HYDRAULIC PUMP BELT 3 23 VACUUM FAN BELT 3 24 TO REPLACE AND ADJUST VACUUM FAN BELT 3 24 MAIN BRUSH BELT 3 25 TO REPLACE MAIN BRUSH BELT 3 25 TAPER LOCK BUSHINGS 3 26 TO REMOVE TAPER LOCK BUSHING 3 26 TO INSTALL TAPER LOCK BUSHING 3 26 STATIC DRAG CHAIN 3 26 Page DEBRIS HOPPER AND DUST FILTER 3 27 DEBRIS HOPPER 3 27...

Page 34: ...MAINTENANCE 235E MM165 3 91 3 2 ...

Page 35: ... AND SEALS 2 Check the side brush and main brush patterns See BRUSHES 3 Change the gearbox gear lubricant and the drain and fill level plug seals 4 Tighten the wheel nuts 5 Replace the hydraulic fluid filter element 6 Torque the rear wheel nuts in a star pattern to 122 to 150 Nm 90 to 110 ft lb See REAR WHEEL 7 Perform all 50 hour interval lubrication and maintenance procedures listed in the MAINT...

Page 36: ...opper lip skirt Check for damage and wear 1 1 Main brush Check for damage and wear 1 9 Side brush Check for damage and wear 1 50 Hours 1 Main brush Rotate end for end 1 100 Hours 1 Dust Seals Check for damage and wear 6 6 Dust filter Clean or replace 1 5 Hydraulic reservoir Check fluid level HYDO 1 6 Thermo Sentryt Test 1 14 Rear tire Inspect for wear 1 10 Front tires Inspect for wear 2 15 Gearbox...

Page 37: ...7 Steering linkage Lubricate SPL 2 400 Hours 5 Hydraulic fluid reservoir Change hydraulic fluid HYDO 1 4 Hydraulic fluid filter Change filter element 1 800 Hours 13 Rear wheel Torque wheel nuts 1 1000 Hours 15 Gearbox Change gear lubricant GL 1 3 Accessory motor Check brushes 1 16 Propelling motor Check brushes 1 GL SAE 90 Gear weight lubricant HYDO TENNANT or approved hydraulic fluid SPL Special ...

Page 38: ...the ground Fill one grease fitting with Lubriplate EMB grease Tennant Part No 01433 1 while rotating the gearbox from stop to stop Fill the second grease fitting while rotating the gearbox back to the original postition The bearing cavity is full when grease comes out of the fitting or out of the top seal Apply the lubricant after every 200 hours of operation or after steam cleaning the propelling...

Page 39: ...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 200 hours of operation A B 03394 FRONT STEERING LINK A Steering Link B Grease Fitting B A 03367 REAR STEERING LINK A Steering Link B Grease Fitting ...

Page 40: ...ents depend on system hydraulic fluid for internal lubrication Malfunctions accelerated wear and damage will result if dirt or other contaminants enter the hydraulic system HYDRAULIC FLUID RESERVOIR Hydraulic fluid is stored in the hydraulic fluid reservoir It holds 1 gal 3 8 L of hydraulic fluid The reservoir is mounted on the back of the hydraulic pump The fluid level is checked by opening the f...

Page 41: ... element 4 Apply a thin coat of hydraulic fluid to the seal of the new hydraulic fluid filter element 5 Thread and hand tighten the new hydraulic fluid filter element on the filter head 6 Close the seat support 7 Operate the machine and check for leaks Correct any leaks found 8 Check the hydraulic fluid reservoir level and fill as required HYDRAULIC FLUID LEAKS Fluid escaping from a very small hol...

Page 42: ...MAINTENANCE 235E MM165 3 94 3 10 03380 HYDRAULIC SCHEMATIC ...

Page 43: ...Hopper will not lift Hydraulic control valve failure See HYDRAULIC COMPONENTS TROUBLESHOOTING Hydraulic control valve failure Hydraulic orifice at lift cylinder plugged Replace orifice Lift cylinder failure See HYDRAULIC COMPONENTS TROUBLESHOOTING Hydraulic cylinder failure Gear pump failure See HYDRAULIC COMPONENTS TROUBLESHOOTING Hydraulic gear pump failure Hopper overloaded Empty hopper Lift ar...

Page 44: ...leaking Install seal kit Hydraulic control valve failure Relief valve stuck open leaking Clean or replace relief valve Hydraulic motor failure Motor leaking Install seal kit 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 pum...

Page 45: ...tops of the batteries clean and dry Keep all metallic objects off the top of the batteries as they may cause a short circuit Replace worn or damaged wires Check the electrolyte level in each battery cell before and after charging the batteries Never add acid to batteries only water Do not overfill Keep vent plugs firmly in place at all times except when adding water or taking hydrometer readings F...

