Green Machines 525 Hi-Speed User manual

525 Hi- Speed
*YM137*
YM044
Rev. 9 (2-2006)
To view, print or download
the latest manual, visit:
www.tennantco.com/manuals
www.greenmachines.com
English EN
Operators Manual

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,
old machine components 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
Tennant UK Cleaning Solutions Ltd.
Bankside, Falkirk FK2 7XE
Scotland, United Kingdom
Phone: [phone]
www.greenmachines.com
Tennant Company
PO Box 1452
Minneapolis, MN 55440
Phone: [phone] or (763) 513- 2850
www.tennantco.com
Specifications and parts are subject to change without notice.
Original Instructions, copyright E2006 Tennant Company

Issue 9 ii February 2006
ADDITIONAL DOCUMENTATION
The Green Machine 525 is supplied with:
•An Operators Manual
•Service Schedule
•Warranty Card
•Kubota Engine Manual
The above items are provided as part of a support package for the machine and everyone who is involved in
Operating, Supervising and managing the machines and their tasking, should be made aware of the above
documentation and the information contained therein.

Issue 9 iii February 2006
GREEN MACHINES
OPERATORS MANUAL FOR
The 525 Hi-Speed Green Machine®
Issue 9 – February 2006

Issue 9 iv February 2006
NOTE
Throughout this manual, left and right hand sides apply when sitting in the cab, looking forward.
Right hand
side
Left hand
side

Issue 9 v February 2006
CONTENTS
SECTION 1 – BEFORE YOU START 1
1.1 Always top ten 1
1.2 Never top ten 1
1.2.1 Operator Check List 2
1.3 How the machine works 3
1.4 Things to avoid while sweeping 3
1.5 Get to know your machine 4
1.6 Setting the brush angle 5
1.7 Changing the brushes 6
1.8 Setting the nozzle height 6
SECTION 2 – GETTING STARTED 7
2.1 Adjusting the driving controls 8
2.2 Learning about the switches 9
2.2.1 Switch column 9
2.2.2 Multifunction lever switch 10
2.3 Driving the machine 11
2.3.1 Movement mode 11
2.3.2 Speed control (accelerator) pedal 11
2.3.3 Braking 12
2.3.4 Wheel Tracking 12
2.3.5 Gauges and beacons 13
2.3.6 Forward / Neutral / Reverse 13
2.3.7 Starting & stopping the engine 14
2.3.8 Going up pavement kerbs 15
2.4 Using the Sweep mode 16
2.4.1 Switching to Sweep mode 16
2.4.2 Water system 16
2.4.3 Setting the brush height 18
2.4.4 Moving the brushes sideways 18
2.4.5 Setting impeller/brush speed 19
Setting engine speed see 2.7.2
2.4.6 Tilting the hopper 20
2.5 Whoosh hose 22
2.5.1 Using the whoosh hose 22
2.5.2 Unblocking a blocked whoosh hose 22
2.6 Cab comfort 22
2.6.1 Cab temperature 22
2.6.2 Other devices 23
2.7 Electronic control system (“brain”) 24
2.7.1 MDM (“brain” & display) 24
2.7.2 Setting engine speed 25
2.7.3 XT2 (“slave”) 27
2.8 Safety features & procedures 28
2.9 Fuse boxes 30
SECTION 3– OPERATOR CHECKS 31
3.1 Daily Operator Checks 31
3.2 Weekly Operator Checks 34

Issue 9 vi February 2006
SECTION 4– OPTIONS & ACCESSORIES 35
4.1 Rear-view camera 35
4.2 Pressure Washer 38
4.3 Street Washer 39
4.4 Air Conditioning 42
4.5 Dog Excrement Attachment (DEA) & (CSA) (Option) 43
4.6 Automatic Greasing 45
4.7 Acto bac 46
4.8 Ice X 46
SECTION 5– THE WASH DOWN 47
SECTION 6– FAULT FINDING 49
SECTION 7– GENERAL SPECIFICATIONS 51
7.1 Machine 51
7.2 Engine 51
7.3 Fuel (diesel) 51
7.4 Speed 51
7.5 Noise 52
7.6 Suction system 52
7.7 Dust suppression system 52
7.8 Brushes 52
7.9 Tyres & wheels 52
7.10 Hopper 52
7.11 Electrical system 52
7.12 Hydraulic system 53
7.13 Pressure Washer (Option) 53
7.14 DEA (CSA) (Option) 53
7.15 Vibrations 53
SECTION 8 – CHASSIS PLATE INDENTIFICATION 54
SECTION 9 – VEHICLE RESCUE 55

