Tennant 235E User manual

235E
MM165
(Operator Manual)

Thismanual isfurnished with each newTENNANTModel235E.Itprovidesnecessaryoperating and preventive
maintenanceinstructions.Read thismanualcompletelyand understand the machine before operating orservicing
it.
Thismanualcoversall machine variationsand standard accessories.The tabbed instruction portion of the
manualconsistsof the Specification, Operation,Maintenance,and Appendix sections.The tabbed parts section
consistsof the StandardModelParts; Options;HydraulicComponents;and Cross Referencesections.
All rightside and left side referencestothe machine are determined byfacing the direction of forwardtravel.All
hardwareconsidered to be ofacommon nature orlocallyavailable hasbeen omitted fromthe parts sections.Be
awarethat thismachine may containmetrichardware.Makesureyou use equivalenthardwarewhen
replacementbecomesnecessary.
Thismachine will provide excellentservice.However, the bestresultswill be obtained atminimumcostsif:
DThe machine isoperated withreasonablecare.
DThe machine ismaintained regularly-- perthe maintenanceinstructionsprovided.
DThe machine ismaintained withTennantCompany supplied orequivalentparts.
Partsand suppliesmaybe ordered byphone or mail fromanyTennantCompanypartsand servicecenter,
distributor,orfromanyof the TennantCompany subsidiaries.Before ordering partsorsupplies,be sureto have
your machine modelnumberand serialnumberhandy.Fill out the data block belowforfuturereference.The
telephone numbers, telexnumbers,mailing addresses,and locationsof those outletsarelisted inthe Customer
Documents section of the manual.
MACHINEDATA
Pleasefill outat time ofinstallation.
Machine Serial Number --
Engine Serial Number --
SalesRepresentative--
CustomerNumber --
Date of Installation --
Manual Number -- MM165
Revision:09
Published:8--95
TrademarkRegisteredin:Austria,Benelux,Denmark,England,France, Germany, Italy,Spain,Switzerland,
United States,Argentina,Australia,Canada,Japan,Mexico,Sweden,byTENNANTCOMPANY,Minneapolis,
Minnesota,U.S.A.
Acknowledgements:Technical information and/orillustrations supplied byCessna FluidPowerDivision;Eaton
Corporation,Hydraulics Division.
Copyright1986,1987,1988,1989,1991,1993,1994,1995 TennantCompany,Printed inU.S.A.

ABOUT THISMANUAL
a
235EMM165 (3--91)
ABOUT THISMANUAL
The machine manualthatyou received withyour
TENNANTmachine contains valuableinformation
about the operation and maintenance,and
numerous sectionsfilled withTENNANTpart
numbersforthe repairof the machine.Please
read through this section titled ABOUT THIS
MANUALto becomefamiliarwiththe contentsof
the machine manual,making the information you
arelooking foreasiertofind.
The machine manualconsistsofseveralsections
ofreferenceinformation,and the remainder
contain partnumberinformation forordering
repairpartsforthe machine.Eachsection hasa
shaded barat the top of the page withthe name
of thatsection.Justasthis section hasthe title
ABOUT THISMANUALonthe top ofeach page.
Thisway you can tell whichsection you arein at
all times.
REFERENCE SECTIONS
The referenceinformation sectionsof the manual
are; GeneralInformation,Specifications,
Operation,Maintenance,and Appendix.
GENERALINFORMATION-- The General
Information section of the manualcontainsthe
safetyprecautions, the location of the safety
labelson the machine,and a table ofcontentsof
the entiremanual.The SafetyPrecautionsare an
overviewof the safetymeasuresto be observed
when operating and maintaining your machine.
The location of the safetylabels showthe
mounting location of the safetylabelsforusein
the replacementof the labels.The table of
contentsinthis section isalistofall the table of
contentsthatappearinthe frontofeachsection in
the manual.This can be used foreasy reference
tolocateinformation in a particularsection of the
manual.
SPECIFICATIONS-- The Specifications section of
the manualcontainsmachine specification
information useful inthe operation and
maintenance of the machine.This section gives
you specification information on the engine,
electricmotors,brakesystem,hydraulics, fluid
capacities,and machine weight tomentionafew.
The section also hasaillustration of the top and
side viewof the machine withthe heightand width
dimensionsdisplayed.
OPERATION-- The Operation section of the
manualcontainsinformation needed to operate
the machine.This section will list the controlsand
instrumentson the machine,overviewthe
machine operation,and tell you howtotransport
and storethe machine.
MAINTENANCE-- The Maintenancesection
containsinformation on the suggested
maintenance proceduresand adjustmentstokeep
your machine intop operating condition.The
section includesaMaintenanceChartlisting the
maintenanceschedule and the areasof the
machine to be addressed.Eachsubjectof
maintenanceis covered inmore detail insuch
areasasLubrication,Hydraulics,Engine,and
ElectricalSystem.
APPENDIX-- The Appendix containshardware
and hydraulicinformation.Standard hardware
torquesand identification information isincluded,
plushydraulictorquesifyour machine is
hydraulically controlled.
PARTSECTIONS
The remaining sectionsof the manualcontain part
numberinformation forordering repairpartsfor
your machine.The manualcontainspartnumber
information on everytype ofmachine model
availableinthe modelsize ofyourparticular
machine.Thereforetherewill be partnumber
information inyour manualyou will notneed to
refertowhen wanting to place an order.
The mainthing you need toknowaboutyour
machine iswhat type ofmodel isit. Isthe
machine powered byan engine orbatteries?If the
machine hasan engine,isit fueled fromgasoline,
LPG, ordiesel?If itisamid-sized orlarger
sweeper,isitmulti-levelorlowdump? Forthe
scrubbers,isitSRSrorstandard.Determining
thisinformation aboutyour machine will help
guide you through the separate parts sectionsto
find the repairpartyou need.

