235 (operator Manual) Mm166

Transcript

235 (Operator Manual) MM166 This manual is furnished with each new TENNANT Model 235. It provides necessary operating and preventive maintenance instructions. Read this manual completely and understand the machine before operating or servicing it. This manual covers all machine variations and standard accessories. The tabbed instruction portion of the manual consists of the Specification, Operation, Maintenance, and Appendix sections. The tabbed parts section consists of the Standard Model Parts; LPG Parts; Options; Hydraulic Components; Engine Parts, Gasoline, LPG; and Cross Reference sections. All right side and left side references to the machine are determined by facing the direction of forward travel. All hardware considered to be of a common nature or locally available has been omitted from the parts sections. Be aware that this machine may contain metric hardware. Make sure you use equivalent hardware when replacement becomes necessary. This machine will provide excellent service. However, the best results will be obtained at minimum costs if: D D D The machine is operated with reasonable care. The machine is maintained regularly -- per the maintenance instructions provided. 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 serial number handy. Fill out the data block below for future reference. The telephone numbers, telex numbers, mailing addresses, and locations of those outlets are listed in the Customer Documents section of the manual. MACHINE DATA Please fill out at time of installation. Machine Serial Number -Engine Serial Number -Sales Representative -Customer Number -Date of Installation -Manual Number -- MM166 Revision: 10 Published: 8--95 Trademark Registered in: Austria, Benelux, Denmark, England, France, Germany, Italy, Spain, Switzerland, United States, Argentina, Australia, Canada, Japan, Mexico, Sweden, by TENNANT COMPANY, Minneapolis, Minnesota, U.S.A. Acknowledgments: Technical information and/or illustrations supplied by Kolher Company, Engine Division. Copyright 1986, 1987,1988, 1989, 1991, 1993, 1994, 1995 Tennant Company, Printed in U.S.A. ABOUT THIS MANUAL ABOUT THIS MANUAL The machine manual that you received with your TENNANT machine contains valuable information about the operation and maintenance, and numerous sections filled with TENNANT part numbers for the repair of the machine. Please read through this section titled ABOUT THIS MANUAL to become familiar with the contents of the machine manual, making the information you are looking for easier to find. The machine manual consists of several sections of reference information, and the remainder contain part number information for ordering repair parts for the machine. Each section has a shaded bar at the top of the page with the name of that section. Just as this section has the title ABOUT THIS MANUAL on the top of each page. This way you can tell which section you are in at all times. REFERENCE SECTIONS The reference information sections of the manual are; General Information, Specifications, Operation, Maintenance, and Appendix. GENERAL INFORMATION -- The General Information section of the manual contains the safety precautions, the location of the safety labels on the machine, and a table of contents of the entire manual. The Safety Precautions are an overview of the safety measures to be observed when operating and maintaining your machine. The location of the safety labels show the mounting location of the safety labels for use in the replacement of the labels. The table of contents in this section is a list of all the table of contents that appear in the front of each section in the manual. This can be used for easy reference to locate information in a particular section of the manual. SPECIFICATIONS -- The Specifications section of the manual contains machine specification information useful in the operation and maintenance 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. 235 MM166 (5--91) OPERATION -- The Operation section of the manual contains information needed to operate the machine. This section will list the controls and instruments on the machine, overview the machine operation, and tell you how to transport and store the machine. MAINTENANCE -- The Maintenance section contains information on the suggested maintenance procedures and adjustments to keep your machine in top operating condition. The section includes a Maintenance Chart listing the maintenance schedule and the areas of the machine to be addressed. Each subject of maintenance is covered in more detail in such areas as Lubrication, Hydraulics, Engine, and Electrical System. APPENDIX -- The Appendix contains hardware and hydraulic information. Standard hardware torques and identification information is included, plus hydraulic torques if your machine is hydraulically controlled. PART SECTIONS The remaining sections of the manual contain part number information for ordering repair parts for your machine. The manual contains part number information on every type of machine model available in the model size of your particular machine. Therefore there will be part number information in your manual you will not need to refer to when wanting to place an order. The main thing you need to know about your machine is what type of model is it. Is the machine powered by an engine or batteries? If the machine has an engine, is it fueled from gasoline, LPG, or diesel? If it is a mid-sized or larger sweeper, is it multi-level or low dump? For the scrubbers, is it SRSror standard. Determining this information about your machine will help guide you through the separate parts sections to find the repair part you need. a ABOUT THIS MANUAL The smaller line of sweeper and scrubbers have less complicated part section arrangement, and are easier to find your way through the parts sections. The larger machines can have quite a variety of model types which significantly increases the size to the machine manual. Because of this, on the larger machine we made the first part section, Section 5, a part section which contains parts common to all type of the machine. If the machine has an engine, this section contains parts information on a gasoline powered machine. The remaining sections contain only parts information which is unique to that particular machine type, such as unique diesel parts on the machine, or unique SRSrparts. Knowing the machine model type you have is important when searching for that part information you need for ordering repair parts. Start in that unique section first when looking for a part, then go to the first parts section, Section 5, if the part can’t be found in the unique section. MACHINE SERIAL NUMBERS When a design change takes place to a machine, the changes are indicated in the parts sections with machine serial numbers. Know the serial number of your machine which can be found on the machine data plate mounted on the machine. Record this number on the inside front cover of your manual along with your customer number. Machine number usage is recorded in the Machine Serial Number column of the parts lists in the parts sections of the manual. If the machine serial number column lists zeros on the left side of the dash, then this part is 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). b 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 spaces on the right side of the dash; such as (002346-). This part would be used on machines starting with that machine serial number and greater. Finally, parts can be used on machines with serial numbers in a certain block of numbers. In this situation there is a serial number on the left and right side of the dash. The part is then used on a machine with a serial number starting at the number on the left and up to and including the number on the right; such as (002346--008900). PARTS ASSEMBLIES A part assembly has parts within the assembly, such as a parking brake consisting of other smaller parts. What parts are contained in a part assembly can be determined by an indentation arrangement in the description column of the parts lists. Here is an example of a part assembly, in this case we will use the parking brake mentioned previously: Machine Serial Number (000000-) (000000-) (000000-) (000000-) (000000-) (000000-) (000000-) (000000-) (000000-) Description Qty. Parking Brake 1 Pin, Roll 1 Link 1 Spring, Compression 1 Pin, Roll 1 Support 1 Lever, Release 1 Rod, Parking Brake 1 Washer, 0.50” 3 In this example, the parts whose descriptions are indented under the parking brake are all parts of the parking brake. When you order the parking brake you will receive all the parts listed under it. You also can order any of the individual parts listed under the parking brake if it is the only part you need. 235 MM166 (5--91) ABOUT THIS MANUAL SUPPLIER COMPONENT BREAKDOWNS ORDERING REPAIR PARTS TENNANT purchases certain components of the machine from suppliers. Some of these components are engines, hydraulic pumps and motors, electric motors, and solution pumps. Once you have located a part to order, there are several things you need to have to place the order. At the beginning of each parts section is an Ordering Repair Parts page which lists the information you will need to place your order. Review this list before placing the order. For those purchased components that are repairable, lists of parts for them appear in the later part of the parts sections. These are the supplier breakdowns. The engine breakdown contains both 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. 235 MM166 (5--91) c ABOUT THIS MANUAL d 235 MM166 (5--91) GENERAL INFORMATION SAFETY PRECAUTIONS The following symbols are used throughout this manual as indicated in their descriptions: WARNING: To warn of hazards or unsafe practices which could result in severe personal injury or death. FOR SAFETY: To identify actions which must be followed for safe operation of equipment. The following information signals potentially dangerous conditions to the operator or equipment. Read this manual carefully. Know when these conditions can exist. Locate all safety devices on the machine. Then, take necessary steps to train machine operating personnel. Report machine damage or faulty operation immediately. Do not use the machine if it is not in proper operating condition. FOR SAFETY: 1. Do Not Operate Machine: -- Unless Trained And Authorized. -- Unless Operation Manual Is Read And Understood. -- In Flammable Or Explosive Areas Unless Designed For Use In Those Areas. -- In Areas With Possible Falling Objects Unless Equipped With Overhead Guard. 2. Before Starting Machine: -- Check For Fuel Leaks. -- Keep Sparks And Open Flame Away From Refueling Area. -- Make Sure All Safety Devices Are In Place And Operate Properly. -- Check Brakes And Steering For Proper Operation. 3. When Starting Machine: -- Keep Foot On Brake And Directional Pedal In Neutral. 4. When Using Machine: -- Use Brakes To Stop Machine. -- Go 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. 235 MM166 (5--91) 5. Before Leaving Or Servicing Machine: -- Stop On Level Surface. -- Set Parking Brake. -- Turn Off Machine And Remove Key. 6. When Servicing Machine: -- Avoid Moving Parts. Do Not Wear Loose Jackets, Shirts, Or Sleeves When Working On Machine. -- Block Machine Tires Before Jacking Machine Up. -- Jack Machine Up At Designated Locations Only. Block Machine Up With Jack Stands. -- Use Hoist Or Jack Of Adequate Capacity To Lift Machine. -- Wear Eye And Ear Protection When 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 Equivalent Replacement Parts. WARNING: Engine Emits Toxic Gases. Severe Respiratory Damage Or Asphyxiation Can Result. Provide Adequate Ventilation. Consult With Your Regulatory Agency For Exposure Limits. Keep Engine Properly Tuned. WARNING: Machine Can Emit Excessive Noise. Consult With Your Regulatory Agency For Exposure Limits. Hearing Loss Can Result. Wear Hearing Protection. WARNING: Lift Arm Pinch Point. Stay Clear Of Hopper Lift Arms. WARNING: Raised Hopper May Fall. Engage Hopper Support Bar. WARNING: Moving Belt. Keep Away. i GENERAL INFORMATION The following safety labels are mounted on the machine in the locations indicated. If these, or any, labels become damaged or illegible, install a new label in its place. FOR SAFETY LABEL -- LOCATED ON THE SIDE OF THE CONTROL PANEL. FOR SAFETY THERMO SENTRYt LABEL -LOCATED ON THE LIFT ARM CROSS MEMBER. 03403 03402 03486 ii 235 MM166 (5--91) GENERAL INFORMATION HOPPER SUPPORT BAR WARNING LABEL -LOCATED ON THE OPERATOR SIDE OF HOPPER LIFT ARM. 03398 03397 FAN BELT DRIVE WARNING LABEL -LOCATED ON THE VACUUM FAN. 03486 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. 