Green Machines 500ze User manual

500ze
*ym180*
YM180
Rev. 03 (8-2013)
CloudMakerTechnology
Air Sweeper
Operator Manual
To view, print or download
the latest manual, visit:
www.tennantco.com/manuals
Global

INTRODUCTION
This manual is furnished with each new model. It provides necessary operation and maintenance instructions.
Read this manual completely and understand
the machine before operating or servicing it.
Read this manual completely and understand the machine before operating or servicing it.
This machine will provide excellent service. However, the best results will be obtained at minimum costs if:
SThe machine is operated with reasonable care.
SThe machine is maintained regularly - per the machine maintenance instructions provided.
SThe machine is maintained with manufacturer supplied or equivalent parts.
PROTECT THE ENVIRONMENT
Please dispose of packaging materials,
used components such as batteries
and fluids in an environmentally safe
way according to local waste disposal
regulations.
Always remember to recycle.
Model No. −
Serial No. −
Installation Date −
Please fill out at time of installation for future reference.
MACHINE DATA
The following publications are included with this
machine:
Operators Manual
Service Schedule
Parts Catalog
Please contact a local TENNANT distributor to
order additional publications.
INTENDED USE
The 500ze is designed to sweep disposable debris from hard surfaces (concrete, asphalt, stone, synthetic, etc…)
typically found in outdoor urban areas (city streets, pedestrian malls, sidewalks, parking lots, etc…). Do not use
this machine on soil, grass, artificial turf, or outdoor carpet surfaces, Do not use the machine other than described
in this Operator Manual.
Tennant UK Cleaning Solutions Ltd.
Bankside, Falkirk FK2 7XE
Scotland, United Kingdom
Phone: (+44) 1324−611666
www.greenmachines.com
Tennant Company
PO Box 1452
Minneapolis, MN 55440
Phone: (800) 553−8033 or (763) 513−2850
www.tennantco.com
DECLARATION OF CONFORMITY FOR MACHINERY
(according to Annex II A of the Machinery Directive)
TENNANT N.V.
Industrielaan 6 5405 AB
P.O. Box 6 5400 AA
Uden −The Netherlands
Uden, 21−05−2010
EN
Herewith declares, on our own responsibility, that the machinery
500ze
−is in conformity with the provisions of the Machinery Directive (2006/42/EC), as amended and with national
implementing legislation
−is in conformity with the provisions of the Electro Magnetic Compatibility Directive 2004/108/EC
−is in conformity with the provisions concerning noise emission for outdoor use (Directive 2000/14/CE) and
with national implementing legislation −Lwa = 96 dB(A) Average & Lwa = 99 dB(A) Guaranteed
and that
−the following harmonized standards or parts of these standards have been applied: EN ISO 14121−1, EN
1037, EN 60335−1, EN 60204−1, EN ISO 13849−1, EN ISO 13849−2, EN 60529, EN ISO 4413, EN 349, EN
55012, EN 61000−6−2, EN ISO 11201, EN ISO 4871, EN ISO 3744*, EN ISO 13059*, EN ISO 3450, EN
60335−2−72.
−the following national standards or parts of these standards have been used:
Specifications and parts are subject to change without notice.
Original Instructions, copyright E2011 −2013 TennantCompany