ABOUT THISMANUAL
235EMM165 (3--91)
b
The smallerline ofsweeperand scrubbershave
less complicated partsection arrangement, and
are easiertofind yourwaythrough the parts
sections.The larger machines can have quite a
varietyofmodeltypeswhichsignificantly
increasesthe sizetothe machine manual.
Because of this,on the larger machine wemade
the firstpartsection,Section 5,a partsection
whichcontainsparts common to all type of the
machine. If the machine hasan engine, this
section containspartsinformation on a gasoline
powered machine.
The remaining sections contain onlyparts
information whichisunique tothatparticular
machine type,such asunique dieselpartson the
machine,orunique SRSrparts.Knowing the
machine modeltype you haveisimportantwhen
searching forthatpartinformation you need for
ordering repairparts.Startinthatunique section
firstwhen looking fora part, then go tothe first
parts section,Section 5,if the partcan’tbe found
inthe unique section.
MACHINE SERIALNUMBERS
When a design change takesplacetoamachine,
the changesareindicated inthe parts sections
withmachine serialnumbers.Knowthe serial
numberofyour machine whichcan be found on
the machine data platemounted on the machine.
Recordthisnumberon the inside frontcoverof
your manualalong withyourcustomernumber.
Machine numberusage isrecorded inthe
Machine Serial Numbercolumn of the partslists
inthe parts sectionsof the manual. If the machine
serialnumbercolumnlists zeroson the left side of
the dash, then thispartisused on all machines;
such as(000000-- ).
If the columnlists zeroson the left of the dash
and a numberon the rightof the dash, then the
partisused on machinesup to and including that
machine serialnumber;such as(00000--002345).
Forpartsthatare used on machinesbeginning at
and continuing on fromacertainserialnumber,
the columnwouldlistaserialnumberon the left of
the dash and have blank spaceson the rightside
of the dash;such as(002346-- ).Thispart
would be used on machines starting withthat
machine serialnumberand greater.
Finally,parts can be used on machineswithserial
numbersinacertain block ofnumbers. Inthis
situation thereisaserialnumberon the left and
rightside of the dash.The partisthen used on a
machine withaserialnumberstarting at the
numberon the left and up to and including the
numberon the right; such as(002346--008900).
PARTS ASSEMBLIES
Apartassemblyhaspartswithinthe assembly,
such asa parking brakeconsisting ofother
smallerparts.Whatpartsarecontained in a part
assembly can be determined byan indentation
arrangementinthe description column of the
partslists.
Hereisan example ofa partassembly,inthis
casewewill usethe parking brakementioned
previously:
Machine
SerialNumberDescription Qty.
(000000-- ) Parking Brake 1
(000000-- ) Pin,Roll 1
(000000-- ) Link1
(000000-- ) Spring,Compression 1
(000000-- ) Pin,Roll 1
(000000-- ) Support1
(000000-- ) Lever,Release 1
(000000-- ) Rod,Parking Brake 1
(000000-- ) Washer,0.50”3
Inthisexample, the partswhose descriptionsare
indented underthe parking brake are all partsof
the parking brake.When you orderthe parking
brakeyou will receive all the partslisted underit.
You alsocan orderanyof the individualparts
listed underthe parking brakeifitisthe onlypart
you need.