235 MM166 (5--91) iii GENERAL INFORMATION CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . SAFETY PRECAUTIONS . . . . . . . . . . . . Page i i SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . MACHINE SPECIFICATIONS . . . . . . . . . POWER TYPE . . . . . . . . . . . . . . . . . . . POWER TRAIN . . . . . . . . . . . . . . . . . . STEERING . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM . . . . . . . . . . . . BRAKING SYSTEM . . . . . . . . . . . . . . SUSPENSION SYSTEM . . . . . . . . . . SYSTEM FLUID CAPACITIES . . . . . GENERAL MACHINE DIMENSIONS -CAPACITIES . . . . . . . . . . . . . . . MACHINE WEIGHTS . . . . . . . . . . . . . MACHINE DIMENSIONS . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR OPERATION . . . . AFTER UNCRATING AND BEFORE OPERATING MACHINE: . . . . . . . OPERATION OF CONTROLS . . . . . . . . MACHINE COMPONENTS . . . . . . . . CONTROLS AND INSTRUMENTS . BRAKE PEDAL . . . . . . . . . . . . . . . . . . DIRECTIONAL PEDAL . . . . . . . . . . . . PARKING BRAKE LEVER . . . . . . . . . OPERATOR SEAT . . . . . . . . . . . . . . . . ADJUSTABLE SEAT LEVER (OPTION) SEAT SUPPORT LEVER . . . . . . . . . . SIDE BRUSH AND HOPPER LEVER THROTTLE LEVER . . . . . . . . . . . . . . . TEMP LIGHT . . . . . . . . . . . . . . . . . . . . AMPS LIGHT . . . . . . . . . . . . . . . . . . . . OIL PRESSURE LIGHT . . . . . . . . . . . HOPPER DOOR SWITCH . . . . . . . . . LIGHT SWITCH . . . . . . . . . . . . . . . . . . KEY-OPERATED IGNITION SWITCH MAIN BRUSH LEVER . . . . . . . . . . . . . CHOKE KNOB . . . . . . . . . . . . . . . . . . . VACUUM LEVER . . . . . . . . . . . . . . . . . HOUR METER . . . . . . . . . . . . . . . . . . . FUEL LEVEL GAUGE . . . . . . . . . . . . . FLASHER SWITCH . . . . . . . . . . . . . . . STEERING WHEEL . . . . . . . . . . . . . . HORN BUTTON . . . . . . . . . . . . . . . . . . SIDE BRUSH LEVER . . . . . . . . . . . . . SIDE BRUSH ADJUSTMENT KNOB AUXILIARY SIDE BRUSH IN-OUT SWITCH (OPTION) . . . . AUXILIARY SIDE BRUSH UP-DOWN SWITCH (OPTION) . . CIRCUIT BREAKERS . . . . . . . . . . . . . HOPPER SUPPORT BAR . . . . . . . . . iv 1-1 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-4 1-4 1-4 1-5 2-1 2-3 2-3 2-4 2-4 2-5 2-6 2-6 2-6 2-6 2-6 2-6 2-6 2-6 2-6 2-6 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-8 2-8 2-8 2-8 2-9 2-9 MACHINE OPERATION . . . . . . . . . . . . . . NORMAL SWEEPING OPERATION PRE-START CHECKLIST . . . . . . . TO START MACHINE . . . . . . . . . . TO SWEEP . . . . . . . . . . . . . . . . . . . TO DUMP HOPPER . . . . . . . . . . . POST OPERATION CHECKLIST -ENGINE OPERATING . . . . TO STOP MACHINE . . . . . . . . . . . POST OPERATION CHECKLIST -ENGINE STOPPED . . . . . . TO ENGAGE HOPPER SUPPORT BAR . . . . . . . . . . . . . . . TO DISENGAGE HOPPER SUPPORT BAR . . . . . . . . . . . . . . . . OPERATION ON GRADES . . . . . . . . MACHINE TROUBLESHOOTING . . TRANSPORTING MACHINE . . . . . . . . . . PUSHING OR TOWING MACHINE . MACHINE JACKING . . . . . . . . . . . . . . TO JACK UP MACHINE . . . . . . . . MACHINE TIE-DOWNS . . . . . . . . . . . MACHINE STORAGE . . . . . . . . . . . . . . . . STORING MACHINE . . . . . . . . . . . . . Page 2-10 2-10 2-10 2-10 2-11 2-11 2-11 2-12 2-12 2-12 2-13 2-13 2-14 2-15 2-15 2-15 2-15 2-16 2-17 2-17 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 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 CONTROL PEDAL . 3-10 TO ADJUST DIRECTIONAL CONTROL 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 . . . . . . . . . 3-15 235 MM166 (8--95) GENERAL INFORMATION ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE LUBRICATION . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . AIR INTAKE SYSTEM . . . . . . . . . . . . AIR FILTER . . . . . . . . . . . . . . . . . . . . . . TO CLEAN OR REPLACE AIR FILTER ELEMENT . . . . . . . . . . FUEL SYSTEM, GASOLINE . . . . . . . FUEL FILTER . . . . . . . . . . . . . . . . . CARBURETOR . . . . . . . . . . . . . . . . FUEL SYSTEM -- LPG . . . . . . . . . . . . LPG FUEL SYSTEM . . . . . . . . . . . FUEL TANKS . . . . . . . . . . . . . . . . . TO CHANGE AN LPG FUEL TANK . . . . . . . . . . . . . . . . FUEL FILTER LOCK . . . . . . . . . . . VAPORIZER-REGULATOR . . . . . CARBURETOR . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH . . . . . . LPG FUEL TROUBLESHOOTING . . ELECTRICAL SYSTEM . . . . . . . . . . . SPARK PLUG . . . . . . . . . . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . STARTER . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . VALVE TAPPET CLEARANCE . . CRANKCASE VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . TUNE-UP CHART . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . BATTERY . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATIC . . . . . . . . ELECTRICAL SCHEMATIC, AUXILIARY SIDE BRUSH . . . . . . BELTS AND CHAINS . . . . . . . . . . . . . . . . HYDRAULIC PUMP BELT . . . . . . . . . TO REPLACE AND ADJUST HYDRAULIC PUMP BELT . . . VACUUM FAN BELT . . . . . . . . . . . . . . TO REPLACE AND ADJUST VACUUM FAN BELT . . . . . . . . MAIN BRUSH BELT . . . . . . . . . . . . . . TO REPLACE MAIN BRUSH BELT . . . . . . . . . . . . . . TAPER LOCK BUSHINGS . . . . . . . . . TO REMOVE TAPER LOCK BUSHING . . . . . . . . . . . TO INSTALL TAPER LOCK BUSHING . . . . . . . . . . . STATIC DRAG CHAIN . . . . . . . . . . . . 235 MM166 (8--95) Page 3-16 3-16 3-16 3-16 3-16 3-16 3-17 3-17 3-17 3-18 3-18 3-19 3-20 3-21 3-21 3-21 3-21 3-21 3-22 3-22 3-22 3-22 3-22 3-22 3-23 3-23 3-23 3-24 3-24 3-25 3-26 3-27 3-27 3-27 3-27 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 FILTER . . . . . . . . . . . 3-32 TO REMOVE AND REPLACE HOPPER DUST FILTER . . . . . 3-33 BRUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 MAIN BRUSH . . . . . . . . . . . . . . . . . . . . 3-34 TO REMOVE MAIN BRUSH . . . . 3-34 TO INSTALL MAIN BRUSH . . . . . 3-34 TO CHECK AND ADJUST MAIN BRUSH PATTERN . . . . . . . . . . 3-34 SIDE BRUSH . . . . . . . . . . . . . . . . . . . . 3-36 TO REMOVE SIDE BRUSH . . . . . 3-36 TO INSTALL SIDE 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 REAR WHEEL . . . . . . . . . . . . . . . . . . . 3-41 3-27 3-29 3-29 3-30 3-30 3-30 3-30 v GENERAL INFORMATION Page APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 HARDWARE INFORMATION . . . . . . . . . 4-3 STANDARD BOLT 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 STANDARD MODEL PARTS . . . . . . . . . . . . ORDERING REPAIR PARTS . . . . . . . . . Fig. 1 -- Recommended General Maintenance Items . . . . . . . Fig. 2 -- Replacement Brushes . . . . . . . . Fig. 3 -- Main Frame Group . . . . . . . . . . . Fig. 4 -- Seat and Shrouds Group . . . . . Fig. 5 -- Front Wheel and Brake Group . Fig. 6 -- Hopper Lift Arms Group . . . . . . Fig. 7 -- Hopper Middle and Cover Group Fig. 8 -- Hopper Bottom Group . . . . . . . . Fig. 9 -- Hopper Headlights and Access Door Group . . . . . . Fig. 10 -- Hopper Filter and Shaker Motor Group . . . . . . . . . . . . . Fig. 11 -- Hopper Dump Door and Actuator Group . . . . . . . . . . Fig. 12 -- Vacuum Fan Control Group . . . Fig. 13 -- Vacuum Fan Assembly . . . . . . Fig. 14 -- Main Brush Drive Group . . . . . Fig. 15 -- Main Brush Idler Group . . . . . . Fig. 16 -- Side Brush Group . . . . . . . . . . . Fig. 17 -- Hydraulic Lift Cylinder and Filter Group . . . . . . . . . . . . . Fig. 18 -- Pump Group . . . . . . . . . . . . . . . . Fig. 19 -- Control Valve and Throttle Group . . . . . . . . . . . Fig. 20 -- Hydraulic Reservoir Group . . . Fig. 21 -- Rear Drive Wheel Group . . . . . Fig. 22 -- Hydraulic Hoses Group . . . . . . Fig. 23 -- Steering Wheel Group . . . . . . . Fig. 24 -- Directional Pedal Group . . . . . . Fig. 25 -- Speed Limiter Group . . . . . . . . Fig. 26 -- Engine Group . . . . . . . . . . . . . . . Fig. 27 -- Fuel Tank and Line Group . . . . Fig. 28 -- Battery and Air Intake Group . . Fig. 29 -- Control Panel Group . . . . . . . . . Fig. 30 -- Wire Harness Group . . . . . . . . . Fig. 31 -- Labels Group . . . . . . . . . . . . . . . 5-1 5-3 5-4 5-5 5-6 5-8 5-10 5-12 5-14 5-16 5-18 5-19 5-20 5-22 5-24 5-26 5-28 5-30 5-32 5-34 5-36 5-38 5-39 5-40 5-42 5-44 5-45 5-46 5-48 5-50 5-52 5-54 5-56 Page LPG PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ORDERING REPAIR PARTS . . . . . . . . . 6--3 Fig. 1 -- Engine and Fuel Line Group, LPG . . . . . . . . . . . . . 6--4 vi 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 . . . . 7-7 Fig. 5 -- Demo Kit . . . . . . . . . . . . . . . . . . . . 7-8 Fig. 6 -- Foam Filled Tire Kit . . . . . . . . . . . 7-8 Fig. 7 -- Adjustable Seat Kit . . . . . . . . . . . 7-9 Fig. 8 -- Auxiliary Side Brush Group . . . . 7-10 Fig. 9 -- Auxiliary Side Brush Hydraulic Hose Group . . . . 7-12 Fig.10 -- Auxiliary Side Brush Electrical Group . . . . . . . . . . 7-13 HYDRAULIC COMPONENTS . . . . . . . . . . . . 8-1 ORDERING REPAIR PARTS . . . . . . . . . 8-3 Fig. 1 -- Hydraulic Motor Breakdown, 87417 . . . . . . . 8-4 Fig. 2 -- Hydraulic Motor Breakdown, 87475 . . . . . . . 8-5 Fig. 3 -- Hydraulic Valve Breakdown, 87409 . . . . . . . 8-6 Fig. 4 -- Hydraulic Pump Breakdown, 87734 . . . . . . . 8-7 Fig. 5 -- Hydraulic Lift Cylinder Breakdown, 87055 . . . . . . . 8-8 Fig. 6 -- Hydraulic Lift Cylinder Breakdown, 48575 . . . . . . . 8-9 Fig. 7 -- Hydraulic Lift Cylinder Breakdown, 65223 . . . . . . . . . . . . . . . . . . 8-10 Fig. 8 -- Hydraulic Pump Breakdown, 87451 . . . . . . . . . . . . . . . . . . 8-11 Fig. 9 -- Hydraulic Motor Breakdown, 28804 . . . . . . . . . . . . . . . . . . 8-12 ENGINE PARTS, GASOLINE, LPG . . . . . . . ORDERING REPAIR PARTS . . . . . . . . . Fig. 1 -- Crankcase Group . . . . . . . . . . . . Fig. 2 -- Cylinder Head Group . . . . . . . . . Fig. 3 -- Camshaft and Valves Group . . Fig. 4 -- Crankshaft and Flywheel Group Fig. 5 -- Baffles and Shroud Group . . . . Fig. 6 -- Dipstick and Oil Filter Group . . Fig. 7 -- Oil Pump Group . . . . . . . . . . . . . Fig. 8 -- Breather and Vent Group . . . . . Fig. 9 -- Fuel Pump Group . . . . . . . . . . . . Fig. 10 -- Carburetor Group . . . . . . . . . . . Fig. 11 -- Air Intake Group . . . . . . . . . . . . Fig. 12 -- Governor Group . . . . . . . . . . . . Fig. 13 -- Ignition Group . . . . . . . . . . . . . . Fig. 14 -- Starter Group . . . . . . . . . . . . . . . 9-1 9-3 9-4 9-6 9-7 9-8 9-9 9-10 9-11 9-12 9-13 9-14 9-16 9-17 9-18 9-19 CROSS REFERENCE . . . . . . . . . . . . . . . . . . 10-1 PART NUMBER TO PAGE NUMBER CROSS REFERENCE LIST . . . . . . . . . . . . 10-3 235 MM166 (3--94) SPECIFICATIONS SECTION 1 CONTENTS MACHINE SPECIFICATIONS . . . . . . . . . . . . POWER TYPE . . . . . . . . . . . . . . . . . . . . . . POWER TRAIN . . . . . . . . . . . . . . . . . . . . . STEERING . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM . . . . . . . . . . . . . . . BRAKING SYSTEM . . . . . . . . . . . . . . . . . SUSPENSION SYSTEM . . . . . . . . . . . . . SYSTEM FLUID CAPACITIES . . . . . . . . GENERAL MACHINE DIMENSIONS -CAPACITIES . . . . . . . . . . . . . . . . . . . . . MACHINE WEIGHTS . . . . . . . . . . . . . . . . MACHINE DIMENSIONS . . . . . . . . . . . . . . . . 