Issue 9 February 2006
1
SECTION ONE
BEFORE YOU START
Before starting please read the following safety advice, it is provided for your safety, the safety of others and
for the correct and efficient use of the Green Machine 525.
1.1 Always top ten
1. Carry out the daily checks, before using the Sweeper.
2. Wash the machine down at the end of each shift.
3. Ensure that any defects are reported as soon as they are found.
4. Switch the engine off while the machine is being refuelled.
5. Remove the ignition key if leaving the machine unattended.
6. Switch the engine off before opening the machine side covers.
7. Before trying to clear a blockage, switch the engine off and remove the ignition key.
8. Be aware of your surroundings while sweeping.
9. Use water sprays under dry conditions.
10. Ensure that the machine receives the correct maintenance in accordance with the manufacturer’s
recommendations.
1.2 Never top ten
1. Try and clear a blockage with the engine running.
2. Leave the machine unattended with the engine running.
3. Put fingers or loose clothing near moving parts.
4. Run the engine in an enclosed space.
5. Open the coolant cap when the engine is hot (you may be scalded)
6. Run the engine with the fan casing impeller door open, the front suction hose off, when the side cover is
open, or when the cab is tilted.
7. Wash the machine with the engine running.
8. Leave the cab without engaging neutral and applying the hand brake
9. Drive up and down pavement kerbs at too high a speed or too oblique an angle.
10. Make non-approved modifications or use the machine in any other way than that shown or demonstrated
by an official representative of Green Machines.

Issue 9 February 2006
2
1.2.1 Operator Check List for the 525 Green Machine
Detailed operator checks procedure is described in section 3
Detailed machine wash down procedure is described in section 5.
Daily Action
Maintenance Procedure Before
Shift Start
After Shift
Finish
End of
Week
Action
Tilt the hopper, applying the safety stay. Switch engine off and
remove the ignition key.
Check hydraulic oil level – top up if required.
Check engine oil level – top up if required.
Check water tank is full.
Check diesel tank is full.

Check engine coolant header tank – top up as required.
Check window washer bottle is full.
Check engine Filter Minder is set to GREEN.

Check ALL vehicle lights, beacon and audible warning devices. 
Check brush wear – replace as required.
Check nozzle height and side skids.

Check tyre pressure and condition. 
Check all safety devices. 
Check all machine functions prior to leaving depot. 
Check all panels are in place and secure and the wander hose
is correctly located. 
Wash vehicle including ALL hopper screens and cyclones.
Avoid directing high-pressure water at electrical components &
connections.

Clean radiator mesh screen and check radiator is clear. If
required wash radiator carefully with a low-pressure jet. 
Clean dust suppression water filter during machine wash down. 
Carry out a general inspection of the machine wiring, flexible
hoses and piping for security and integrity.

Carry out inspection of hopper door and hopper inlet.

Report any defects as soon as they are found.   
Note Defects……………………………………………………………………………………………………………….
………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………
STOP NEVER wash down the engine with the engine running, as it may ingest water causing
ma
j
or en
g
ine dama
g
e.

Issue 9 February 2006
3
1.3 How the machine works
The machine works due to the air moving through it. The following scheme shows the flow of air through the
machine. The two front brushes sweep dirt, trash and debris into the centre of the machine, so that the airflow
can pick these up and deposit them into the hopper.
The air and debris mixture is made to swirl in a cyclonic action inside the hopper in order to cause the debris
to separate out, falling into the lower part of the hopper and allowing the air to return to atmosphere through
exits in the top of the hopper. There are 3 separating actions inside the hopper:
•The initial entry cyclonic action which is aided by swirl plates in the rear of the hopper;
•Screens in the top of the hopper which prevent light material such as dry leaves and paper from
escaping;
•The final cyclone spinners located in the top of the hopper, which separate out small dust particles.
As long as airflow is maintained, the machine will work correctly. If the machine does not pick up or leaves a
trail, this means the air is not flowing correctly through the machine. Always bear in mind this notion of airflow.
1.4 Things to avoid while sweeping
a. Rope, string
b. Nylon, plastic or metal strapping
c. Large plastic bags
d. Large items of clothing
e. Bricks and very large stones
f. Large pieces of wood, twigs-sticks
g. Aerosols – it is advised to pick these up by hand as they may contain inflammable liquids or gases
All normal litter, leaves, debris or trash will not normally be a problem to pick up. This includes normal soft
drinks cans, glass bottles and broken glass.