ABOUT THISMANUAL
c
235EMM165 (3--91)
SUPPLIER COMPONENTBREAKDOWNS
TENNANTpurchases certaincomponentsof the
machine fromsuppliers.Some of these
componentsare engines,hydraulicpumpsand
motors,electricmotors,and solution pumps.
Forthose purchased componentsthatare
repairable,listsofpartsforthemappearinthe
laterpartof the parts sections.These arethe
supplierbreakdowns.The engine breakdown
containsbothsupplierand TENNANTparts
numbersfor repairparts.Breakdownsfor
hydraulicand electricalcomponentshave
TENNANTpartnumbersforthe partsTENNANT
supplies.The serialnumberslisted in anyof the
partslistsinthesesectionsisaserialnumberthe
manufacturerusestoidentifydesign changesin
theirparticularcomponent.
ORDERINGREPAIRPARTS
Onceyou havelocated a part to order, there are
severalthings you need to haveto placethe
order.At the beginning ofeach parts section isan
Ordering RepairPartspage whichliststhe
information you will need to placeyourorder.
Reviewthislistbefore placing the order.

ABOUT THISMANUAL
235EMM165 (3--91)
d

GENERALINFORMATION
i
235EMM165 (3--91)
SAFETY PRECAUTIONS
The following symbolsare used throughout this
manualasindicated intheirdescriptions:
WARNING:To warn ofhazardsor
unsafepractices whichcouldresultin
severepersonal injuryordeath.
FORSAFETY:To identify actionswhichmust
befollowedforsafeoperation ofequipment.
The following information signalspotentially
dangerous conditionstothe operatoror
equipment. Read thismanualcarefully.Know
when theseconditions can exist. Locate all safety
deviceson the machine.Then, take necessary
stepstotrainmachine operating personnel.
Reportmachine damage orfaultyoperation
immediately.Do notusethe machine ifitisnotin
properoperating condition.
FORSAFETY:
1.DoNotOperateMachine:
-- Unless TrainedAnd Authorized.
-- Unless Operation Manual IsReadAnd
Understood.
-- In FlammableOrExplosive Areas
Unless Designed ForUse In Those
Areas.
-- InAreas WithPossibleFalling Objects
Unless EquippedWithOverhead
Guard.
2.BeforeStarting Machine:
-- Make SureAll SafetyDevices AreIn
Place And OperateProperly.
-- Check Brakes And Steering ForProper
Operation.
3.WhenStarting Machine:
-- Keep FootOnBrake And Directional
Pedal InNeutral.
4.WhenUsing Machine:
-- Use Brakes To Stop Machine.
-- GoSlow OnGrades And Slippery
Surfaces.
-- Use CareWhenBacking Machine.
-- Move MachineWithCareWhen
HopperIsRaised.
-- Make SureAdequateClearance Is
AvailableBeforeRaising Hopper.
-- DoNotCarryRidersOnMachine.
-- Always FollowSafetyAnd Traffic
Rules.
5.BeforeLeaving OrServicing Machine:
-- Stop On LevelSurface.
-- SetParking Brake.
-- TurnOff MachineAnd Remove Key.
6.WhenServicing Machine:
-- AvoidMoving Parts.DoNotWear
Loose Jackets,Shirts, OrSleeves
WhenWorking OnMachine.
-- Block MachineTires Before Jacking
MachineUp.
-- Jack MachineUpAtDesignated
LocationsOnly.Block MachineUp
WithJack Stands.
-- Use HoistOrJack OfAdequate
CapacityTo Lift Machine.
-- WearEye And EarProtection When
Using PressurizedAirOrWater.
-- AvoidContactWithBatteryAcid.
-- Use Cardboard To LocateLeaking
HydraulicFluidUnderPressure.
-- Use TENNANTSuppliedOrEquivalent
ReplacementParts.
-- DisconnectBatteryConnections
BeforeWorking OnMachine.
WARNING:Batteries EmitHydrogen
Gas.Explosion OrFireCanResult.
KeepSparks And Open FlameAway.Keep
CoversOpenWhenCharging.
WARNING:Lift Arm PinchPoint.Stay
ClearOfHopperLift ArmsWhenHopper
IsMoving.
WARNING:Falling Hopper.Engage
HopperSupportBarBeforeWorking
UnderHopper.
WARNING: Moving Belt.KeepAway.