Page 46: ...ger to water Do not touch uninsulated battery terminals or unnecessarily expose any portion of your body to the batteries when making electrical connections TO CHARGE BATTERIES 1 Stop the machine on a flat dry surface next to the charger 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 2 Place t...

Page 47: ...OTE 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 incomplete battery status indicator lamp lights After a short delay the yellow charger on indicator lamp lights showing the charger has turned on A B C D E F 06898 CHARGER PANEL A ...

Page 48: ...Lower the seat support ELECTRIC MOTORS The electric propelling motor and the accessory motor are repairable Blow out the dust and inspect the motor brushes in the motors after every 1000 hours of operation If the brushes are broken cracked chipped or have been worn to less than 0 62 in 15 mm in length on the short side on the propelling motor or 0 38 in 10 mm on the accessory motor replace them Re...

Page 49: ...ss when braking M1 and M2 contactor failure Replace M1 and M2 contactor Weak and uneven braking forward and reverse M1 and M2 contactor failure Replace M1 and M2 contactor Very strong braking Armature and field wires interchanged Correct wire installation Contactors close little or no power High pitched whistle Loose connections Locate and fix or replace wires Contactors close little or no power H...

Page 50: ...hen Servicing Machine Disconnect Battery Connections Before Working On Machine C C A D B E 03630 CONTROLLER PANEL A 80 A Fuse Main B Controller C Contactor D Logic Board E 40 A Fuse Accessory TO ADJUST NEUTRAL POSITION Loosen the set screws on the accelerator shaft and allow the pedal to center First tighten the set screw on the round part of the shaft then the set screw on the flat part of the sh...

Page 51: ...MAINTENANCE 3 19 235E MM165 3 93 03382 ELECTRICAL SCHEMATIC For machine below serial number 002205 ...

Page 52: ...MAINTENANCE 235E MM165 3 93 3 20 03382 ELECTRICAL SCHEMATIC For machines from serial number 002205 to 002310 ...

Page 53: ...MAINTENANCE 3 21 235E MM165 3 94 03382 ELECTRICAL SCHEMATIC For machines serial number 002311 and above ...

Page 54: ...MAINTENANCE 235E MM165 3 94 3 22 03382 ELECTRICAL SCHEMATIC AUXILIARY SIDE BRUSH For machines serial number 002311 and above ...

Page 55: ... Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove 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 main brush belt idler spring arm back and remove the main brush belt A B 03377 IDLER SPRING A Idler Spring Arm B Main Brush Belt 7 Loosen the motor adjustment and mounting bolts ...

Page 56: ...ension after every 200 hours of operation The belt is properly tensioned when the belt deflects 0 25 in 6 mm from a force of 6 lb 3 kg applied at belt midpoint TO REPLACE AND ADJUST VACUUM FAN BELT 1 Stop the motor and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Open the seat support 3 Remove the bel...

Page 57: ...t the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Raise the main brush 3 Open the seat support 4 Remove the left side access door and vacuum fan belt guard 5 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 6 Hold the idler spring...

Page 58: ...rt 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 55 in lb 6 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 is the same a...

Page 59: ... BUMPER STOP BOLT A Stop Bolt B Frame 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 C A 03387 HOPPER STOP BOLT A Hopper B Stop Bolt C Lintel 6 Replace the filter cover and check the hoppe...

Page 60: ...ke the excess dust from the filter 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 ma...

Page 61: ...the 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 Screw 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 decal pointing up 6 Secure the filter with the shaker motor assembly 7 Check the two filter hold down screws They should c...

Page 62: ...ad the retaining 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 Raise the main brush 2 Slide the main brush into the main brush compartment 3 A...

Page 63: ...serial 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 TAPE...

Page 64: ...t knob 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 Before Working Under Hopper 3 Stop the motor and set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set P...

Page 65: ...HT 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 motor and set the machine parking brake...

Page 66: ...the 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 f...

Page 67: ...ck 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 Hopper Support Bar Before Working Under Hopper 4 Stop the motor and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remo...

Page 68: ...er 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 69: ...he knurled knob on the end of the 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 All of the machine tires are solid They should be inspected for wear after every 100 hours of operation REAR WHE...

Page 70: ...MAINTENANCE 235E MM165 3 94 3 38 ...

Page 71: ...T 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 72: ...APPENDIX 235E MM165 3 91 4 2 ...

Page 73: ... 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 with Locktite 242 blue Front wheel nut 10 to 12 ft lb 14 to 16 Nm while turning wheel tighten to spec then backo...

Page 74: ...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 235E, Operator'S Manual

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