CONTENTS
1
500zeYM180 (11−2012)
CONTENTS
Page
Safety Precautions 3.......................
Operation 9...............................
Machine Components 9..................
Controls And Instruments 10...............
Symbol Definitions 12.....................
Operation Of Controls 13..................
Drive Lever
(Forward / Neutral / Reverse) 13......
Brush Levers 13.......................
Parking Brake Indicator (Red) 13........
Turn Signal / Hazard Warning Light
Indicator (Green) 13................
Headlight High Beam Indicator (Clear) 13.
Hopper Drain Switch 14................
Brush Speed Knob 14..................
12−Volt Outlet 14......................
Windshield Defroster Switch 14.........
Heater Fan Switch 14..................
Transit / Work Modes Switch 15.........
Vacuum Fan Speed Knob 16............
Vacuum Fan Speed Boost 16...........
Master Light Switch 17.................
Rear Fog Light Switch 18...............
Overhead Work Light Switch 18.........
Hazard Warning Light Switch 18.........
Warning Beacon / Audible
Alarm Switch 18....................
Air Conditioner (Option) 19.............
Water Switch (Dust Suppression) 20.....
Water Flow Control Knob 20............
Brush Pressure Adjustment Knob 21.....
Parking Brake Lever 21................
Accelerator Pedal 21...................
Brake Pedal 21.......................
Steering Wheel Height
Adjustment Handle 22...............
Headlight And Multifunctional Switch 22..
Windshield Wiper / Washer Switch 22....
Horn Button 22........................
Operator Seat 23......................
Seat Belts 23.........................
Operator Seat Safety Switch 23.........
Door Locks 24........................
Battery Isolation Button 24..............
MD3 Machine Management System 25...
Right And Left Battery
Charge Displays 25..............
Speedometer 25....................
Total Distance Display 25............
Operation Mode Display 25..........
Fan Speed Display 26...............
Hour / Distance Displays 26..........
Information Screen Display 27........
Brush Information 28.....................
How The Machine Works 28...............
Pre−Operation Checklist 29................
Post−Operation Checklist 29...............
Starting The Machine 30..................
Turning Off The Machine 30...............
Page
While Operating The Machine 31...........
Sweeping 31............................
Descending And Ascending Inclines 33......
Driving Over Curbs 34....................
Raising / Lowering The Hopper 34..........
Engaging The Hopper Safety Arm 35.......
Disengaging The Hopper Safety Arm 36.....
Using The Wander Hose 36...............
Emptying The Hopper 38..................
Cleaning The Machine 39.................
Cleaning The Vacuum Fan Assembly 41....
Checking / Filling The Water Tank 41.......
MD3 Machine Management System
Fault Screens 42......................
Options 44..............................
Pressure Washer (Option) 44...........
Rear View Camera (Option) 45..........
Radio And Compact Disk
Player (Option) 45..................
Automatic Lubrication
System (Option) 45.................
Machine Troubleshooting 46...............
Conditions Table 48.......................
Maintenance 49.............................
Maintenance Chart 49....................
Lubrication 52...........................
Lubrication Points 52...................
Hydraulics 53............................
Hydraulic Hoses 53....................
Hydraulic Fluid 54.....................
Battery Isolation Button 54.................
Battery Packs 54.........................
Charging The Battery Packs 55.........
Battery (12−volt) 58.......................
Fuses 59...............................
Replacing The Fuses 59................
Brushes 60..............................
Replacing The Brushes 60..............
Adjusting The Brush Angle 60...........
Brush Arms 61........................
Brush Motors 61......................
Dust Suppression / Vacuum 62.............
Adjusting / Replacing The Nozzle Flap 62.
Vacuum Nozzle Skid 63................
Cast Iron Skid 63......................
Spray Jets 63.........................
CloudMaker 63........................
Water Tank 64...........................
Drain Cap Filter 64....................
Water Tank Door Retainer Chain 64......
Hopper 65...............................
Hopper Door, Hopper Inlet, And
Vacuum Fan Access Door Seals 65...
Hopper Drain Seal 65..................
Hopper Cyclone Screens 65............
Hopper Drain Screen 65................
Hopper External Drain Tube 66..........
Hopper Door Screen 66................
Vacuum Fan Access Door 66...........

CONTENTS
500zeYM180 (12−2011)
2
Page
Cab 67..................................
Windshield Wiper Blade 67.............
Rear View Camera (Option) 67..........
Windshield Washer Fluid 67...............
Brakes And Tires 68......................
Service Brakes 68.....................
Parking Brake Lever 68................
Tires 68..............................
Wheel Torque 68......................
Air Conditioner 69........................
Wander Hose 69.........................
Pressure Washer (Option) 69..............
Automatic Lubrication System 70...........
Filling The Automatic Lubrication
System Reservoir 70................
Tilting / Lowering The Cab 71..............
Tilting The Cab 71.....................
Lowering The Cab 71..................
Tilting / Lowering The Hopper Manually 72...
Tilting The Hopper Manually 72..........
Lowering The Hopper Manually 73.......
Towing / Transporting The Machine 74......
Towing The Machine 74................
Transporting The Machine 74...........
Machine Jacking 76......................
Storage And Freeze Protection 77..........
Storing The Machine 77................
Freeze Protection 77...................
Specifications 78............................
General Machine Dimensions/Capacities 78.
General Machine Performance 78..........
Hydraulic System 79......................
Steering 79..............................
Power Type 79...........................
Tires 79.................................
Machine Dimensions 80...................