GENERALINFORMATION
235EMM165 (3--91)
ii
The following safetylabelsaremounted on the
machine inthe locationsindicated. If these,or
any,labelsbecome damaged orillegible,install a
new label initsplace.
03402
03403
03400 03365
FORSAFETYLABEL-- LOCATEDONTHE
SIDEOF THECONTROLPANEL.FORSAFETYTHERMOSENTRYtLABEL--
LOCATEDONTHELIFT ARMCROSS
MEMBER.
EXPLOSIVE GASCAUTIONLABEL(2) --
LOCATEDONTHEINSIDEOF THE SEAT
SUPPORT.

GENERALINFORMATION
iii
235EMM165 (3--91)
03365
03398
03401
03397
03399
HOPPERSUPPORTBAR WARNINGLABEL--
LOCATEDONTHEOPERATORSIDEOF
HOPPERLIFT ARM.
FAN BELT DRIVE WARNINGLABEL--
LOCATEDONTHE VACUUMFAN.
HOPPERLIFT ARMPINCH POINTCAUTION
LABEL(2)--LOCATEDONTHEHOPPERLIFT
ARMS.FALLINGHOPPERWARNINGLABEL--
LOCATEDONTHEFRONTOF THEBRUSH
WRAP.

GENERALINFORMATION
235EMM165 (8--95)
iv
CONTENTS
Page
GENERALINFORMATION i..............
SAFETY PRECAUTIONSi............
SPECIFICATIONS1-1.....................
MACHINE SPECIFICATIONS1-3.........
POWERTYPE 1-3...................
POWERTRAIN1-3..................
STEERING1-3......................
HYDRAULICSYSTEM1-3............
BRAKINGSYSTEM1-3..............
SUSPENSIONSYSTEM1-3..........
SYSTEMFLUID CAPACITIES 1-3.....
GENERALMACHINEDIMENSIONS--
CAPACITIES 1-3..................
MACHINEWEIGHTS1-3.............
GENERALMACHINE
PERFORMANCE1-3..............
MACHINEDIMENSIONS1-4............
OPERATION2-1............................
PREPARATIONFOROPERATION2-3....
AFTER UNCRATINGAND BEFORE
OPERATINGMACHINE:2-3.......
OPERATIONOFCONTROLS2-4........
MACHINECOMPONENTS2-4........
CONTROLS AND INSTRUMENTS2-5.
BRAKE PEDAL 2-6..................
DIRECTIONALPEDAL 2-6............
PARKINGBRAKE LEVER2-6.........
OPERATORSEAT2-6................
ADJUSTABLE SEATLEVER(OPTION)2-6
SEATSUPPORTLEVER2-6..........
SIDE BRUSHAND HOPPERLEVER2-6
HOPPER DOORSWITCH 2-6.........
ACCESSORY SWITCH 2-6...........
LIGHTSWITCH 2-7..................
KEY-OPERATEDON-OFF SWITCH 2-7
MAINBRUSHLEVER2-7.............
VACUUMLEVER2-7.................
HOUR METER2-7...................
BATTERYCONDITIONGAUGE2-7....
FLASHERSWITCH 2-7...............
STEERINGWHEEL 2-7..............
HORN BUTTON2-7..................
SIDE BRUSHLEVER2-8.............
SIDE BRUSHADJUSTMENTKNOB2-8
AUXILIARY SIDE BRUSH
IN-OUTSWITCH (OPTION)2-8....
AUXILIARY SIDE BRUSH
UP-DOWNSWITCH (OPTION)2-8. .
CIRCUITBREAKERS AND FUSES 2-9.
HOPPERSUPPORTBAR2-9.........
Page
MACHINEOPERATION2-10..............
NORMALSWEEPING OPERATION2-10
PRE-STARTCHECKLIST2-10.......
TOSTARTMACHINE2-10..........
TOSWEEP 2-10...................
TODUMPHOPPER2-11...........
POSTOPERATION CHECKLIST--
MOTOROPERATING2-11....
TOSTOPMACHINE2-11...........
POSTOPERATION CHECKLIST--
MOTORSTOPPED2-11......
TOENGAGEHOPPER
SUPPORTBAR2-12...............
TODISENGAGEHOPPER
SUPPORTBAR2-12...............
OPERATIONONGRADES 2-12........
MACHINETROUBLESHOOTING2-13. .
TRANSPORTINGMACHINE2-14..........
PUSHING ORTOWINGMACHINE2-14.
MACHINEJACKING2-14..............
TOJACKUPMACHINE2-14........
MACHINETIE-DOWNS2-15...........
MACHINE STORAGE2-16................
STORINGMACHINE2-16.............
MAINTENANCE3-1.......................
RECOMMENDEDFIRST50-HOUR
MACHINEINSPECTION3-3..........
MAINTENANCECHART3-4.............
LUBRICATION3-6......................
GEARBOX3-6......................
REARWHEELSUPPORTBEARING3-6
SIDE BRUSHLEVERPIVOT3-6......
STEERINGLINKAGE3-7.............
HYDRAULICS3-8......................
HYDRAULICFLUID3-8..............
HYDRAULICFLUID RESERVOIR3-8. .
HYDRAULICFILTER3-9.............
TOREPLACEFILTERELEMENT3-9
HYDRAULICFLUIDLEAKS 3-9.......
HYDRAULICSCHEMATIC3-10.........
HYDRAULICSYSTEM
TROUBLESHOOTING3-11.........
HYDRAULIC COMPONENTS
TROUBLESHOOTING3-12.........