235 MM166 (5--91) Page 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-4 1-4 1-4 1-5 1-1 SPECIFICATIONS 1-2 235 MM166 (5--91) SPECIFICATIONS MACHINE SPECIFICATIONS POWER TYPE Engine type -- piston Ignition -- breakerless--type spark Cycle -- 4 Aspiration -- natural Cylinders -- 2 Bore -- 3.12 in (80 mm) Stroke -- 2.75 in (70 mm) Displacement -- 42 cu in (690 cc) Net power -- 13 hp (9.7 kw) @ 2200 rpm, governed Net power -- 18 hp (13.5 kw) @ 3600 rpm, maximum Fuel -- gasoline, 87 octane minimum, unleaded or LPG Cooling system -- air Electrical system -- 12 V nominal, 25 A alternator POWER TRAIN Propelling -- hydraulic motor driven Main brush -- belt driven Side brush -- hydraulic motor driven Vacuum fan -- belt driven Hydraulic pump -- belt driven STEERING Type -- rear wheel controlled, automotive cam and lever Power source -- manual HYDRAULIC SYSTEM Function -- operates propelling, hopper lift, side brush drive Control valve, 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, side brush -- internal gear type, 2.8 cu in (46 cc) per revolution, 2500 psi (17,240 kPa) maximum rated pressure Cylinder, hopper lift -- single action type, 2.5 in (65 mm) bore x 12 in (305 mm) stroke, 1.125 in (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 -- 4.80 x 8 pneumatic tire (1) 235 MM166 (3--93) 1-3 SPECIFICATIONS SYSTEM FLUID CAPACITIES Hydraulic system -- reservoir 3.9 gal (14.8 L) Hydraulic system -- total 4.4 gal (16.7 L) Engine lubricating oil, with filter -- 1.7 qt (1.6 L) Fuel tank -- 7.3 gal (28 L) gasoline 20 lb (9 kg) LPG GENERAL MACHINE DIMENSIONS -CAPACITIES Length -- 77.5 in (1970 mm) Width with side brush -- 48 in (1220 mm) Height without overhead guard -- 53 in (1345 mm) Height with overhead guard -- 79.5 in (2020 mm) Track -- 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 Maximum forward speed -- 6 mph (10 km/h) Maximum reverse speed -- 3 mph (5 km/h) Maximum forward speed with raised hopper -2 mph (3.2 km/h) Turning radius -- left, 60 in (1525 mm) right, 78 in (1980 mm) Maximum rated climb and descent angle -- 10_ 1-4 235 MM166 (3--93) SPECIFICATIONS MACHINE DIMENSIONS 48 in (1220 mm) 77.5 in (1970 mm) TOP VIEW 53 in (1345 mm) SIDE VIEW 03366 235 MM166 (3--93) 1-5 SPECIFICATIONS 1-6 235 MM166 (5--91) OPERATION SECTION 2 CONTENTS PREPARATION FOR OPERATION . . . . . . . AFTER UNCRATING AND BEFORE OPERATING MACHINE: . . . . . . . . . . OPERATION OF CONTROLS . . . . . . . . . . . MACHINE COMPONENTS . . . . . . . . . . . CONTROLS AND INSTRUMENTS . . . . BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . DIRECTIONAL PEDAL . . . . . . . . . . . . . . . PARKING BRAKE LEVER . . . . . . . . . . . . OPERATOR SEAT . . . . . . . . . . . . . . . . . . ADJUSTABLE SEAT LEVER (OPTION) SEAT SUPPORT LEVER . . . . . . . . . . . . . SIDE BRUSH AND HOPPER LEVER . . THROTTLE LEVER . . . . . . . . . . . . . . . . . TEMP LIGHT . . . . . . . . . . . . . . . . . . . . . . . AMPS LIGHT . . . . . . . . . . . . . . . . . . . . . . . OIL PRESSURE LIGHT . . . . . . . . . . . . . . HOPPER DOOR SWITCH . . . . . . . . . . . . LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . KEY-OPERATED IGNITION SWITCH . . MAIN BRUSH LEVER . . . . . . . . . . . . . . . . CHOKE KNOB . . . . . . . . . . . . . . . . . . . . . . VACUUM LEVER . . . . . . . . . . . . . . . . . . . . HOUR METER . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL GAUGE . . . . . . . . . . . . . . . FLASHER SWITCH . . . . . . . . . . . . . . . . . STEERING WHEEL . . . . . . . . . . . . . . . . . HORN BUTTON . . . . . . . . . . . . . . . . . . . . . SIDE BRUSH LEVER . . . . . . . . . . . . . . . . SIDE BRUSH ADJUSTMENT KNOB . . . AUXILIARY SIDE BRUSH IN-OUT SWITCH (OPTION) . . . . . . . AUXILIARY SIDE BRUSH UP-DOWN SWITCH (OPTION) . . . . CIRCUIT BREAKERS . . . . . . . . . . . . . . . . HOPPER SUPPORT BAR . . . . . . . . . . . . 235 MM166 (8--95) Page 2-3 2-3 2-4 2-4 2-5 2-6 2-6 2-6 2-6 2-6 2-6 2-6 2-6 2-6 2-6 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-8 2-8 MACHINE OPERATION . . . . . . . . . . . . . . . . . NORMAL SWEEPING OPERATION . . . PRE-START CHECKLIST . . . . . . . . . TO START MACHINE . . . . . . . . . . . . . TO SWEEP . . . . . . . . . . . . . . . . . . . . . . TO DUMP HOPPER . . . . . . . . . . . . . . POST OPERATION CHECKLIST -ENGINE OPERATING . . . . . . . . . . TO STOP MACHINE . . . . . . . . . . . . . . POST OPERATION CHECKLIST -ENGINE STOPPED . . . . . . . . . . . . TO ENGAGE HOPPER SUPPORT BAR TO DISENGAGE HOPPER SUPPORT BAR . . . . . . . . . . . . . . . . . . OPERATION ON GRADES . . . . . . . . . . . MACHINE TROUBLESHOOTING . . . . . TRANSPORTING MACHINE . . . . . . . . . . . . PUSHING OR TOWING MACHINE . . . . MACHINE JACKING . . . . . . . . . . . . . . . . . TO JACK UP MACHINE . . . . . . . . . . . MACHINE TIE-DOWNS . . . . . . . . . . . . . . MACHINE STORAGE . . . . . . . . . . . . . . . . . . STORING MACHINE . . . . . . . . . . . . . . . . Page 2-10 2-10 2-10 2-10 2-11 2-11 2-11 2-12 2-12 2-12 2-13 2-13 2-14 2-15 2-15 2-15 2-15 2-16 2-17 2-17 2-8 2-8 2-9 2-9 2-1 OPERATION 2-2 235 MM166 (5--91) OPERATION PREPARATION FOR OPERATION AFTER UNCRATING AND BEFORE OPERATING MACHINE: 1. Check the machine for shipping damage. 2. Read this manual carefully before operating or servicing the machine. FOR SAFETY: Do Not Operate Machine, Unless Operation Manual Is Read And Understood. 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 Sparks Away From Fuel System Service Area. Keep Area Well Ventilated. 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. 235 MM166 (3--93) 2-3 OPERATION OPERATION OF CONTROLS C A B D E F H G 03486 MACHINE COMPONENTS A. B. C. D. 2-4 Operator Seat Seat Support Steering Wheel Filter Cover E. F. G. H. Hopper Hopper Inspection Door Side Brush Access Door 235 MM166 (5--91) OPERATION U N Q L H I J O M K P R S F T G E D C V A W B CONTROLS AND INSTRUMENTS A. B. C. D. E. F. G. H. I. J. K. L. 235 MM166 (3--94) Brake Pedal Directional Pedal Parking Brake Lever Operator Seat Seat Support Lever Side Brush and Hopper Lever Throttle Lever Temp Light Amps Light Oil Pressure Light Hopper Door Switch Lights Switch M. N. O. P. Q. R. S. T. U. V. W. 03487 Key-Operated Ignition Switch Main Brush Lever Choke Knob Side Brush Lever Vacuum Lever Hour Meter Fuel Level Gauge Flasher Switch Steering Wheel Horn Button Auxiliary Side Brush Switches 2-5 OPERATION BRAKE PEDAL ADJUSTABLE SEAT LEVER (OPTION) The brake pedal operates the brakes on the two front wheels. To stop the machine, return the direction pedal to neutral, then apply pressure to the brake pedal. 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. DIRECTIONAL PEDAL SEAT SUPPORT LEVER The directional pedal controls the propelling drive. It is used to select the direction of travel and the speed of the machine. 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. E A B D C DIRECTIONAL PEDAL POSITIONS A. B. C. D. E. SIDE BRUSH AND HOPPER LEVER 00116 “Reverse” Position “Neutral” Position “Forward” Position “Heel” Position “Toe” Position The side brush and hopper lever controls side brush rotation and hopper position. To start the side brush turning, push the lever forward into the “ON”position. To stop the side brush, pull the lever back into the “LOWER”position. To raise the hopper, pull the lever back into the “LIFT” position. To hold the hopper in any raised position, pull the lever back into the “HOLD”position. To lower the hopper, push the lever forward into the “LOWER”position. THROTTLE LEVER Gradually press the “toe”portion of the pedal for forward travel or the “heel”portion for reverse travel. Regulate the machine speed by varying the pressure on the directional pedal. The throttle lever controls the engine governed speed. To speed the engine to the normal governed speed, push the lever into the “FULL” position. To slow the engine to idle speed, pull the lever back into the “IDLE”position. PARKING BRAKE LEVER TEMP LIGHT The parking brake lever operates the front wheel brakes. To set the parking brake, pull the handle up. To release the parking brake, push the handle down. Always park on a level surface, stop the engine, and set the parking brake before leaving the machine unattended and before working on the machine. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. OPERATOR SEAT The operator seat is of the fixed-back style with a forward-backward adjustment. To adjust the seat, remove the seat mounting bolts, slide the seat to the position desired, and reinstall and tighten the bolts. 2-6 The temp light indicates when the engine is overheating. If the light glows, stop the engine immediately and determine the cause. Failure to stop the engine will result in engine damage. Engine overheating may happen because of a clogged radiator or cooling fins, a loose fan belt, or other engine malfunctions. AMPS LIGHT The amps light indicates when the electrical system is not operating properly. If the light glows, stop the engine and determine the cause. The electrical system may not be accepting or getting a charge from the alternator. Overcharging and undercharging are indications that one or more electrical components are in need of repair. 235 MM166 (8--95) OPERATION OIL PRESSURE LIGHT CHOKE KNOB The engine oil pressure light indicates inadequate engine oil pressure. If the light glows, stop the engine immediately and determine the cause. Failure to stop the engine will result in engine damage. 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. HOPPER DOOR SWITCH The hopper door switch controls the hopper door. To open the hopper door, press and hold the switch in the “OPEN”position until a ratcheting noise is heard. To close the hopper door, press and hold the switch in the “CLOSE”position until a ratcheting noise is heard. The hopper door should always be open except when high dumping the hopper. LIGHT SWITCH The light switch operates the head lights and the tail lights.To operate the lights, move the switch to the “ON”position. To turn off the lights, move the switch to the “OFF”position. KEY-OPERATED IGNITION SWITCH The key-operated ignition switch has three positions: “OFF,”“ON,”and “START.”To start the engine, turn the key fully clockwise to the “START”position. Release the key as soon as the engine starts and the key will return to the “ON” position. To stop the engine, turn the key to the “OFF”position. FOR SAFETY: Before Starting Machine, Make Sure All Safety Devices Are In Place And Operate Properly. MAIN BRUSH LEVER The main brush lever controls the position and the drive of the main brush. To raise the main brush, push the lever all the way forward 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. 235 MM166 (3--93) VACUUM LEVER The vacuum lever controls the vacuum that is applied to the hopper. The lever also controls the dust filter shaker. When sweeping dry debris, place the lever in the “Normal Sweeping”position. When sweeping wet debris, place the lever in the “Wet Sweeping”position. To shake the dust filter, place and hold the lever in the “Filter Shaker” position for 20 seconds. HOUR METER The hour meter records the number of hours the machine has operated. This information is useful in determining when to service the machine. FUEL LEVEL GAUGE The fuel level gauge on a gasoline powered machine indicates how much fuel is left in the fuel tank. FLASHER SWITCH The flasher switch is present on machines with the flashing light option. To operate the flashing light, move the switch to the “ON”position. To stop the light, move the switch to the “OFF” position. STEERING WHEEL The steering wheel controls the rear caster wheel. The machine is very responsive to the movement of the steering wheel. The operator should use care until he or she becomes experienced in guiding the machine. HORN BUTTON The horn button operates the machine horn. It is located to the left of the foot brake pedal. 2-7 OPERATION SIDE BRUSH LEVER The side brush lever controls the position of the side brush. To raise the side brush, pull the lever into the “Raised”position. To lower the brush, push the lever down and release it into the “Down”position. When the machine is parked, always raise the brush to prevent the bristles from taking a set. 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 brush out, press the bottom of the in-out switch. A B 03396 SIDE BRUSH LEVER AUXILIARY SIDE BRUSH SWITCHES SIDE BRUSH ADJUSTMENT KNOB The side brush adjustment knob controls the height of the side brush when it is in the “Down” position. To reduce the brush pattern and the side brush contact with the floor, turn the knob to the right. To increase the brush pattern and the side brush contact with the floor, turn the knob to the left. B A. Up-Down Switch B. In-out Switch AUXILIARY SIDE BRUSH UP-DOWN SWITCH (OPTION) The auxiliary side brush up-down switch controls the up and down movement of the auxiliary side brush option. To raise the brush, press the top of the up-down switch.To lower the brush, press the bottom of the up-down switch. A SIDE BRUSH ADJUSTMENT KNOB 03386 A. Side Brush Adjustment Knob B. Hopper 2-8 235 MM166 (3--94) OPERATION CIRCUIT BREAKERS HOPPER SUPPORT BAR Circuit breakers are resetable 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. The hopper support bar is located on the right side lift arm. It holds the hopper in a raised position to allow work to be done under the hopper. Do not rely on the machine hydraulic system to keep the hopper raised. WARNING: Raised Hopper May Fall. Engage Hopper Support Bar. The circuit breakers are located on the instrument panel bracket under the seat support. The following chart shows the various circuit breakers and the electrical components they protect. PROTECTIVE DEVICE RATING CIRCUIT PROTECTED CB--1 CB--2 CB--3 CB--4 CB--5 15 A 10 A 10 A 10 A 7A CB--6 15 A Controls Horn Filter Shaker Hopper Dump Door Hopper Dump Door, Thermo Sentryt and Air Flow Solenoids Lights A B CIRCUIT BREAKERS 03491 A. Instrument Panel Bracket B. Circuit Breakers 235 MM166 (5--91) 2-9 OPERATION MACHINE OPERATION NORMAL SWEEPING OPERATION A normal sweeping operation consists of seven typical operations: pre-start checklist, starting machine, sweeping, dumping hopper, post operation checklist -- engine operating, stopping machine, and post operation checklist -- engine stopped. The PRE-START CHECKLIST lists things to check before starting the machine. TO START MACHINE lists the steps required to start the machine. TO SWEEP lists things to keep in mind before and during the sweeping operation. TO DUMP HOPPER lists the steps required to dump the hopper. POST OPERATION CHECKLIST -- ENGINE OPERATING lists things to check before stopping the machine engine. TO STOP MACHINE lists the steps required to stop the machine. The POST OPERATION CHECKLIST -- ENGINE STOPPED lists things to check after stopping the machine engine. PRE-START CHECKLIST Check under the machine for leak spots. Check the engine lubricating oil level. Check the fuel level. Check for LPG odor or frosting on hoses or components indicating a leak. 1. LPG powered machines: 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 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, Check Brakes And Steering For Proper Operation. 