SAFETY PRECAUTIONS
3
500zeYM180 (11−2012)
IMPORTANT SAFETY INSTRUCTIONS −SAVE THESE INSTRUCTIONS
The following precautions are used throughout
this manual as indicated in their description:
WARNING: To warn of hazards or unsafe
practices that could result in severe
personal injury or death.
CAUTION: To warn of unsafe practices
that could result in minor or moderate
personal injury.
FOR SAFETY: To identify actions that must be
followed for safe operation of equipment.
The following information signals potentially
dangerous conditions to the operator. Know when
these conditions can exist. Locate all safety
devices on the machine. Report machine damage
or faulty operation immediately.
WARNING: Batteries emit hydrogen gas.
Explosion or fire can result. Keep
sparks and open flame away. Keep
covers open when charging.
WARNING: Raised hopper may fall.
Engage hopper support arm.
WARNING: Lift arm pinch point. Stay
clear of hopper lift arms.
WARNING: Flammable materials can
cause explosion or fire. Do not use
flammable materials in tank. Only use
water.
WARNING: Do not spray people or
animals. Severe personal injury can
result. Wear eye protection. Hold
sprayer with two hands.
FOR SAFETY:
1. Do not operate machine:
−Unless 18 years of age or older.
−Unless trained and authorized.
−Unless operator manual is read and
understood.
−Unless mentally and physically
capable of following machine
instructions.
−If it is not in proper operating
condition.
−In areas that are too dark to safely see
the controls or operate the machine
unless operating / headlights are
turned on.
−In areas where flammable
vapors/liquids or combustible dusts
are present.
2. Before starting machine:
−Check machine for fluid leaks.
−Make sure all safety devices are in
place and operate properly.
−Check brakes and steering for proper
operation.
−Adjust seat and fasten seat belt.
3. When starting machine:
−Keep foot on brake and place
directional lever in neutral.
4. When using machine:
−Do not pick up burning or smoking
debris, such as cigarettes, matches or
hot ashes
−Use brakes to stop machine.
−Go slowly on inclines and slippery
surfaces.
−Keep all parts of body inside operator
station while machine is moving.
−Use care when reversing machine.
−Move machine with care when hopper
is raised.
−Make sure adequate clearance is
available before raising hopper.
−Do not raise hopper when machine is
on an incline.
−Do not make adjustments on MD3
machine management system while
the machine is moving. Always stop
machine before making adjustments.
−Do not operate machine if MD3 display
screen is inoperable.
−Never allow children to play on or
around machine.
−Do not carry passengers on machine.
−Always follow safety and traffic rules.
−Report machine damage or faulty
operation immediately.

SAFETY PRECAUTIONS
500zeYM180 (8−2013)
4
5. Before leaving or servicing machine:
−Stop on level surface.
−Place the drive lever in neutral.
−Set parking brake.
−Turn off machine and remove key.
6. When servicing machine:
−All work must be done with sufficient
lighting and visibility.
−Avoid moving parts. Do not wear loose
clothing, jewelry and secure long hair.
−Block machine tires before jacking
machine up.
−Jack machine up at designated
locations only. Support machine with
jack stands.
−Use hoist or jack that will support the
weight of the machine.
−Do not power spray or hose off
machine near electrical components.
−Engage and lock battery isolation
button before working on machine.
−Avoid contact with battery acid.
−Battery installation must be done by
trained personnel.
−Use cardboard to locate leaking
hydraulic fluid under pressure.
−The use of incompatible battery
chargers may damage battery packs
and potentially cause a fire hazard.
−Use Tennant supplied or approved
replacement parts.
−Wear personal protective equipment
as needed and where recommended in
this manual.
For Safety: Wear hearing protection.
For Safety: Wear protective gloves.
For Safety: Wear eye protection.
For Safety: Wear protective dust mask.
7. When loading/unloading machine
onto/off truck or trailer:
−Drain tanks before loading machine.
−Empty debris hopper before loading
machine.
−Use ramp, truck or trailer that will
support the weight of the machine and
operator.
−Use winch. Do not drive the machine
onto/off the truck or trailer unless the
load height is 380 mm (15 in) or less
from the ground.
−Set parking brake after machine is
loaded.
−Turn off machine and remove key.
−Block machine tires.
−Tie machine down to truck or trailer.