GENERALINFORMATION
v
235EMM165 (8--95)
Page
ELECTRICALSYSTEM3-13..............
BATTERIES 3-13.....................
BATTERYCHARGING3-14............
ELECTRICMOTORS3-16.............
PROPELLINGSYSTEM
TROUBLESHOOTING3-17.........
PROPELLINGCIRCUIT3-18...........
TOADJUST“NEUTRAL”
POSITION3-18.................
ELECTRICALSCHEMATIC(For machine
belowserialnumber002205)3-19....
ELECTRICALSCHEMATIC(For machines
fromserialnumber002205
to 002310)3-20....................
ELECTRICALSCHEMATIC(For machines
serialnumber002311 and above)3-21
ELECTRICALSCHEMATIC,AUXILIARY
SIDE BRUSH(For machines serial
number002311 and above)3-22.....
BELTS AND CHAINS3-23................
HYDRAULICPUMP BELT3-23.........
TOREPLACE AND ADJUST
HYDRAULICPUMP BELT3-23...
VACUUMFANBELT3-24..............
TOREPLACE AND ADJUST
VACUUMFANBELT3-24........
MAINBRUSHBELT3-25..............
TOREPLACEMAIN
BRUSHBELT3-25..............
TAPERLOCK BUSHINGS3-26.........
TOREMOVE TAPER
LOCK BUSHING3-26...........
TO INSTALL TAPER
LOCK BUSHING3-26...........
STATIC DRAGCHAIN3-26............
DEBRISHOPPERAND DUST FILTER3-27.
DEBRISHOPPER3-27................
TOCHECK AND ADJUST
HOPPERFLOOR
CLEARANCE3-27..............
THERMOSENTRYt3-27.............
TOCHECKTHE
THERMOSENTRYt3-27........
HOPPER DUST FILTER3-28...........
TOREMOVE AND REPLACE
HOPPER DUST FILTER3-29.....
BRUSHES 3-30..........................
MAINBRUSH3-30....................
TOREMOVE MAINBRUSH3-30....
TO INSTALL MAINBRUSH3-30.....
TOCHECK AND ADJUSTMAIN
BRUSHPATTERN 3-30..........
SIDE BRUSH3-32....................
TOREMOVE SIDE BRUSH3-32.....
TO INSTALL SIDE BRUSH3-32.....
Page
SKIRTS AND SEALS3-33................
BRUSHSKIRTS3-33..................
TOREPLACE AND ADJUST
BRUSHSKIRTS3-33............
REARSKIRTS3-33...................
TOREPLACE AND ADJUST
REARSKIRTS3-33.............
HOPPERLIP SKIRT3-34..............
TOREPLACEHOPPER
LIP SKIRT3-34.................
DUSTSEALS3-34....................
TOREPLACEDUSTSEALS3-34....
HOPPER DUMPDOORSEAL 3-35.....
TOREPLACEHOPPER DUMP
DOORSEAL 3-35...............
VACUUMFANSEAL 3-36..............
FILTER COVERSEAL 3-36............
BRAKES AND TIRES 3-37................
BRAKES 3-37........................
TIRES 3-37..........................
REARWHEEL 3-37...................
APPENDIX4-1.........................
HARDWAREINFORMATION4-3.........
STANDARD BOLT TORQUECHART4-3
METRICBOLT TORQUECHART4-3. .
BOLTIDENTIFICATION4-3...........
THREADSEALANTAND LOCKING
COMPOUNDS4-3................
HYDRAULICFITTING INFORMATION4-4.
HYDRAULICTAPEREDPIPE FITTING
(NPT)TORQUECHART4-4........
HYDRAULICTAPEREDSEAT FITTING
(JIC)TORQUECHART4-4.........
HYDRAULICO--RINGFITTING
TORQUECHART4-4..............