3. Gasoline powered machines: When the engine is cold, pull out the choke knob about three-fourths of the way. Push choke in after the engine has started and is running smoothly. 4. Gasoline powered machines: Move the throttle control lever to the “IDLE”position. LPG powered machines: Move the throttle control lever to the “HIGH”position. 5. Turn the ignition switch key to the “START” position until the engine starts. NOTE: Do not operate the starter motor for more than 10 seconds at a time or after the engine has started. Allow the starter to cool between starting attempts. The starter motor may be damaged if it is operated incorrectly. 6. Allow the engine and hydraulic system to warm up three to five minutes. Check the brakes and controls for proper operation. 7. Release the machine parking brake. Check the service records to determine service requirements. 8. Move the throttle control lever to the “FULL” position, and drive the machine to the area to be swept. TO START MACHINE NOTE: Before starting machine, perform the pre-start checks. 2-10 235 MM166 (3--93) OPERATION 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 floor or section at one time. Overlap brush paths. Pick up oversize debris before sweeping. Flatten or remove bulky cartons from aisles before sweeping. Pick up pieces of wire, twine, string, etc., which could become entangled in brush or brush plugs. Place large debris in hopper through hopper inspection door. Avoid turning the steering wheel too sharply when the machine is in motion. The machine is very responsive to the movement of the steering wheel. Avoid sudden turns, except in emergencies. Sweep as straight a path as possible. Avoid bumping into posts or scraping the sides of the sweeper. 1. Move the vacuum lever to the “Normal Sweeping”position to sweep dry debris, or “Wet Sweeping”position to sweep wet debris. 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” position for 20 seconds to shake the dust filter. 4. Slowly drive the machine up to the dump site or dumpster. 5. Press and hold the hopper door switch in the “CLOSE”position. 6. Pull the side brush and hopper lever to the “LIFT”position, then into the “HOLD” position when at the desired dump height. 7. Press and hold the hopper door switch in the “OPEN”position to dump the hopper. 8. Press and hold the hopper door switch in the “CLOSE”position to close the hopper door. 9. Slowly back the machine away from the dump site or dumpster. 2. Push the main brush lever forward and to the left, then release the lever to lower the main brush. 10. Push the side brush and hopper lever to the “LOWER”position to lower the hopper. 3. Move the side brush lever into the “Down” position. 11. Press and hold the hopper door switch in the “OPEN”position to open the hopper door. 4. Push the side brush and hopper lever into the “ON”position. 5. Press and hold the hopper door switch in the “OPEN”position. POST OPERATION CHECKLIST -- ENGINE OPERATING Check brush patterns for width and evenness. 6. Sweep as required. 235 MM166 (5--91) 2-11 OPERATION 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 into the “Raised”position. 4. Pull the side brush and hopper lever into the “LOWER”position to stop the side brush. 5. Place the throttle control lever in the “IDLE” position. TO ENGAGE HOPPER SUPPORT BAR WARNING: Raised Hopper May Fall. Engage Hopper Support Bar. 1. 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. Raise the hopper. 3. Position the hopper support bar on the bar stand. 6. Set the machine parking brake. 7. Turn the key-operated ignition switch key to the “OFF”position. Remove the key from the ignition switch. B A FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level 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. HOPPER SUPPORT BAR STAND 03369 A. Bar Stand B. Support Bar Check for leaks. 2-12 235 MM166 (3--93) OPERATION 4. Slowly lower the hopper so the bar is secure. 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_. A B ENGAGED HOPPER SUPPORT BAR 03370 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. 235 MM166 (5--91) 2-13 OPERATION MACHINE TROUBLESHOOTING Problem Cause Remedy Excessive dusting Dust skirts and seals worn, damaged, not adjusted properly Replace or adjust skirts or seals Dust filter clogged Shake and clean or replace filter Vacuum hose damaged Replace vacuum hose Vacuum fan failure Belt loose, broken or off sheave Brush bristles worn Replace brushes 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 floor clearance Hopper dump door closed Open dump door Hopper full Empty hopper Poor sweeping performance Hopper floor skirts worn, damaged Replace skirts 2-14 235 MM166 (5--91) OPERATION TRANSPORTING MACHINE PUSHING OR TOWING MACHINE The machine may be slowly pushed from the front or rear, pushing on the bumper or the machine frame. The machine may be slowly towed from the front. Use care when attaching towing cables or chains to avoid damaging the machine. MACHINE JACKING The machine may be jacked up for service at the designated locations. Use a jack of adequate capacity and good working condition. Always stop the machine on a flat, level surface and block the tires before jacking the machine up. The front jacking locations are on the flat bottom edge of the machine frame next to the front tires. The rear jacking location is the middle flat bottom edge of the rear bumper. TO JACK UP MACHINE 1. Empty and lower the debris hopper. A FRONT JACKING LOCATION 03372 A. Jacking Location 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 raise the machine. Jack up the machine only at the designated locations. FOR SAFETY: When Servicing Machine, Use Hoist Or Jack Of Adequate Capacity To Lift Machine, Jack Machine Up At Designated Locations Only. Block Machine Up With Jack Stands. A REAR JACKING LOCATION 03373 A. Jacking Location 5. Block machine up with jack stands or similar devices in the designated locations to secure the machine. FOR SAFETY: When Servicing Machine, Jack Machine Up At Designated Locations Only. Block Machine Up With Jack Stands. 235 MM166 (5--91) 2-15 OPERATION 6. Lower the machine onto the jack stands. MACHINE TIE-DOWNS 7. Check to make sure the machine is secure. The machine may be tied down at each corner of the main frame using the tie-down brackets supplied in the tie-down kit. 8. Service the machine as required. 9. When finished servicing the machine, raise the machine off the jack stands. 10. Remove the jack stands from under the machine. 11. Lower the machine. 12. Remove the blocks from the tires. A FRONT TIE-DOWN LOCATION 03372 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 tires to prevent the machine from rolling. 2-16 235 MM166 (5--91) OPERATION MACHINE STORAGE STORING MACHINE When storing the machine for extended periods 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. Change the engine oil. To store the machine 90 days to 6 months also: G. Seal the air cleaner inlet and the exhaust outlet with weatherproof masking tape. H. Tighten the engine oil filler cap, the fuel tank cap, and the radiator cap to make certain they are securely in place. 3. Raise the main brush and side brush. 4. Park the machine on a level surface in a cool, dry area. 5. Stop the engine and set the machine parking brake. 6. LPG powered machines: Close the LPG tank service valve. Remove and store LPG tank. 7. Fill the hydraulic reservoir with hydraulic fluid to prevent excessive condensation from forming. 8. To store the machine 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 surfaces. D. Replace the high tension coil wire and spark plugs. E. Drain the gasoline from the carburetor bowl by removing the carburetor anti-diesel solenoid. F. Replace the carburetor drain plug. 235 MM166 (3--93) 2-17 OPERATION 2-18 235 MM166 (5--91) MAINTENANCE SECTION 3 CONTENTS RECOMMENDED FIRST 50-HOUR MACHINE INSPECTION . . . . . . . . . . . . . MAINTENANCE CHART . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE BRUSH LEVER PIVOT . . . . . . . . . REAR WHEEL SUPPORT BEARING . . STEERING LINKAGE . . . . . . . . . . . . . . . . HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC FLUID . . . . . . . . . . . . . . . . . HYDRAULIC FLUID RESERVOIR . . . . . HYDRAULIC FILTER . . . . . . . . . . . . . . . . TO REPLACE FILTER ELEMENT . . HYDRAULIC PUMPS . . . . . . . . . . . . . . . . TO START AND BREAK-IN HYDRAULIC PUMP . . . . . . . . . . . . DIRECTIONAL PEDAL . . . . . . . . . . . . . . . TO ADJUST DIRECTIONAL PEDAL LINKAGE . . . . . . . . . . . . . . LIFT ARM SPEED LIMITER . . . . . . . . . . HYDRAULIC FLUID LEAKS . . . . . . . . . . HYDRAULIC SCHEMATIC . . . . . . . . . . . HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . HYDRAULIC COMPONENTS TROUBLESHOOTING . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE LUBRICATION . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . AIR INTAKE SYSTEM . . . . . . . . . . . . . . . AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . TO CLEAN OR REPLACE AIR FILTER ELEMENT . . . . . . . . . . . . . FUEL SYSTEM, GASOLINE . . . . . . . . . . FUEL FILTER . . . . . . . . . . . . . . . . . . . . CARBURETOR . . . . . . . . . . . . . . . . . . FUEL SYSTEM -- LPG . . . . . . . . . . . . . . . LPG FUEL SYSTEM . . . . . . . . . . . . . . FUEL TANKS . . . . . . . . . . . . . . . . . . . . TO CHANGE AN LPG FUEL TANK . FUEL FILTER LOCK . . . . . . . . . . . . . . VAPORIZER-REGULATOR . . . . . . . . CARBURETOR . . . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH . . . . . . . . . LPG FUEL TROUBLESHOOTING . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . . . . STARTER . . . . . . . . . . . . . . . . . . . . . . . 235 MM166 (3--94) Page 3-3 3-4 3-6 3-6 3-6 3-7 3-7 3-8 3-8 3-8 3-8 3-9 3-9 3-9 3-10 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-16 3-16 3-16 3-16 3-16 3-17 3-17 3-17 3-18 3-18 3-19 3-20 3-21 3-21 3-21 3-21 3-21 3-22 3-22 3-22 3-22 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . VALVE TAPPET CLEARANCE . . . . . CRANKCASE VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . TUNE-UP CHART . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATIC . . . . . . . . . . . ELECTRICAL SCHEMATIC, AUXILIARY SIDE BRUSH . . . . . . . . . . BELTS AND CHAINS . . . . . . . . . . . . . . . . . . . HYDRAULIC PUMP BELT . . . . . . . . . . . . TO REPLACE AND ADJUST HYDRAULIC PUMP BELT . . . . . . VACUUM FAN BELT . . . . . . . . . . . . . . . . . TO REPLACE AND ADJUST VACUUM FAN BELT . . . . . . . . . . . MAIN BRUSH BELT . . . . . . . . . . . . . . . . . TO REPLACE MAIN BRUSH BELT . TAPER LOCK BUSHINGS . . . . . . . . . . . . TO REMOVE TAPER LOCK BUSHING . . . . . . . . . . . . . . TO INSTALL TAPER LOCK BUSHING . . . . . . . . . . . . . . STATIC DRAG CHAIN . . . . . . . . . . . . . . . DEBRIS HOPPER AND DUST FILTER . . . DEBRIS HOPPER . . . . . . . . . . . . . . . . . . . TO CHECK AND ADJUST HOPPER FLOOR CLEARANCE . . . . . . . . . . THERMO SENTRYt . . . . . . . . . . . . . . . . TO CHECK THE THERMO SENTRYt . . . . . . . . . . HOPPER DUST FILTER . . . . . . . . . . . . . TO REMOVE AND REPLACE HOPPER DUST FILTER . . . . . . . . Page 3-22 3-22 3-23 3-23 3-23 3-24 3-24 3-25 3-26 3-27 3-27 3-27 3-27 3-27 3-29 3-29 3-30 3-30 3-30 3-30 3-31 3-31 3-31 3-31 3-31 3-32 3-33 3-1 MAINTENANCE BRUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN BRUSH . . . . . . . . . . . . . . . . . . . . . . . TO REMOVE MAIN BRUSH . . . . . . . TO INSTALL MAIN BRUSH . . . . . . . . TO CHECK AND ADJUST MAIN BRUSH PATTERN . . . . . . . . . . . . . SIDE BRUSH . . . . . . . . . . . . . . . . . . . . . . . TO REMOVE SIDE BRUSH . . . . . . . . TO INSTALL SIDE BRUSH . . . . . . . . SKIRTS AND SEALS . . . . . . . . . . . . . . . . . . . BRUSH SKIRTS . . . . . . . . . . . . . . . . . . . . TO REPLACE AND ADJUST BRUSH SKIRTS . . . . . . . . . . . . . . . REAR SKIRTS . . . . . . . . . . . . . . . . . . . . . . TO REPLACE AND ADJUST REAR SKIRTS . . . . . . . . . . . . . . . . HOPPER LIP SKIRT . . . . . . . . . . . . . . . . . TO REPLACE HOPPER LIP SKIRT . DUST SEALS . . . . . . . . . . . . . . . . . . . . . . . TO REPLACE DUST SEALS . . . . . . . HOPPER DUMP DOOR SEAL . . . . . . . . TO REPLACE HOPPER DUMP DOOR SEAL . . . . . . . . . . . . . . . . . . VACUUM FAN SEAL . . . . . . . . . . . . . . . . . FILTER COVER SEAL . . . . . . . . . . . . . . . BRAKES AND TIRES . . . . . . . . . . . . . . . . . . . BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . 3-2 Page 3-34 3-34 3-34 3-34 3-34 3-36 3-36 3-36 3-37 3-37 3-37 3-37 3-37 3-38 3-38 3-38 3-38 3-39 3-39 3-40 3-40 3-41 3-41 3-41 3-41 235 MM166 (8--95) MAINTENANCE RECOMMENDED FIRST 50-HOUR MACHINE INSPECTION After the first 50 hours of operation, the following procedures are recommended: 1. Check the floor skirts to floor clearance. See SKIRTS AND SEALS. 2. Check the side brush and main brush patterns. See BRUSHES. 235 MM166 (8--95) 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. 3-3 MAINTENANCE MAINTENANCE CHART 2 1 3 4 5 8 6 9 7 17 10 16 14 13 13 12 15 4 18 8 11 Interval Key Description Procedure 03488 Lubricant No. of Service Points Daily 1 4 18 5 11 Engine Brush and rear skirts Hopper lip skirt Main brush Side brush Check oil level Check for damage and wear Check for damage and wear Check for damage and wear Check for damage and wear EO ----- 1 4 1 1 1 25 Hours 1 Engine Clean air filter precleaner Change oil and oil filter Clean cooling fins -EO -- 1 1 1 50 Hours 5 Main brush Rotate end-for-end -- 1 3-4 235 MM166 (3--94) MAINTENANCE Interval 100 Hours 200 Hours 400 Hours 800 Hours Key Description Procedure 1 Engine 3 9 15 10 17 8 Dust Seals Dust filter Hydraulic reservoir Thermo Sentryt Rear tire Front tires Clean or replace spark plugs Clean or replace dry-type air filter element Check for damage and wear Clean or replace Check fluid level Test Check pressure and wear Inspect for wear 1 Engine 6 2 12 14 16 13 Vacuum fan belt Hydraulic pump belt Side brush lever pivot Parking brake Rear wheel support bearing Steering linkage 1 Engine 15 7 Hydraulic fluid reservoir Hydraulic fluid filter Check and adjust idle speed Clean carbon deposits Check valve clearance Check starter motor brushes Change hydraulic fluid Change filter element 17 Rear wheel Torque wheel nuts Lubricant No. of Service Points --- 2 1 --HYDO ---- 6 1 1 1 1 2 Clean breather valve Check crankcase ventilation hoses, tubes and fittings Check tension Check tension Lubricate Check adjustment Lubricate --- 1 4 --SPL -SPL 1 1 1 1 1 Lubricate SPL 2 ----HYDO -- 1 2 4 1 1 1 -- 1 EO -- Engine oil HYDO -- TENNANT or approved hydraulic fluid SPL -- Special lubricant, Lubriplate EMB grease (TENNANT part number 01433--1) NOTE: More frequent intervals may be required in extremely dusty conditions. 235 MM166 (8--95) 3-5 MAINTENANCE LUBRICATION ENGINE SIDE BRUSH LEVER PIVOT Check the engine oil level daily. 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 operation. Change the engine oil and oil filter after every 25 hours of operation. Use a straight SAE 30-weight, API class SF engine oil. If multiviscosity oil is used, oil consumption and combustion 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). A B SIDE BRUSH LEVER PIVOT 03396 A. Side Brush Lever B. Pivot 3-6 235 MM166 (3--94) MAINTENANCE REAR WHEEL SUPPORT BEARING STEERING LINKAGE The rear wheel support bearing allows the rear wheel assembly to rotate freely. It is lubricated with Lubriplate EMB grease (TENNANT part number 01433--1). Apply the lubricant with a hand grease gun after every 200 hours of operation. 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 200 hours of operation. C A B A B FRONT STEERING LINK REAR WHEEL SUPPORT BEARING 03501 03394 A. Steering Link B. Grease Fitting A. Rear Wheel Support B. Support Grease Fitting C. Rear Steering Link Grease Fitting 235 MM166 (5--91) 3-7 MAINTENANCE HYDRAULICS HYDRAULIC FLUID HYDRAULIC FLUID RESERVOIR The quality and condition of the hydraulic fluid play a very important role in how well the machine operates. TENNANT’s hydraulic fluid is specially selected to meet the needs of TENNANT machines. 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. TENNANT’s hydraulic fluids provide a longer life for the hydraulic components. There is one recommended fluid. TENNANT part no. 65870 Fluid Weight 5--20W 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. B If a locally-available hydraulic fluid is used, make sure the specifications match TENNANT hydraulic fluid specifications. Using substitute fluids can cause premature failure of hydraulic components. European marketed machines are filled with locally available hydraulic fluids. Check the label on the hydraulic fluid reservoir. ATTENTION! Hydraulic components depend on system hydraulic fluid for internal lubrication. Malfunctions, accelerated wear, and damage will result if dirt or other contaminants enter the hydraulic system. A HYDRAULIC FLUID RESERVOIR 03502 A. Reservoir B. Breather-Filler Cap Check the hydraulic fluid level at operating temperature every 100 hours of operation. Change the hydraulic fluid after every 400 hours of operation. Do not overfill the hydraulic fluid reservoir. Hydraulic fluid expands as it heats to its normal operating temperature. Always allow for expansion when filling the reservoir. Lubricate the filler cap gasket with a film of hydraulic fluid before putting the cap back on the reservoir. HYDRAULIC FILTER The hydraulic fluid filter keeps the machine hydraulic system clean to a level of 10 microns. The hydraulic fluid filter is located next to the vacuum fan. Replace the hydraulic fluid filter element after the first 50 hours of operation and then after every 400 hours of operation. 3-8 235 MM166 (3--94) MAINTENANCE TO REPLACE FILTER ELEMENT HYDRAULIC PUMPS 1. 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. 2. Open the seat support. The machine propelling pump is a variable displacement hydraulic piston pump. It is driven by the engine via a dual belt. The machine accessories pump is a hydraulic gear pump. It is driven by a belt from the propelling pump sheave. After repairing or replacing a hydraulic pump, or when system contamination is likely, change the hydraulic fluid in 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 machine. A FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Jack up the rear of the machine at the designated locations. HYDRAULIC FLUID FILTER 03395 A. Filter Element 3. Unthread and discard the hydraulic fluid filter 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. FOR SAFETY: When Servicing Machine, Block Machine Tires Before Jacking Machine Up. 3. Block up the machine with jack stands in the designated locations. Make sure the rear tire clears the floor by 2 in (50 mm) and all obstacles within a 24 in (610 mm) radius. FOR SAFETY: When Servicing Machine, Jack Machine Up At Designated Locations Only. Block Machine Up With Jack Stands. 6. Close the seat support. 4. Fill the hydraulic fluid reservoir with 3 gal (11 L) of new, approved hydraulic fluid. 7. Operate the machine and check for leaks. Correct any leaks found. 5. Fill the hydraulic pump through the case drain port with hydraulic fluid. 8. Check the hydraulic fluid reservoir level and fill as required. 6. Remove the engine coil wire from the engine distrinbutor or turn off fuel flow. 7. Operate the engine starter motor for three 10 second periods. 235 MM166 (5--91) 3-9 MAINTENANCE 8. Replace the engine coil wire. 9. Start the engine and operate it at an idle for two minutes. 10. Press the directional pedal one-half of its travel in the “forward”direction while also operating the main brush and side brush for one minute. 11. Adjust the directional pedal as described in TO ADJUST DIRECTIONAL PEDAL LINKAGE. 12. Stop the engine. 13. Raise the rear of the machine, remove the jack stands, and lower the machine. 14. Fill the hydraulic fluid reservoir with new, approved hydraulic fluid. 15. Check the hose routings to be sure the hoses do not contact any moving, hot, or sharp surfaces. TO ADJUST DIRECTIONAL PEDAL LINKAGE 1. 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. 2. Block the machine tires and jack up the rear of the machine at the designated location. FOR SAFETY: When Servicing Machine, Block Machine Tires Before Jacking Machine Up. 3. Block up the machine with jack stands in the designated locations. Make sure the rear tire clears the floor by 2 in (50 mm) and all obstacles within a 24 in (610 mm) radius. FOR SAFETY: When Servicing Machine, Jack Machine Up At Designated Locations Only. Block Machine Up With Jack Stands. 4. Loosen the two centering bolts jam nuts. 16. Replace the hydraulic fluid filter after the first hour of operation. DIRECTIONAL PEDAL B C The directional pedal controls the flow of hydraulic fluid to the hydraulic drive motor. The pedal has three positions -- ”forward,”“neutral,”and “reverse.”The “forward”and “reverse”positions send hydraulic fluid to the drive motor to propel the machine. The “neutral”position is the position in which 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 excessive or inadequate. 3-10 A CENTERING BOLTS 03505 A. Adjustment Bolts B. Pintle Arm C. Centering Stop 235 MM166 (5--91) MAINTENANCE 5. Start the engine. 6. Move the directional pedal into the “forward” position and release it. The rear wheel should stop rotating as soon as the pedal is released. Stop the engine and adjust the centering bolt as required. To adjust the limited speed, raise the hopper and engage the hopper support bar. Loosen the two bracket bolts and slide the bracket and cam forward to increase speed or slide the bracket backward to decrease speed. Tighten the bolts. 7. Move the directional pedal into the “reverse” position and release it. The rear wheel should stop rotating as soon as the pedal is released. Stop the engine and adjust the centering bolt as required. NOTE: If there is not enough adjustment in the centering bolts, reposition the centering stop. A 8. Tighten the jam nuts. 9. Raise the rear of the machine, remove the jack stands, and lower the machine. 10. Adjust the position of the directional pedal ball joints so the pedal hits the floor when the directional pedal is pressed backward. 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. B SPEED LIMITER LINK 03507 A. Bracket and Cam B. Bracket Bolts 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 2 mph (3 km/h) with the hopper raised. The speed limiter consists of a cam under the directional pedal with a link to the lift arms. When the hopper is raised, the link lifts the cam under the pedal. This limits how far the directional pedal can be pressed, limiting the machine speed. 235 MM166 (5--91) 3-11 MAINTENANCE HYDRAULIC FLUID LEAKS Fluid escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. A B C HYDRAULIC PINHOLE LEAK 00002 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. 