SAFETY PRECAUTIONS
5
500zeYM180 (11−2012)
The following safety labels are mounted on the
machine in the locations indicated. Replace
damaged or missing labels.
Do Not Operate Machine Without
Cab Lock Down Bracket Installed −
Located on frame of machine.
Maximum Gradient / Speed−
Located on windshield.
Consult Workshop
Manual Before
Welding −Located on
right panel.
Do Not Operate Machine
Without Cab Lock Down
Bracket Installed −
Located on windshield.
Do Not Operate
Machine Without Cab
Lock Down Bracket
Installed −Located on
right panel.
Be Sure Tires Are
Properly Inflated −
Located on right
panel.
Consult Workshop
Manual Before
Welding −Located
on windshield.
Use Caution When
Approaching Curbs −
Located on windshield.
Moving Fan. Keep Away.
Read Operator Manual.
Remove Key From
Machine. Refer To
Workshop Manual −
Located above vacuum fan
access door.

SAFETY PRECAUTIONS
500zeYM180 (11−2012)
6
Raised Hopper May Fall.
Engage Hopper Support
Arm −Located on hopper
and water tank.
Do Not Spray People Or
Animals. Always Wear Eye
Protection −Machines with
optional spray wand only
Lift Arm Pinch Point. Stay
Clear Of Hopper Lift Arms.
Read Operator Manual.
Remove Key From Machine.
Refer To Workshop Manual −
Located on front of hopper.
Read Manual Before
Operating Machine −
Located on both doors.
Moving Fan. Keep Away. Read Operator
Manual. Remove Key From Machine. Refer
To Workshop Manual −Located on lower
front of hopper.

SAFETY PRECAUTIONS
7
500zeYM180 (11−2012)
Do Not Spray Battery Packs
With Pressurized Water.
Read Operator Manual −
Located on top of battery
connection box.
Do Not Insert Fingers
Into Battery Pack Power
Terminal −Located on
front of battery
connection box cover.
Only Properly Trained Personnel
Are Permitted To Charge Battery
Packs. Read Operator Manual.
Remove Key From Machine. Refer
To Workshop Manual −Located on
top of battery connection box cover.
Battery Pack Cart Location. Read
Operator Manual −Located on
top of both battery packs.
Potential High Voltage Hazard −
Located on main electrical box at
rear of machine.
Potential High Voltage
Hazard −Located on
various electric
components on machine.

SAFETY PRECAUTIONS
500zeYM180 (11−2012)
8
Fill Water Tank With Water
Only. Read Operator Manual −
Located on back of water tank.
Clean Water Tank Filter With
Clean Water Only. Remove
Key From Machine. Refer To
Workshop Manual −Located
on back of water tank.
Center Of Battery Pack −
Located underneath
side panel on center of
both battery packs.
A−Rated Sound Power Level
Per CE Compliance −Located
on operator seat base.
Battery Pack Cart Location −
Located underneath side
panel near bottom on both
battery packs.
Consult Workshop
Manual Before Changing
Hydraulic Filter −Located
on hydraulic tank.
Brush Arm Pinch Point.
Stay Clear. Read Operator
Manual. Remove Key
From Machine. Refer To
Workshop Manual −
Located on frame of
machine.