GENERALINFORMATION
235EMM165 (3--94)
vi
Page
STANDARD MODELPARTS5-1............
ORDERINGREPAIRPARTS5-3.........
Fig.1-- Recommended General
MaintenanceItems5-4.......
Fig.2-- ReplacementBrushes5-5........
Fig.3-- MainFrameGroup 5-6...........
Fig.4-- Seatand RearShroud Group 5-8.
Fig.5-- FrontWheeland BrakeGroup 5-10.
Fig.6-- HopperLift ArmsGroup 5-12......
Fig.7-- Hopper Middle and CoverGroup 5-14
Fig.8-- HopperBottomGroup 5-16........
Fig.9-- HopperHeadlightsand
Access DoorGroup 5-18......
Fig.10 -- HopperFilterand
Shaker MotorGroup 5-19......
Fig.11 -- HopperDumpDoorand
ActuatorGroup 5-20..........
Fig.12 -- VacuumFan ControlGroup 5-22...
Fig.13 -- VacuumFan Assembly5-24......
Fig.14 -- HydraulicLift Cylinderand
FilterGroup 5-26.............
Fig.15 -- MainBrushDriveGroup 5-28.....
Fig.16 -- MainBrushIdlerGroup 5-30......
Fig.17 -- Side BrushGroup 5-32...........
Fig.18 -- MainBrushMotorand
HydraulicPumpGroup 5-34....
Fig.19 -- HopperControlValveGroup 5-36. .
Fig.20 -- HydraulicHosesGroup 5-37......
Fig.21 -- Steering WheelGroup 5-38.......
Fig.22 -- DirectionalPedalGroup 5-40......
Fig.23 -- RearDriveWheelGroup 5-42.....
Fig.24 -- ControlPanelGroup 5-44.........
Fig.25 -- Electrical Component
PlateGroup 5-46.............
Fig.26 -- ControlBoxGroup 5-48..........
Fig.27 -- ControlBoxGroup 5-50..........
Fig.28 -- WireHarness Group 5-52.........
Fig.29 -- LabelsGroup 5-54...............
Page
OPTIONS6-1.............................
ORDERINGREPAIRPARTS6-3.........
Fig.1-- Cab Kit6-4.....................
Fig.2-- Overhead GuardKit6-6..........
Fig.3-- Revolving LightKit,
Overhead Guard 6-7.........
Fig.4-- Revolving LightKit, Shroud 6-8...
Fig.5-- BatteryKit, 295 A/h,Wet6-9.....
Fig.6-- BatteryKit, 295 A/h,Dry,
InternationalOnly6-10........
Fig.7-- BatteryKit, 306 A/h,Wet6-11.....
Fig.8-- BatteryKit, 306 A/h,Dry,
InternationalOnly6-12........
Fig.9-- BatteryInstallation Kit, 295 A/h 6-13
Fig.10 -- BatteryInstallation Kit, 306 A/h 6-14
Fig.11 -- BatteryChargerGroup,
36A,36V,115 V6-15..........
Fig.12 -- BatteryChargerGroup,
40A,36V,50 Hz6-16.........
Fig.13 -- BatteryChargerGroup,
30A,36V,230V,50Hz6-17....
Fig.14 -- BatteryChargerGroup,60A6-18. .
Fig.15 -- BatteryChargerGroup,50A6-19. .
Fig.16 -- DemoKit6-20...................
Fig.17 -- AdjustableSeatKit6-21..........
Fig.18 -- AuxiliarySide BrushGroup 6-22...
Fig.19 -- AuxiliarySide Brush
HydraulicHoseGroup 6-24....
Fig.20 -- AuxiliarySide Brush
ElectricalGroup 6-25...........
HYDRAULIC COMPONENTS
ORDERINGREPAIRPARTS7-3.........
Fig.1-- HydraulicPowerUnit
Breakdown,87340 7-4.......
Fig.2-- HydraulicMotor
Breakdown,87475 7-5.......
Fig.3-- HydraulicValve
Breakdown,87409 7-6.......
Fig.4-- HydraulicMotor
Breakdown,28804 7-7.......
Fig.5-- HydraulicLift Cylinder
Breakdown,87055 7-8.......
Fig.6-- HydraulicLift Cylinder
Breakdown,48575 7-9.......
Fig.7-- HydraulicLift Cylinder
Breakdown,65223 7-10.......
CROSS REFERENCE8-1..................
PARTNUMBERTOPAGENUMBER CROSS
REFERENCELIST8-3............