3-12 235 MM166 (5--91) MAINTENANCE HYDRAULIC SCHEMATIC 235 MM166 (3--94) 03460 3-13 MAINTENANCE HYDRAULIC SYSTEM TROUBLESHOOTING Problem Cause Remedy Machine travels slowly or not at all Parking brake set Release parking brake Control linkage broken or not adjusted properly Replace and/or adjust linkage Relief valve stuck open (leaking) valve Clean or replace relief valve -- one forward, one reverse Motor failure See HYDRAULIC COMPONENTS TROUBLESHOOTING: Hydraulic motor failure Pump failure See HYDRAULIC COMPONENTS TROUBLESHOOTING: Hydraulic piston pump failure Hydraulic fluid level low Fill hydraulic fluid reservoir Hydraulic control valve failure See HYDRAULIC COMPONENTS TROUBLESHOOTING: Hydraulic control valve failure 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 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 arms binding Replace and/or adjust lift arm linkage Lift cylinder failure See HYDRAULIC COMPONENTS TROUBLESHOOTING: Hydraulic cylinder failure Lift arms binding Replace and/or adjust lift arm linkage Hydraulic orifice at lift cylinder plugged Replace orifice Side brush turns slowly or not at all Hopper will not lift Hopper will not lower 3-14 235 MM166 (5--91) MAINTENANCE HYDRAULIC COMPONENTS TROUBLESHOOTING Problem Cause Remedy Hydraulic cylinder failure Piston seals leaking Install seal kit Barrel worn or rod bent Replace cylinder rod Valve seals leaking Install seal kit Relief valve stuck open (leaking) Clean or replace relief valve Motor leaking Install seal kit Drive link failure Replace drive link Gerotor worn Replace gerotor set Output shaft failure Replace output shaft and bearings Pump leaking Install seal kit Gear set failure Replace gear set Shaft failure Replace gear set Pump leaking Install seal kit Relief valve stuck Clean or replace relief valve Integral charge pump failure Replace charge pump Rotating group worn Replace rotating group Shaft failure Replace shaft Backplate worn Replace backplate Engine-to-pump coupling failure Replace coupling Hydraulic control valve failure Hydraulic motor failure Hydraulic gear pump failure Hydraulic piston pump failure 235 MM166 (5--91) 3-15 MAINTENANCE ENGINE ENGINE LUBRICATION AIR INTAKE SYSTEM Check the engine oil level daily. The importance of maintaining an air filter in proper condition cannot be overemphasized. Dirt induced through improperly 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 cleaner is removed for servicing. Do not neglect servicing the air cleaner. Use only correct parts for replacement. Keep all other air intake components such as hoses, clamps, etc., secure and in good condition to prevent entrance of unfiltered air. Change the engine oil and oil filter after every 50 hours of operation. Use a straight SAE 30-weight, API class SF engine oil. If multiviscosity oil is used, oil consumption and combustion 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). AIR FILTER The engine air filter is made up of two parts, a foam precleaner and a dry cartridge-type filter. The foam precleaner must be cleaned and re-oiled after every 25 hours of operation. The dry cartridge-type filter should be cleaned or replaced after every 100 hours of operation. The filter element must be replaced if it is damaged or has been cleaned three times. B A DIPSTICK AND FILL CAP 03510 A. Dipstick B. Fill Cap COOLING SYSTEM Maintaining cooling system efficiency is important. Engine temperatures must be brought up to and maintained within the satisfactory range for efficient operation. However, the engine must be kept from overheating in order to prevent damage to the valves, pistons, and bearings. TO CLEAN OR REPLACE AIR FILTER ELEMENT 1. 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. 2. Open the seat support. 3. Remove the air filter cover wing nut. 4. Remove the air filter cover. Clean the engine cooling fins after every 50 hours of operation. FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. 3-16 235 MM166 (3--93) MAINTENANCE 5. Remove the foam precleaner. 11. Clean the interior of the air cleaner housing with a damp cloth. Clean the element sealing surfaces. 12. Position the cleaned or new, dry cartridge-type air filter on the engine. A 13. Slide the air filter cup over the air filter stud. B 14. Thread and tighten the nut onto the air filter stud. 15. Oil the foam precleaner 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 REMOVING ENGINE AIR FILTER 03495 A. Foam Precleaner B. Dry Cartridge-Type Air Filter 6. Wash the foam precleaner in liquid detergent and water. 7. Squeeze it dry in a cloth. 8. Remove the dry cartridge-type filter nut and cup. 9. Gently remove the dry cartridge-type air filter. 10. Clean or discard the dry cartridge-type air filter. 235 MM166 (5--91) An in-line fuel filter has been provided to filter the fuel. The filter is located next to the fuel tank. The system is also equipped with a fuel shutoff valve. Replace the filter when necessary. CARBURETOR The carburetor idle speed should be checked and adjusted after every 400 hours of operation. Early machines had an idle and a main fuel valve. Later machines only have an idle fuel valve. The initial setting of the idle fuel needle valve is made by lightly turning it all the way in, then turning it out one-half turn. Final adjustment is made with the engine running and warm. 3-17 MAINTENANCE The initial setting of the main fuel needle valve, if it is present, is made by lightly turning it all the way in, then turning it out two and three-quarter turns. The fuel tank should be approximately one-half full and with the engine running at approximately 2200 RPM. Final adjustment is made with the engine warm. Turn the main fuel adjusting needle valve out until the engine begins to lose speed (rich). Note the position of the needle. Then turn the needle in. The engine speed may increase, then it will decrease as the needle is turned in (lean). Note the position of the needle. Set the needle half way between the rich and lean positions. B The vaporizer converts the LPG fuel into a gaseous LPG fuel. Within the vaporizer, the gaseous LPG fuel is sent to the primary regulator. The primary regulator section reduces the pressure of the LPG fuel. From the primary regulator section of the vaporizer, the LPG fuel is sent to the secondary regulator. The secondary regulator reduces the LPG fuel pressure to the level required by the carburetor. Then the fuel is sent to the carburetor where it is finally metered into the air flow which is sent to the engine combustion chamber. A CARBURETOR ADJUSTMENTS Liquid LPG fuel flows from the LPG tank, under its own pressure, to the pressure relief valve. This valve is normally closed, preventing LPG fuel from escaping into the atmosphere. The valve opens to relieve pressure if 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 oil pressure switch permits an electrical current to open the fuel filter lock which allows LPG fuel to flow on to the vaporizer, then the regulator. The oil pressure switch is bypassed when the engine is being started, allowing LPG fuel to flow. 03496 A B A. Idle Needle Valve B. Main Fuel Needle Valve The LPG fuel system is made up of six components which are: the LPG fuel tank, pressure relief valve, fuel filter lock, vaporizer-regulator, secondary regulator, and the carburetor. 3-18 D F E G H FUEL SYSTEM -- LPG LPG FUEL SYSTEM C LPG FUEL SYSTEM A. B. C. D. E. F. G. H. 04232 Carburetor Secondary Regulator Vaporizer-Regulator Fuel Filter Lock Pressure Relief Valve Tank Service Valve LPG Fuel Tank Oil Pressure Switch 235 MM166 (5--91) MAINTENANCE Never operate an LPG powered machine if the LPG fuel system is leaking, or if any component in the fuel system is malfunctioning. Operating the machine under either of these conditions may cause a fire or explosion. Check for frosting. If frosting occurs on or near any LPG component, there is a possibility of an LPG fuel leak or a malfunctioning component. To locate the leak, apply a soapy water solution to the suspected area. Watch for bubbles forming in the suspected area. This area may have an LPG fuel leak. Repair or replace the part. Use Loctite brand Stainless Steel PST thread sealant when reassembling. This epoxy-type sealant is not affected by aging or high humidity. Be sure to follow application directions and apply proper torque when reconnecting fittings. Never bypass safety components except to test. If the safety components are defective, replace them before operating the machine. Tank Service Valve Coupling -- Check for proper functioning, thread condition, and damaged or missing washers or o-rings. Safety Relief Valve -- Check for damage. Check for the presence of the relief valve elbow and the proper direction of the elbow. If the rain cap is missing, check for foreign matter and replace the rain cap. Do not tamper with the relief valve setting. Magnetic Liquid Level Gauge -- Check operation against the maximum filling point as determined by weight. B C Check routings of all LPG hoses. Keep them away from sharp edges, exhaust manifolds, or other hot surfaces. Check for signs of abrasion or deterioration. Replace hoses found to be worn or damaged. A D FUEL TANKS The LPG fuel tanks should be inspected for sharp dents, gouges, leaks, and broken protecting rings whenever the tanks 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 of the handwheel. The valve must be closed except when in service. 235 MM166 (5--91) 00115 TYPICAL LPG VAPOR WITHDRAWAL FUEL TANK A. B. C. D. Filler Valve Safety Relief Valve Vapor Service Valve Liquid Level Gauge An LPG fuel tank with any of the stated defects must be removed from service and be repaired or destroyed accordingly. If an LPG fuel tank is damaged or leaking, it should be removed to a designated safe area, and the proper personnel should be notified. Do not attempt to make repairs to the tank, regardless of condition. Repairs or disposal must only be made by qualified personnel. 3-19 MAINTENANCE The care an LPG fuel tank receives has a direct bearing on how long that tank can be used safely. LPG fuel tanks must not be dropped or dragged across any surface. To move LPG fuel tanks, use a hand truck or roll the tank on its foot ring while it is being held in a position slightly off vertical. Whether the storage is inside or outside, fuel tanks should not be stored in the vicinity of combustible materials or high temperature sources such as ovens and furnaces, since the heat may raise the pressure of the fuel to a point where the safety relief valves would function. Take care to insure that the tanks are stored in such a way that if the safety relief valves do function, they will relieve vapor, rather than liquid. Valves on empty tanks must be closed during storage and transportation. Similar precautions should be taken in storing machines fitted with LPG fuel tanks. The machines may be stored or serviced inside buildings, provided there are no leaks in the fuel system and the tanks are not overfilled. While machines are being repaired inside a building, the shut-off valve on the tank must be closed, except when the engine must be operated. Changing the tank is a chance for the machine operator to carefully observe the tank, fittings, and the fuel lines and fittings. If abnormal wear is detected, the operator should report 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. 4. Put on gloves and remove the quick-disconnect tank coupling. 5. Inspect the LPG fuel lines for wear or damage. 6. Remove the empty LPG fuel tank from the machine. 7. Check the tank for damage or wear. 8. Store the tank in a designated safe area. 9. Select a filled LPG fuel tank and inspect it for damage or leaks. NOTE: Make sure the LPG fuel tank matches the fuel system (vapor tank with vapor system). 10. Carefully place the LPG tank in the machine so that the tank centering pin enters the aligning hole in the tank collar. NOTE: If the pin cannot be engaged, make sure you have the correct LPG fuel tank and then adjust the mounting bracket up or down. 11. Fasten the tank hold-down clamp to lock the tank in position. 12. Connect the LPG fuel line to the tank service coupling. Make sure the service coupling is clean and free of damage. Also make sure it matches the machine service coupling. 13. Open the tank service valve slowly and check for leaks. If an LPG leak is found, close the service valve immediately and notify the appropriate personnel. 14. If no leaks are found, the engine is ready to start. 2. Close the tank service valve. 3. Operate the engine until it stops from lack of fuel. FOR SAFETY: When Servicing Machine, Keep Flames And Sparks Away From Fuel System Service Area. Keep Area Well Ventilated. 3-20 235 MM166 (3--93) MAINTENANCE FUEL FILTER LOCK CARBURETOR The fuel filter lock filters the LPG fuel. It also stops the flow of LPG fuel to the engine when the engine is not operating or when the engine oil pressure is less than 4 psi (30 kPa). If any malfunction is noted, completely disassemble the carburetor. Clean all of the parts in alcohol. Replace the filter pack with the filter pack replacement kit if diminished gas flow indicates the filter is clogged. A drain plug is provided for purging the filter bowl. Clean out the bowl when replacing the filter pack. VAPORIZER-REGULATOR nIf any malfunction is noted, completely disassemble the vaporizer-regulator. Clean all of the parts in alcohol. Inspect all of the parts and replace where needed. Carefully reassemble the vaporizer-regulator with the seal repair kit. Check for proper operation. Inspect all of the parts and replace when needed. Carefully reassemble the carburetor with the seal repair kit. 