OPERATION
9
500zeYM180 (12−2011)
OPERATION
MACHINE COMPONENTS
23
4
5
1
11
14
17
6
7
10
9
18 12
19
8
16
20
13
15
1. Wander hose
2. Hopper
3. Warning beacon
4. Overhead work lights
5. Headlights / Turn signals
6. Right access door
7. Vacuum fan access door
8. Right brush
9. CloudMaker (Dust suppression)
10. Spray jets (Dust suppression)
11. Rear view camera (Optional)
12. Water tank
13. Water tank level tube
14. Taillights / Turn signals
15. Rear fog light
16. Water tank door
17. Left access door
18. Left access door
19. Battery compartment
20. Left brush

OPERATION
10 500zeYM180 (12−2011)
CONTROLS AND INSTRUMENTS
2
3
1
9
8
7
4
6
10
11
12
5
13
14
15
16 17
18
19
20
21
22
23
24
25
1. Headlight High Beam Indicator (Clear)
2. Turn Signal / Hazard Warning Light
Indicator (Green)
3. Parking Brake Indicator (Red)
4. Master Light Switch
5. Rear Fog Light Switch
6. Windshield Defroster Switch
7. Heater Fan Switch
8. Air Conditioner Switch (Optional)
9. 12−Volt Outlet
10. MD3 Machine Management System
Display
11. Hazard Warning Light Switch
12. Overhead Work Light Switch
13. Warning Beacon / Audible Alarm Switch
14. USB Port
15. Drive Lever
(Forward / Neutral / Reverse)
16. Left Brush Lever
17. Right Brush Lever
18. Transit / Work Modes Switch
19. Hopper Raise / Lower Switch
20. Hopper Drain Switch
21. Vacuum Fan Speed Knob
22. Brush Speed Knob
23. Pressure Washer Switch (Optional)
24. Water Control Knob (Dust Suppression)
25. Wander Hose Switch

OPERATION
11
500zeYM180 (11−2012)
1
3
5
6
7
4
2
10
98
1. Parking Brake Lever
2. Brush Pressure Adjustment Knob
3. Water Flow Control Knob
4. Accelerator Pedal
5. Brake Pedal
6. Steering Wheel
7. Steering Wheel Height Adjustment
Handle
8. Headlight and Multifunctional Switch
9. Windshield Wiper / Washer Switch
10. Horn Button

OPERATION
12 500zeYM180 (12−2011)
SYMBOL DEFINITIONS
These symbols are used on the machine to
identify controls, displays, and features.
Transit / Work Mode Hazard Lights
Brush Speed Signal Light / 4−Way Hazard Light
Brush Pressure Air Conditioner (Option)
Vacuum Fan Speed Parking Brake
Horn Bright Headlights
Warning Beacon Overhead Lights
Operating Lights Dust Suppression 0
Windshield Defroster Dust Suppression 1
Master Lights Dust Suppression 2
Heater Fan Water Flow Control
Rear Fog Lights Wander Hose (Option)
Raise / Lower Hopper Pressure Washer (Option)
Hopper Drain

OPERATION
13
500zeYM180 (12−2011)
OPERATION OF CONTROLS
DRIVE LEVER
(FORWARD / NEUTRAL / REVERSE)
NOTE: Lift the lock toward the ball handle before
moving the Drive lever to the desired position.
Forward: Place the Drive lever into the forward
position and press the accelerator pedal.
Neutral: Place the Drive lever into the middle
position.
Reverse: Place the Drive lever into the reverse
position and press the accelerator pedal.
BRUSH LEVERS
Use the Brush levers to adjust the brush path
width and edge sweep.
PARKING BRAKE INDICATOR (RED)
The Parking brake indicator illuminates when the
parking brake is engaged.
TURN SIGNAL / HAZARD WARNING LIGHT
INDICATOR (GREEN)
The Turn signal /Hazard warning light indicator
illuminates when the turn signals or hazard
warning lights are activated.
HEADLIGHT HIGH BEAM INDICATOR (CLEAR)
The Headlight high beam indicator illuminates
when the headlight high beams are on.

OPERATION
14 500zeYM180 (12−2011)
HOPPER DRAIN SWITCH
Use the Hopper drain switch to drain excess water
from the hopper.
BRUSH SPEED KNOB
Turn the Brush speed knob clockwise to increase
the speed of both brushes and counterclockwise
to decrease the speed of both brushes.
12−VOLT OUTLET
Remove the cover to access the 12−volt outlet.
WINDSHIELD DEFROSTER SWITCH
Use the Windshield defroster switch to defrost the
windshield.
HEATER FAN SWITCH
Use the 3−way Heater fan speed switch to
operate / adjust the heater.