SPECIFICATIONS
1-1
235EMM165 (3--91)
SECTION1
CONTENTS
Page
MACHINE SPECIFICATIONS1-3............
POWERTYPE 1-3......................
POWERTRAIN1-3.....................
STEERING1-3.........................
HYDRAULICSYSTEM1-3...............
BRAKINGSYSTEM1-3.................
SUSPENSIONSYSTEM1-3.............
SYSTEMFLUID CAPACITIES 1-3........
GENERALMACHINEDIMENSIONS--
CAPACITIES 1-3.....................
MACHINEWEIGHTS1-3................
GENERALMACHINE PERFORMANCE1-3
MACHINEDIMENSIONS1-4...............

SPECIFICATIONS
235EMM165 (3--91)
1-2

SPECIFICATIONS
1-3
235EMM165 (3--91)
MACHINE SPECIFICATIONS
POWERTYPE
Electricpropelling motor -- nominalvoltage
36 VDC,1.2hp(0.9kw)@2550 rpm,34 A
Electricaccessoriesmotor -- nominalvoltage
36 VDC,1.9hp(1.4kw)@2500 rpm,52 A
Batteries,standard(6) -- 6V,295 A/h@
6 hour rate
Batteries,heavy duty(2) -- 18 V,306 A/h@
4 hour rate
Battery charger -- 36 VDC 40 A,115 VAC60 hz
36 VDC 60 A,208--230 VAC60 hz
36 VDC 40 A,230 VAC50 hz
POWERTRAIN
Propelling -- electricmotordriven
Main brush-- beltdriven
Side brush-- hydraulicmotordriven
Vacuumfan -- beltdriven
Hydraulicpump-- beltdriven
STEERING
Type -- rearwheelcontrolled,automotivecam
and lever
Powersource-- manual
HYDRAULICSYSTEM
Function -- operateshopperlift, side brush drive
Controlvalve,hopperlift, side brush drive-- open
center,singlespooltype
Pump-- geartype,0.26 cuin(4cc)displacement
per revolution,1350 psi(9310 kPa)
@1.0 gpm (3.8 L/min) reliefsetting
Motor,side brush-- internalgeartype,2.8cuin
(46 cc)per revolution,2500 psi(17,240 kPa)
maximum rated pressure
Cylinder,hopperlift -- single action type,2.5in
(65 mm) borex12 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
BRAKINGSYSTEM
Service brakes-- mechanicaldrumbrakes(2) --
1 perfrontwheel,linkage actuated
Parking brakes-- utilizes service brakes,linkage
actuated
SUSPENSIONSYSTEM
Front-- 15 x3.00 solidtires(2)
Rear -- 16 x4.00 solidtire(1)
SYSTEMFLUID CAPACITIES
Hydraulic system -- reservoir1 gal(3.8 L)
Hydraulic system -- total1.25 gal(4.7 L)
Gearboxgreasecapacity-- 2.7 qt(2.6 L)
GENERALMACHINEDIMENSIONS--
CAPACITIES
Length-- 77.5in(1970 mm)
Widthwithside brush-- 48 in(1220 mm)
Heightless overhead guard-- 53 in(1345 mm)
Heightwith overhead guard-- 79.5in(2020 mm)
Track -- front44 in(1115 mm)
Wheelbase-- 41 in(1040 mm)
Main brush-- width36in(915 mm)
Main brush-- outside diameter14 in(355 mm)
Side brush-- rotarydiameter19 in(480 mm)
Sweeping pathwidth(total) -- 48 in(1220 mm)
Hoppercapacity-- 10 cuft (0.28 m#)650 lb
(295 kg)
Dust filter -- 49 sqft (4.5m@),pleated panelfilter
element
MACHINEWEIGHTS
Netweight, dry-- 2500 lb(1135 kg)
GVWR-- 3400 lb(1540 kg)
GENERALMACHINE PERFORMANCE
Maximumforwardspeed -- 5mph (8km/h)
Maximum reversespeed -- 3mph (5km/h)
Maximumforwardspeed withraised hopper --
2mph (3.2km/h)
Turning radius-- left, 60 in(1525 mm) right, 78 in
(1980 mm)
Maximum rated climb and descentangle-- 10_