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 Service valve opened too quickly -- engaging safety valve Close valve and reopen slowly Plugged fuel filter Replace filter Kinked or restricted fuel line Straighten or replace fuel line Engine out of tune Tune-up engine Oil pressure switch failure Replace oil pressure switch Fuel lock valve failure Repair or replace fuel filter lock Vaporizer-regulator failure Repair or replace vaporizer-regulator Wrong type of fuel tank Replace with either vapor or liquid withdrawal tank for proper system Plugged fuel filter Replace filter Kinked or restricted fuel line Straighten or replace fuel line Engine out of tune Tune-up engine Restricted air filter Clean or replace air filter element Vaporizer-regulator maladjusted Adjust vaporizer-regulator Engine runs unevenly or lacks power 235 MM166 (5--91) 3-21 MAINTENANCE ELECTRICAL SYSTEM STARTER SPARK PLUG The starter motor brushes must be inspected after every 400 hours of operation. Clean or replace, and adjust spark plugs after 100 hours of operation. A wire gauge is best for checking the spark plug gap. A flat gauge should not be used unless the electrode surfaces have been dressed with a small file to get parallel surfaces between the center and side electrodes. Set the spark plug gap by bending the side electrode. All spark plugs, new or used, should have the gaps checked and reset if necessary. A B CYLINDER HEAD CYLINDER HEAD The cylinder head may develop carbon deposits. After every 400 hours of operation, remove the cylinder head and clean it of any accumulated deposits. Replace the cylinder head, making sure the cylinder head screws are lubricated with graphite grease and are returned to the same hole. Alternately snug the screws; tighten them to one-half of the specified value, then torque the screws to 15 to 20 ft lb (20 to 25 Nm). 6 5 2 3 9 GAPPING THE SPARK PLUG 03559 A. Spark Plug B. Gapping Tool 4 7 1 8 CYLINDER HEAD SCREW TIGHTENING SEQUENCE 03497 The proper spark plug gap is 0.025 in (0.6 mm) for gasoline engines. The proper spark plug gap is 0.018 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). 3-22 235 MM166 (8--95) MAINTENANCE VALVE TAPPET CLEARANCE The valve tappet clearance should be checked after every 400 hours of operation. The intake valve clearance should be 0.003 to 0.006 in (0.07 to 0.15 mm) cold. The exhaust valve clearance for engines serial numbers up to 1816500655 should be 0.016 to 0.019 in (0.40 to 0.50 mm) cold. The exhaust valve clearance for engines serial number 1816500656 to 1917809295 should be 0.011 to 0.014 in (0.25 to 0.35 mm) cold. The exhaust valve clearance for engines serial number 1917809296 and above should be 0.013 to 0.016 in (0.35 to 0.40 mm) cold. Grind off the end 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. 235 MM166 (8--95) 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 exhaust (for engines serial number up to 1816500655) 0.016 to 0.019 in (0.40 to 0.50 mm) Valve clearances, cold exhaust (for engines serial number 1816500656 to 1917809295) 0.011 to 0.014 in (0.25 to 0.35 mm) Valve clearances, cold exhaust (for engines serial number 1917809296 and above) 0.013 to 0.016 in (0.35 to 0.40 mm) 3-23 MAINTENANCE ELECTRICAL SYSTEM BATTERY The battery used in this machine is rated at 12 V, 330 ccA. It is located in the front left of the machine behind the hopper. When removing battery cables, remove the negative (--) cable before the positive (+) cable. Clean the top surface and the terminals of the battery periodically. Use a strong solution of baking soda and water. Brush the solution sparingly over the battery top, terminals, and cable clamps. Do not allow any baking soda solution to enter the battery. Use a wire brush to clean the terminal posts and the cable connectors. After cleaning, apply a coating of clear petroleum jelly to the terminals and the cable connectors. Keep the top of the battery clean and dry. Keep all metallic objects off the top of the battery, as they may cause a short circuit. Replace worn or damaged wires. The electrolyte level in regular nonsealed batteries can be checked. It 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. NOTE: Do not take readings immediately after adding water----if the water and acid are not thoroughly mixed, the readings may not be accurate. Check the hydrometer readings against this chart: SPECIFIC GRAVITY AT 80_F (27_C) 1.265 1.225 1.190 1.155 1.120 BATTERY CONDITION 100% charged 75% charged 50% charged 25% charged Discharged NOTE: If the readings are taken when the battery electrolyte is any temperature other than 80_F (27_C), the reading must be temperature corrected. To determine the corrected specific gravity reading when the temperature of the battery electrolyte is other than 80_F (27_C): Add to the specific gravity reading 0.004 (4 points) for each 10_F (6_C) above 80_F (27_C). Subtract from the specific gravity reading 0.004 (4 points) for each 10_F (6_C) below 80_F (27_C). 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 damaged, shorted, or is about to fail. 3-24 235 MM166 (3--93) MAINTENANCE ELECTRICAL SCHEMATIC 235 MM166 (3--94) 03489 3-25 MAINTENANCE ELECTRICAL SCHEMATIC, AUXILIARY SIDE BRUSH 3-26 03489 235 MM166 (3--94) MAINTENANCE BELTS AND CHAINS HYDRAULIC PUMP BELT The hydraulic pump belt transfers power from the engine sheave to the hydraulic pump. Check belt condition and tension after every 200 hours of operation. The belt is properly tensioned when it deflects 0.26 in (7 mm) from a force of 7 lb (3 kg) applied at belt midpoint. 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. TO REPLACE AND ADJUST HYDRAULIC PUMP BELT 1. 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. 2. Open the seat support. 3. Remove the vacuum fan and engine belt guards. A 4. Loosen the pump plate mounting and adjustment bolts. CHECKING BELT TENSION A 04233 A. Hydraulic Pump Belt 8. Replace belt guards. B 9. Lower the seat support. VACUUM FAN BELT The vacuum fan belt transfers power from the pump sheave to the vacuum fan and the accessories pump. Check the belt condition and tension 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. D C TO REPLACE AND ADJUST VACUUM FAN BELT HYDRAULIC PUMP A. B. C. D. Hydraulic Pump Pump Plate Adjustment Bolts Mounting Bolts 235 MM166 (3--94) 03498 1. 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. 2. Open the seat support. 3-27 MAINTENANCE 3. Remove the vacuum fan belt guard. 5. Slide the pump assembly backward to remove the belts. 6. Replace the existing vacuum fan belt with a new belt. A B B A C 03499 BELTS 04322 VACUUM FAN BELT GUARD A. Vacuum Fan Belt B. Pump Belt 7. Position the pump belt on the sheaves. A. Turnbuckle B. Vacuum Fan C. Belt Guard 8. Push the pump forward keeping the sheaves aligned and snug the mounting bolts. 4. Loosen the pump plate mounting and adjustment bolts. 9. Tighten the pump belt as described in TO REPLACE AND ADJUST HYDRAULIC PUMP BELT. A 10. Turn the turnbuckle to tighten the vacuum fan belt to specification. B A D HYDRAULIC PUMP A. B. C. D. 3-28 Hydraulic Pump Pump Plate Adjustment Bolts Mounting Bolts C 03498 CHECKING BELT TENSION 04234 A. Vacuum Fan Belt 235 MM166 (3--94) MAINTENANCE 11. Replace the belt guard. 7. Position the new belt on the belt sheaves. 12. Lower the seat support. 8. Replace the vacuum fan belt guard. 9. Lower the seat support. MAIN BRUSH BELT The main brush belt transfers power from the accessories pump to the main brush. The belt is tensioned by a belt idler spring. A stop bolt is used to remove tension from the belt when the main brush is raised. TO REPLACE MAIN BRUSH BELT 10. Start the machine and lower the main brush. Then raise the brush. The brush should stop turning within seconds of being raised. If the belt is too tight, the brush will continue to turn. If the belt is too loose, it may jump off the idler or driven sheave. Turn the belt stop bolt to adjust belt tension. 11. Replace the left side access door. 1. 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. 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. C A B MAIN BRUSH BELT 03377 A. Idler Spring Arm B. Main Brush Belt C. Stop Bolt 235 MM166 (3--94) 3-29 MAINTENANCE 5. Using a block, sleeve, or drift, hammer the end of the bushing. Do not hammer bushing directly. TAPER LOCK BUSHINGS Taper lock bushings are used to secure the sheaves on the engine and propelling pump shafts. 6. Repeat steps 4 and 5 until torque wrench reading is the same after hammering as before. TO REMOVE TAPER LOCK BUSHING 1. Remove all set screws. 7. Fill all open holes with grease. 2. Insert a set screw into the threaded hole of the bushing. STATIC DRAG CHAIN The static drag chain prevents the buildup of static electricity in the machine. The chain is attached to the rear skirt retaining strip. B Make sure that the chain is making contact with the floor at all times. D C A TAPER LOCK BUSHING A. B. C. D. 03506 Set Screw Hub Bushing Threaded Hole 3. Tighten the set screw to loosen bushing from shaft. TO INSTALL TAPER LOCK BUSHING 1. Clean shaft, bore and outside of bushing and hub bore of all oil, lacquer, and 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). 3-30 235 MM166 (3--94) MAINTENANCE DEBRIS HOPPER AND DUST FILTER 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. DEBRIS HOPPER The debris hopper collects debris swept by the machine and should be dumped after every work shift. The hopper floor clearance should be checked and adjusted periodically. TO CHECK AND ADJUST HOPPER FLOOR CLEARANCE 1. Empty the hopper and park the machine on a smooth, level surface. B 2. Lower the hopper. C 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 Off Machine And Remove Key. 4. Check the hopper bumper to machine frame match. They should line up within 0.12 in (5 mm). Adjust by repositioning the stop bolts on the frame above the front wheels. A HOPPER STOP BOLT 03387 A. Hopper B. Stop Bolt C. Lintel 6. Replace the filter cover and check the hopper cover seal. It should be slightly compressed. B THERMO SENTRYt A The Thermo Sentryt stops the machine vacuum and closes the hopper door in case of a fire in the hopper. Check to make sure the Thermo Sentryt is operating properly after every 100 hours of operation. TO CHECK THE THERMO SENTRYt 1. 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. BUMPER STOP BOLT A. Frame B. Stop Bolt 235 MM166 (3--94) 03372 2. Unlatch the filter cover latches and remove the filter cover. 3. Place the vacuum lever in the “Normal Sweeping”position. 3-31 MAINTENANCE 4. Apply heat to the bottom of the Thermo Sentryt with a match or lighter. The vacuum lever should move to the “Wet Sweeping”position, the hopper door should close, and their circuit breakers should trip. If they do not, the system is malfunctioning. 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 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. B D AIR -- Blow compressed air, 35 psi (240 kPa) maximum, through the dust filter opposite the direction of the arrows. This may be done with the filter in the machine. Always wear eye protection when using compressed air. FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. D WATER -- Soak the dust filter in a water and mild detergent solution. Rinse the dust filter until it is clean. The maximum water pressure allowable is 40 psi (275 kPa). Air dry the wet filter; do not use compressed air. A NOTE: Be sure the dust filter is dry before reinstalling it in the machine. THERMO SENTRYt 03393 A. Thermo Sentryt B. Shaker Motor 5. Replace the filter cover and check the hopper cover seal. It should be slightly compressed. 6. After the Thermo Sentryt has cooled, reset the circuit breakers behind the control panel. 3-32 235 MM166 (3--94) MAINTENANCE TO REMOVE AND REPLACE HOPPER DUST FILTER 1. Stop the engine and set the machine parking brake. 6. Secure the filter with the shaker motor assembly. 7. Check the two filter hold-down screws. They should clear the filter by 0.03 in (1 mm). FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 8. Secure the filter cover on the filter frame with the two latches. 9. Check the hopper cover seal. It should be slightly compressed. 2. Unlatch the two filter cover latches and remove the filter cover. 3. Remove the two assembly bolts on each side of the filter and slide the assembly back. Remove the dust filter. B C D A DUST FILTER A. B. C. D. 03389 Dust Filter Shaker Motor Assembly Hold-Down Screws 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. 235 MM166 (3--94) 3-33 MAINTENANCE BRUSHES 5. Pull the brush idler arm off the arm hub. MAIN BRUSH The main brush is tubular and spans the width of the machine, sweeping debris into the debris hopper. The brush should be inspected daily for wear or damage. Remove any string or wire found tangled on the main brush, main brush drive hub, or main brush idler hub. Rotate the main brush end-for-end after every 50 hours of operation for maximum brush life and best sweeping performance. Check the main brush pattern whenever installing a new brush. The main brush should be replaced when the remaining bristles measure 1.5 in (40 mm) or less in length. TO REMOVE MAIN BRUSH 1. Stop 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. 