Issue 9 February 2006
4
1.5 Get to know your machine
Twin front
brushes
Fan impeller
Suction
nozzle
Flashing beacon
(knock down)
Side panel
Cab
Hopper
Side access
door
Fan casing
Lights
Impeller
drive
motor
Swing-out
water tank
catch
Dust suppression
water tank
Debris
skirt
Hopper lid
Work
lights
Air exit
ducts
Rear
lights
Brush spray
jets
Water spray
jet
Fan
casing
access
door

Issue 9 February 2006
5
1.6 Setting the brush angle
This operation usually only requires to be carried out when the machine is installed. The requirement is to set
the angle of the brushes so that they sweep the debris into the central part of the machine, where the airflow
will pick it up. To do so, the brushes need to be tilted so as to touch the ground as shown on the following
picture:
a. Remove the plastic brush cover.
b. Loosen the top nut shown on the picture to adjust the roll angle
(usually 5 degrees).
c. Loosen the four screws shown on the picture to adjust the pitch angle.
The front two screws are located in slots.
Brushes do not
touch the ground
Brushes must touch the
ground in this area
(black line)

Issue 9 February 2006
6
1.7 Changing the brushes
a. Remove the plastic brush cover, and then loosen the six M8 fixing
screws shown on the picture using the tools provided.
b. Turn the brush until the head of the screws pass through the keyhole. Now replace the old brush with the
new one, and turn the brush until the screws are located at the end of the keyhole slots. Turn the right hand
brush clockwise (looking down on the brush) and turn the left hand brush anticlockwise.
c. Tighten the flange screws.
1.8 Setting the nozzle height
Setting up
The two chilled iron skids (a) should be set with their lower wear surfaces level with the horse shoe
polyurethane (plastic) wear surface (c).
The nozzle is designed to float lightly on the ground in the lowered position, being supported by the hydraulic
cylinder. The nozzle is automatically raised when Transit, Brush Lift or Reverse is selected.
Adjusting for wear
The side (a) skids can be adjusted via the M16 adjustment screws (b).
(a) cast
iron skids
(c) Horse shoe
(polyurethane
wear surface is
40mm thick)
Forward
(b) M16
adjustment
screws

Issue 9 February 2006
7
SECTION TWO
GETTING STARTED
If the machine is set correctly and has been cleaned in the manner prescribed you will get continued
performance for the whole of the shift.
The most common problem experienced by machine operators is that the machine does not pick up, and
leaves a trail. Usually, this means either the machine has not been set correctly or there is an airflow
restriction (please see 1.3 – How does the machine work).
If you experience problems of the machine not picking up debris/trash, refer to section 6 –
Fault finding
STOP

Issue 9 February 2006
8
2.1 Adjusting the driving controls
a. Your seat is adjustable:
Move the seat forward or backward using the lever below the seat on the right hand side.
Adjust the suspension setting of the seat by adjusting the lever
below the seat, in the middle. Pull out knob to obtain more leverage
and move towards left for increasing driver weight.
Adjust the backrest with the upper lever at the right hand side of the
seat.
To adjust the tilt (thigh support adjustment) use the lower lever at
the right hand side of the seat.
b. Adjust the height of the steering wheel using this lever.
c. Please note that the cab includes a seatbelt
d. It is possible to lock the doors from the inside of the cab.
Moving the catch down unlocks the door, moving the catch up
locks it.
Ensure that the catches are in the down position prior to leaving the cab
If the door is locked from the inside it is not possible to unlock from the outside using
the key.
Locked
Unlocked
STOP
STOP

Issue 9 February 2006
9
2.2 Learning about the switches
2.2.1 Switch column
You have probably noticed the switch column on your right hand side. Here is an overview of the functions it
provides.
Work Light
Hazard Light
Heater Fan
Master Light
Transit / Sweep / Brush Lift
(see 2.3.1)
Windscreen
Defrost
Beacon/Beeper
Water Pump
Rear Fog
Light
Turn the impeller on/off
while sweeping
Hopper Tip
(see 2.4.6)
AC where fitted
(See 4.3)

Issue 9 February 2006
10
2.2.2 Multifunction lever switch
The steering column multifunction lever switch is similar to the ones used in cars.
Pushing the lever forwards or backwards controls the indicators.
Pushing the lever down controls the main beam (The lights will
turn on only if the appropriate column switch is on).
Pushing the lever up flashes the main beam, whatever the position of the column switch.
Horn
Turn the lever
to switch on the
wipers and to
set their speed
The ring controls
the windscreen
washer