OPERATION
15
500zeYM180 (12−2011)
TRANSIT / WORK MODES SWITCH
Transit Mode (top position) is for moving between
job sites. The machine can reach speeds of up to
25 km/h (16 mph) when in this mode. The brushes
raise and stop rotating, the vacuum head rises,
and the vacuum fan stops operating when the
machine is placed into the Transit Mode.
Work Mode 1 (middle position) is for sweeping.
The machine can reach speeds of up to 12 km/h
(8 mph) when in this mode. The brushes lower
and begin rotating, the vacuum head lowers, and
the vacuum fan begins operating when the
machine is placed into Work Mode 1.
Work Mode 2 (bottom position) is for moving
short distances between work areas within a job
site and driving over curbs or speed bumps. The
machine can reach speeds of up to12 km/h (8
mph) when in this mode. The brushes raise and
stop rotating, the vacuum head rises, and the
vacuum fan stops operating when the machine is
placed into Work Mode 2. The machine
automatically provides increased traction.

OPERATION
16 500zeYM180 (12−2011)
VACUUM FAN SPEED KNOB
Turn the Vacuum fan speed knob clockwise to
increase the vacuum and counterclockwise to
decrease the vacuum.
Observe the MD3 machine management system
display for the vacuum fan speed.
NOTE: For normal operating conditions the
vacuum fan speed should be set below 2400 rpm.
VACUUM FAN SPEED BOOST
The vacuum fan speed can be set above 2400
rpm (boost). The vacuum fan speed boost is
available only five times per hour for up to 5
minutes per boost period (25 minutes total per
hour). The vacuum fan speed will be limited to
2300 rpm for the remainder of the hour after the
five boost periods.
A countdown bar on the MD3 machine
management system display shows the amount of
time remaining for the vacuum fan speed to stay
above 2400 rpm.
If the vacuum fan speed is left above 2400 rpm
beyond the 5−minute interval an audible alarm will
sound, the vacuum fan speed control system will
automatically reduce the fan speed to below 2400
rpm, and a warning message will appear on the
MD3 machine management system display.

OPERATION
17
500zeYM180 (12−2011)
The vacuum fan speed control must be reset after
the audible alarm sounds. To reset the vacuum
fan speed control system, stop the machine, place
the Drive lever in neutral, turn off the machine,
turn on the machine, and set the vacuum speed to
below 2400 rpm.
To continue cleaning beyond the 5−minute interval
and avoid resetting the vacuum fan speed control
system, reduce the vacuum fan speed to less
than 2400 rpm, for at least 30 seconds, before the
countdown bar expires at the end of the 5−minute
interval. The vacuum fan speed can again be set
above 2400 rpm for up to an additional 5 minutes.
If this is not done before the end of 5 minutes, the
vacuum fan speed control system will
automatically reduce the fan speed and the
system will need to be reset.
MASTER LIGHT SWITCH
Use the 3−position Master light switch to control
the headlights, overhead work lights, and rear fog
lights. Push the switch to the second position to
operate only the running lights. Push the switch to
the third position to operate the headlights and
allow use of the overhead work lights and rear fog
light.
Push the switch back to the first position to turn
off all lights.
NOTE: The rear fog light and overhead work light
switches must be in the on position for the lights
to function.

OPERATION
18 500zeYM180 (12−2011)
REAR FOG LIGHT SWITCH
Use the Rear fog light switch to operate the rear
fog lights. The Master light switch must be in the
third position to operate the rear fog lights.
OVERHEAD WORK LIGHT SWITCH
Use the Overhead work light switch to operate the
overhead work lights. The Master light switch
must be in the third position to operate the
overhead work lights.
HAZARD WARNING LIGHT SWITCH
Use the Hazard warning light switch to activate
the hazard lights.
WARNING BEACON / AUDIBLE ALARM
SWITCH
Use the 3−position Warning beacon / audible
alarm switch to activate the warning beacon and
audible alarm. Push the switch to the second
(middle) position to activate only the warning
beacon.
Push the switch to the third (lower) position to
activate both the warning beacon and audible
alarm. Push the switch back to the first position to
turn off the warning beacon and audible alarm.
The warning beacon can be swung back behind
the cab to allow for lower clearances.