2. Lower the main brush. NOTE: If the brush idler arm does not come off easily, thread 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. Push the main brush lever into the “UP” position. 2. Slide the main brush into the main brush compartment. 3. Align the main brush drive slots with the drive keys on the main brush drive plug. 4. Slide the main brush onto the drive plug. Make sure the drive slots and keys mate. 5. Align the main brush idler plug slots with the main brush keys. Slide the main brush idler plug into the main brush tube. 3. Remove the right side access door. 4. Remove the brush idler arm retaining bolt from the arm hub. 6. Slide the brush idler arm onto the arm hub. 7. Thread the brush idler arm retaining bolt through the idler arm and into the arm hub. 8. Tighten the brush idler arm retaining bolt. B A 9. Replace the right side access door. D TO CHECK AND ADJUST MAIN BRUSH PATTERN C MAIN BRUSH IDLER ARM A. B. C. D. Brush Idler Arm Arm Retaining Bolt Main Brush Threaded Hole 03390 1. Apply chalk, or some other material that will not blow away easily, to a smooth, level floor. 2. With the side brush and main brush raised, position the main brush over the chalked area. 3. While keeping a foot on the brakes to keep the machine from moving, lower the main brush to the floor for 15 to 20 seconds; raise the main brush and drive the machine off the test area. 3-34 235 MM166 (3--94) MAINTENANCE NOTE: If no chalk or other material is available, allow the brushes to spin on the floor for two minutes. 4. Observe the brush pattern made. The pattern should be of equal width across the length of the pattern. 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: A B 00601 TAPERED MAIN BRUSH PATTERN NORMAL MAIN BRUSH PATTERN 00582 A. Main Brush Pattern B. 2 to 2.5 in (51 to 54 mm) for machines serial number 002594 and above For machines serial number 002594 and above, and machines with the Brush Limiter Kit installed, the brush pattern width should be 2 to 2.5 in (51 to 54 mm). The brush pattern width can be adjusted by loosening and moving the brush limiter nut. A. Park the machine on a level surface. B. 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. C. Lower the main brush. D. Remove the right side access door. E. Remove the main brush. F. Reinstall the idler arm. G. Loosen the cross shaft bearing flange bolts. B C A A B 03487 BRUSH LIMITER NUT (For machines 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. 235 MM166 (3--94) CROSS SHAFT BEARING FLANGE 03550 A. Flange B. Bolts C. Cross Shaft 3-35 MAINTENANCE H. Position the idler plug so it is the same distance from the floor as the drive plug and tighten the bolts. A B I. Reinstall the main brush. J. Recheck the main brush pattern. K. Replace the right side access door. SIDE BRUSH The side brush sweeps debris from curbs or gutters into the path of the main brush. The side brush should be inspected daily for wear or damage. Remove any string or wire found tangled on the side brush or side brush drive hub. The side brush pattern should be checked periodically. One-third of the side brush bristles should contact the floor when the brush is in motion. The side brush pattern adjustment is made by turning the side brush adjustment 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. Read Manual. 03392 SIDE BRUSH A. Side Brush B. Retaining Bolts 6. Slide the side brush off the side brush hub. TO INSTALL SIDE BRUSH 1. Position the side brush on the side brush drive hub. 2. Secure the side brush to the hub with the four bolts removed earlier. 3. Check the side brush pattern. Adjust the pattern with the side brush adjustment knob. 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 Off Machine And Remove Key. A 4. Raise the side brush. 5. Remove the four side brush retaining bolts from the bottom of the side brush. SIDE BRUSH PATTERN 03376 A. Contact Area 3-36 235 MM166 (3--94) MAINTENANCE SKIRTS AND SEALS BRUSH SKIRTS REAR SKIRTS Brush skirts control main brush dusting. They are located on each of the brush access doors. The skirts should be inspected for wear or damage daily. They should clear the floor by 0 to 0.12 in (0 to 5 mm) at all times. 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 BRUSH SKIRTS TO REPLACE AND ADJUST REAR SKIRTS 1. Park the machine on a smooth, level floor. 1. Park the machine on a smooth, level surface. 2. Stop the engine and set the machine parking brake. 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. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Remove the side access doors. 3. Remove the side access doors. 4. Replace or loosen the skirt and retaining strip bolts. Adjust the skirt height and retighten the retaining strip bolts. 4. Remove the rear skirt retaining strips and the rear skirts. A C B REAR SKIRTS B RIGHT SIDE BRUSH SKIRT A. Retaining Strip B. Brush Skirt 5. Replace the doors. 6. Check the skirt clearance. A 03388 03390 A. Brush Skirt B. Vertical Rear Skirt C. Retaining Strip 5. Loosely install new skirts with the existing retaining strips. 6. Slide the vertical rear skirt up or down so it is 0 to 0.12 in (0 to 5 mm) above the floor. 7. Retighten the retaining strip bolts. 235 MM166 (3--94) 3-37 MAINTENANCE HOPPER LIP SKIRT The hopper lip skirt floats over debris and helps deflect the 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. 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 wear or damage after every 100 hours of operation. TO REPLACE HOPPER LIP SKIRT 1. Empty the machine debris hopper. 2. Raise the hopper. 3. Engage the hopper support bar. TO REPLACE DUST SEALS 1. Empty the debris hopper. WARNING: Falling Hopper. Engage Hopper Support Bar. Read Manual. 2. Raise the hopper. 4. Stop the machine on a level surface, 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. 5. Remove the skirt retaining strip and the skirt. 3. Engage the hopper support bar. WARNING: Falling Hopper. Engage Hopper Support 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 Key. 5. Remove the side access doors to gain access to the side seals. A B C HOPPER LIP SKIRT 03384 A. Hopper B. Lip Skirt C. Retaining Strip 3-38 235 MM166 (3--94) MAINTENANCE 6. Remove the retaining strip of the seal to be replaced. 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 Key. 5. Open the dump door. 6. Remove the seal retaining strip. A A B HOPPER SEALS 03369 A. Top Hopper Seal B. Side Hopper Seal 7. Remove the existing seal or skirt. 8. Mount the new seal or skirt to the machine with the retaining strip removed earlier. 9. Replace the side access doors if removed. 10. Raise the hopper, place the hopper support bar in its storage position, and lower the hopper. HOPPER DUMP DOOR SEAL The hopper dump door seal allows the hopper to be high dumped without scattering debris. Check the seal for damage after every 100 hours of operation. B 03384 HOPPER DUMP DOOR SEAL A. Hopper B. Dump Door Seal 7. Remove the seal. 8. Mount the new seal to the door with the sponge core and retaining strip removed earlier. 9. Raise the hopper, position the hopper support bar in its storage position, and lower the hopper. TO REPLACE HOPPER DUMP DOOR SEAL 1. Empty the debris hopper. 2. Raise the hopper. 235 MM166 (3--94) 3-39 MAINTENANCE VACUUM FAN SEAL FILTER COVER SEAL The vacuum fan seal seals the vacuum fan to the filter cover. Check the seal for damage after every 100 hours of operation. The filter cover seal seals the filter box to the filter cover. Check the seal for damage after every 100 hours of operation. A A VACUUM FAN SEAL A. Vacuum Fan Seal 3-40 03387 B FILTER COVER SEAL 03375 A. Filter Cover B. Seal 235 MM166 (3--94) MAINTENANCE BRAKES AND TIRES BRAKES TIRES The foot brake and the parking brake operate the linkage which controls the brakes on the front wheels. 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 100 hours of operation. The foot brake needs no regular adjustment. The parking brake should be adjusted after every 200 hours of operation or whenever it becomes very easy to set. To adjust the parking brake, turn the 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. REAR WHEEL Torque the rear wheel nuts in a star pattern to 122 to 150 Nm (90 to 110 ft lb) after the first 50-hours of operation, and every 800 hours there after. A B BRAKE ASSEMBLY 03369 A. Clevis B. Brake Rod 235 MM166 (8--95) 3-41 MAINTENANCE 3-42 235 MM166 (3--94) APPENDIX SECTION 4 CONTENTS HARDWARE INFORMATION . . . . . . . . . . . . STANDARD BOLT TORQUE CHART . . METRIC BOLT TORQUE CHART . . . . . BOLT IDENTIFICATION . . . . . . . . . . . . . . THREAD SEALANT AND LOCKING COMPOUNDS . . . . . . . . . . . . . . . . . . . HYDRAULIC FITTING INFORMATION . . . . HYDRAULIC TAPERED PIPE FITTING (NPT) TORQUE CHART . . . . . . . . . . HYDRAULIC TAPERED SEAT FITTING (JIC) TORQUE CHART . . . . . . . . . . . HYDRAULIC O--RING FITTING TORQUE CHART . . . . . . . . . . . . . . . . 235 MM166 (5--91) Page 4-3 4-3 4-3 4-3 4-3 4-4 4-4 4-4 4-4 4-1 APPENDIX 4-2 235 MM166 (5--91) APPENDIX HARDWARE INFORMATION The following charts state standard plated hardware tightening ranges for normal assembly applications. Decrease the specified torque by 20% when using a thread lubricant. Do not substitute lower grade hardware for higher grade hardware. If higher grade hardware than specified is substituted, tighten only to the specified hardware torque value to avoid damaging the threads of the part being threaded into, as when threading into speed nuts or weldments. STANDARD BOLT TORQUE CHART Thread Size SAE Grade 5 Torque ft lb (Nm) SAE Grade 8 Torque ft lb (Nm) 0.25 in 0.31 in 0.38 in 0.44 in 0.50 in 0.62 in 0.75 in 1.00 in 7--10 (9--14) 15--20 (20--27) 27--35 (37--47) 43--56 (58--76) 65--85 (88--115) 130--170 (176--231) 215--280 (291--380) 500--650 (678--881) 10--13 (14--38) 20--26 (27--35) 36--47 (49--64) 53--76 (72--103) 89--116 (121--157) 117--265 (159--359) 313--407 (424--552) 757--984 (1026--1334) NOTE: Decrease torque by 20% when using a thread lubricant. Front wheel nut -- 10 to 12 ft lb (14 to 16 Nm) while turning wheel, tighten to spec, then backoff, retighten by hand till snug, then turn to next slot. Rear hub to shaft nut -- 175 ft lb (240 Nm) then to next slot. Damper solenoid nut -- 20 to 23 in lb (2.5 to 3 Nm). BOLT IDENTIFICATION Identification Grade Marking Specification and Grade SAE--Grade 5 SAE--Grade 8 ISO--Grade 8.8 ISO--Grade 10.9 01395 METRIC BOLT TORQUE CHART Thread Size Class 8.8 Torque ft lb (Nm) Class 10.9 Torque ft lb (Nm) 2 (3) 4 (5) 7 (9) 18 (24) 32 (43) 58 (79) 94 (127) 144 (195) 260 (352) 470 (637) 3 (4) 6 (8) 10 (14) 25 (34) 47 (64) 83 (112) 133 (180) 196 (265) 336 (455) 664 (900) M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 NOTE: Decrease torque by 20% when using a thread lubricant. THREAD SEALANT AND LOCKING COMPOUNDS Thread sealants and locking compounds may be used on this machine. They include the following: Locktite 515 sealant -- gasket forming material. TENNANT Part No. 75567,15 oz (440 ml) cartridge. Locktite 242 blue -- medium strength thread locking compound. TENNANT Part No. 32676, 0.5 ml tube. Locktite 271 red -- high strength thread locking compound. TENNANT Part No. 19857, 0.5 ml tube. 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. 235 MM166 (5--91) 4-3 APPENDIX HYDRAULIC FITTING INFORMATION HYDRAULIC TAPERED PIPE FITTING (NPT) TORQUE CHART NOTE: Ratings listed are when using teflon thread seal. Minimum Torque Maximum Torque 10 ft lb (14 Nm) 25 ft lb (34 Nm) 50 ft lb (68 Nm) 30 ft lb (41 Nm) 50 ft lb (68 Nm) 100 ft lb (136 Nm) Size 1/4 NPT 1/2 NPT 3/4 NPT HYDRAULIC TAPERED SEAT FITTING (JIC) TORQUE CHART Tube O.D. (in) Thread Size Maximum Torque 0.25 0.38 0.50 0.62 0.75 1.0 0.44--20 0.56--18 0.75--16 0.88--14 1.12--12 1.31--12 9 ft lb (12 Nm) 20 ft lb (27 Nm) 30 ft lb (41 Nm) 40 ft lb (54 Nm) 70 ft lb (95 Nm) 90 ft lb (122 Nm) HYDRAULIC O--RING FITTING TORQUE CHART Tube O.D.(in) Thread Size Minimum Torque Maximum Torque 0.25 0.38 0.44--20 0.56--18 0.50 0.75--16 0.62 0.75 1.0 0.88--14 1.12--12 1.31--12 6 ft lb (8 Nm) 13 ft lb (18 Nm) *10 ft lb (14 Nm) 20 ft lb (27 Nm) *21 ft lb (28 Nm) 25 ft lb (34 Nm) 45 ft lb (61 Nm) 60 ft lb (81 Nm) 9 ft lb (12 Nm) 20 ft lb (27 Nm) 12 ft lb (16 Nm) 30 ft lb (41 Nm) 24 ft lb (33 Nm) 40 ft lb (54 Nm) 70 ft lb (95 Nm) 90 ft lb (122 Nm) NOTE: Do not use sealant on o--ring threads. *Aluminum bodied components 4-4 235 MM166 (5--91)