Issue 9 February 2006
11
2.3 Driving the machine
Please note that in the United Kingdom a full B driving license is required to drive the 525 machine. For other
countries please check with your local distributor.
2.3.1 Movement modes
Before actually driving the machine, you need to know about its movement modes.
The machine has three main movement modes,
which you can select on the 3-position rocker
switch at the top of the switch column on the
right hand side of the windscreen.
1. Transit mode is used to drive the machine at high speed (from the storage depot to the sweeping site), up
to 32km/h (20 mph). The brushes and nozzle are raised when using this mode. Please note the machine will
not travel at high speed until the front wheels have tracked out, thereby increasing the overall vehicle stability.
This operation takes about 10 seconds, and will be performed automatically as the machine starts gaining
speed. For short distance travelling from one sweeping zone to another, it may be more efficient to use Brush
lift mode (see 3 below).
2. Sweep mode (work 1) only enables a low-speed drive, up to 15 km/h (9 mph). The front wheels are
tracked-in, to enable sweeping access to narrow alleyways. The brushes and suction nozzle are automatically
deployed when sweep mode is selected.
3. Brush lift mode (work 2) is used to travel at low speed over short distances when not sweeping. Indeed, it
is sometimes not good use of time to use transit mode for a short distance travel, as the front wheels have to
track out and then back in. The Brush lift mode is similar to Sweep mode (same max. speed) except the
brushes and nozzle are raised.
It is important to check that the front wheels are fully tracked in before sweeping
close to a wall or curb. If not fully tracked in tyre damage may result.
2.3.2 Speed control (accelerator) pedal
The pedal is located right of center on the floor. The same pedal is used for both forward and reverse motion.
Pressing the pedal gently will cause the machine to move forward or backward depending on the setting of
the Forward / Reverse lever. If the lever is set to Neutral, then pressing the accelerator will simply speed up
the engine.
Accelerator pedal
Brake pedal
- Transit mode
- Sweep mode
- Brush lift mode
STOP

Issue 9 February 2006
12
2.3.3 Braking
Releasing the accelerator pedal will cause the machine to slow down by automatically applying hydraulic
braking.
The brake pedal operates on the rear brakes.
The handbrake also operates on the rear brakes, and should always be applied when leaving the cab. A
buzzer sounds if Forward or Reverse is selected with the handbrake applied to remind you to release it.
2.3.4 Wheel Tracking
525 is equipped with a variable track width front axle. This enables the machine to operate in narrow
passageways (1.1m machine width) during the low speed (15 kph max.) Sweep (Work) mode.
In high speed (32 kph max.) Transit mode, the front wheel track width is increased to 1.33m over wheels. This
increases machine stability at high speed.
“Tracking” (changing the front wheel track width) is automatically controlled by the MDM electronic control
system.
a. TRACKING-OUT – Changing from WORK to TRANSIT
Reduce machine speed to 5 kph (3.1 mph) (walking speed) and select Transit. When Transit is selected,
Tracking-out does not start until the accelerator pedal is depressed when the machine is in Forward and a
speed of, at least, 4.5 kph (2.8 mph) is reached.
The MDM then limits the maximum speed to 5 kph (3.1 mph) until tracking-out is complete (about 10
sec.). A speed of 32 kph (20 mph) is then permitted. During tracking the following message will appear on
the MDM display “CAUTION – SPEED RESTRICTION – WHEEL TRACKING OPERATING”.
b. TRACKING-IN – Changing from TRANSIT to WORK
Reduce the vehicle speed to 5 kph (3.1 mph) and select Work. Tracking-in does not start until a speed of
at least 2.5 kph (1.6 mph) is achieved. The MDM will then control the speed to a maximum of 3 kph until
Tracking-in is complete. Speeds of up to 15 kph are then permitted. Again, during Tracking-in the MDM
display will show the tracking message.

Issue 9 February 2006
13
2.3.5 Gauges and warning lights
In addition the IQAN system also monitors machine condition and will provide warnings and information on
the graphic display (see Section 2.7).
2.3.6 Forward / Neutral / Reverse
The front joystick switch on the front of the control arm enables you
to choose from Forward, Neutral and Reverse mode.
Raise the safety ring while moving the joystick from Neutral mode.
Remember always to engage Neutral and apply the handbrake before leaving the cab.
Handbrake on
(
red
)
Indicators
(green)
No charge
(red)
Oil warning
(orange)
High beam
(front lights)
(white / blue)
Engine pre-heat
(orange)
Engine rev.
counter and
hour clock
Diesel tank level
Engine temperature gauge
STOP