SPECIFICATIONS
235EMM165 (3--91)
1-4
MACHINEDIMENSIONS
SIDE VIEW
TOP VIEW
77.5in(1970 mm)
48 in
(1220 mm)
53 in
(1345 mm)
03366

OPERATION
2-1
235EMM165 (8--95)
SECTION2
CONTENTS
Page
PREPARATIONFOROPERATION2-3.......
AFTER UNCRATINGAND BEFORE
OPERATINGMACHINE:2-3..........
OPERATIONOFCONTROLS2-4...........
MACHINECOMPONENTS2-4...........
CONTROLS AND INSTRUMENTS2-5....
BRAKE PEDAL 2-6.....................
DIRECTIONALPEDAL 2-6...............
PARKINGBRAKE LEVER2-6............
OPERATORSEAT2-6..................
ADJUSTABLE SEATLEVER(OPTION)2-6
SEATSUPPORTLEVER2-6.............
SIDE BRUSHAND HOPPERLEVER2-6. .
HOPPER DOORSWITCH 2-6............
ACCESSORY SWITCH 2-6..............
LIGHTSWITCH 2-7.....................
KEY-OPERATEDON-OFF SWITCH 2-7...
MAINBRUSHLEVER2-7................
VACUUMLEVER2-7....................
HOUR METER2-7......................
BATTERYCONDITIONGAUGE2-7......
FLASHERSWITCH 2-7.................
STEERINGWHEEL 2-7.................
HORN BUTTON2-7.....................
SIDE BRUSHLEVER2-8................
SIDE BRUSHADJUSTMENTKNOB2-8...
AUXILIARY SIDE BRUSH
IN-OUTSWITCH (OPTION)2-8.......
AUXILIARY SIDE BRUSH
UP-DOWNSWITCH (OPTION)2-8....
CIRCUITBREAKERS AND FUSES 2-9....
HOPPERSUPPORTBAR2-9............
Page
MACHINEOPERATION2-10.................
NORMALSWEEPING OPERATION2-10...
PRE-STARTCHECKLIST2-10.........
TOSTARTMACHINE2-10.............
TOSWEEP 2-10......................
TODUMPHOPPER2-11..............
POSTOPERATION CHECKLIST--
MOTOROPERATING2-11..........
TOSTOPMACHINE2-11..............
POSTOPERATION CHECKLIST--
MOTORSTOPPED2-11............
TOENGAGEHOPPERSUPPORTBAR2-12
TODISENGAGEHOPPER
SUPPORTBAR2-12..................
OPERATIONONGRADES 2-12...........
MACHINETROUBLESHOOTING2-13.....
TRANSPORTINGMACHINE2-14............
PUSHING ORTOWINGMACHINE2-14....
MACHINEJACKING2-14.................
TOJACKUPMACHINE2-14...........
MACHINETIE-DOWNS2-15..............
MACHINE STORAGE2-16..................
STORINGMACHINE2-16................

OPERATION
235EMM165 (3--91)
2-2

OPERATION
2-3
235EMM165 (3--91)
PREPARATIONFOROPERATION
AFTER UNCRATINGAND BEFORE
OPERATINGMACHINE:
1.Check the machine forshipping damage.
2.Read thismanualcarefullybefore operating
orservicing the machine.
FORSAFETY:DoNotOperateMachineUnless
Operation Manual IsReadAnd Understood.
3. Open the seatsupport.
4.Check the batterieselectrolytelevelas
described inBATTERIES inthe
MAINTENANCEsection.
B
A
00879
CHECKINGBATTERY ELECTROLYTELEVEL
A.Battery
B.ElectrolyteIndicatorRing
FORSAFETY:WhenServicing Machine,Avoid
ContactWithBatteryAcid.
5.Check the battery specificgravityto
determine the state ofcharge asdescribed
inBATTERIES inthe MAINTENANCE
section.Charge the batteriesifnecessary.
6.Connect the battery connectortothe
machine connector.
A
B
03367
BATTERYCONNECTOR
A.MachineConnector
B.BatteryConnector
7.Check the hydraulicfluidlevel inthe
hydraulicfluidreservoir.See HYDRAULICS
inthe MAINTENANCEsection.
8.Check the main brush adjustment. See
BRUSHES inthe MAINTENANCEsection.

OPERATION
235EMM165 (3--91)
2-4
OPERATIONOFCONTROLS
C
A
B
H
D
F
E
G
03365
MACHINECOMPONENTS
A. OperatorSeatE.Hopper
B.SeatSupportF.HopperInspection Door
C.Steering Wheel G. SideBrush
D.FilterCoverH.Access Door