Tennant 515 User manual

515
MM420
Rev.09
OperatorManual

Thismanual isfurnished with each newTENNANTModel515.Itprovidesnecessaryoperating and
preventivemaintenanceinstructions.Read thismanualcompletelyand understand the machine before
operating orservicing it.
Thismachine will provide excellentservice.However, the bestresultswill be obtained atminimumcosts
if:
DThe machine isoperated withreasonablecare.
DThe machine ismaintained regularly-- perthe maintenanceinstructionsprovided.
DThe machine ismaintained withTENNANTsupplied orequivalentparts.
Manual Number -- MM420
Revision:09
Published:6--00
CopyrightE1996,1997,1998,1999,2000 TENNANT,Printed inU.S.A.

CONTENTS
1
515 MM420 (6--00)
CONTENTS
Page
SAFETY PRECAUTIONS3.................
OPERATION5............................
OPERATOR RESPONSIBILITY5.........
MACHINECOMPONENTS6.............
SYMBOLDEFINITIONS7................
CONTROLS AND INSTRUMENTS8......
BRAKE PEDAL 9....................
DIRECTIONALPEDAL 9..............
STEERINGWHEEL 10................
SOLUTIONLEVER10.................
BATTERYDISCHARGEINDICATOR11.
HOURMETER11.....................
CONTROLPANELMESSAGE
DISPLAY 12.......................
CHANGINGMESSAGEDISPLAY
LANGUAGE13.................
RECOVERYTANKFULL INDICATOR13.
EStSWITCH (OPTION)14............
EDGE SCRUB SWITCH 14.............
REARSQUEEGEE SWITCH 14........
SCRUB SWITCH 15...................
ON-OFF KEY SWITCH 16..............
HORN BUTTON16....................
OPERATINGLIGHTS SWITCH
(OPTION)16......................
PARKINGBRAKE 17..................
POWERWAND SWITCH (OPTION)17. .
CIRCUITBREAKERS18...............
SOLUTIONTANKDRAIN HOSE 19.....
RECOVERYTANKDRAIN HOSE 19....
POSITIVE SOLUTION CONTROL
DRAIN(OPTION)19................
OPERATORSEAT19..................
HOWTHEMACHINEWORKS 20..........
PRE-OPERATION CHECKLIST21.........
STARTINGTHEMACHINE22.............
FILLINGTHETANKS 22..................
SCRUBBINGAND BRUSH
INFORMATION25....................
SCRUBBING26.........................
DOUBLE SCRUBBING28.................
LOCKINGUP SIDE SQUEEGEES 28....
UNLOCKINGSIDE SQUEEGEES 29....
STOP SCRUBBING30...................
DRAININGAND CLEANINGTHE
TANKS 31.
STOPTHEMACHINE34.................
POST-OPERATION CHECKLIST35........
OPERATIONONINCLINES 36............
OPTIONS37............................
VACUUMWAND 37...................
POWERWAND 41....................
MACHINETROUBLESHOOTING46.......
Page
MAINTENANCE48.........................
MAINTENANCECHART48...............
LUBRICATION50........................
PROPELLING GEARBOX50...........
FRONTWHEELSUPPORT
BEARING50......................
STEERINGUNIVERSALJOINT50......
SCRUBHEADPARALLELARMS51....
REARSQUEEGEE CASTER52........
STEERING GEAR CHAIN52...........
BATTERIES 53..........................
CHARGINGTHE BATTERIES 54.......
CONTROLPANEL 56....................
ELECTRICMOTORS57..................
PROPELLINGCIRCUIT57................
SCRUBHEAD57........................
SCRUBHEADFLOORSKIRTS58......
SCRUBHEADGAS SPRING58........
SCRUBHEADADJUSTMENTS58......
SCRUB BRUSHES 58....................
REPLACINGTHE SCRUB BRUSHES 59
SOLUTIONSYSTEM60..................
SOLUTIONVALVE 60.................
RECOVERYTANK60.................
SOLUTIONTANK61..................
SQUEEGEES 62.........................
REARSQUEEGEE 62.................
LEVELINGTHEREAR
SQUEEGEE 62.................
ADJUSTINGREARSQUEEGEE
BLADEDEFLECTION64.........
SIDE SQUEEGEE ADJUSTMENT65....
SQUEEGEE BLADES 65.................
REARSQUEEGEE BLADES 65.........
REPLACING OR ROTATINGTHE
REARSQUEEGEE BLADES 65...
SIDE SQUEEGEES BLADES 66........
REPLACINGSIDE SQUEEGEE
BLADES 67.....................
CHAINS68..............................
STEERING GEAR CHAIN68...........
STATIC DRAGCHAIN68..............
BRAKES AND TIRES 69..................
BRAKES 69..........................
TIRES 69............................
FRONTWHEEL 69....................
PUSHING, TOWING, AND
TRANSPORTINGTHEMACHINE70....
PUSHING ORTOWINGTHE
MACHINE70......................
TRANSPORTINGTHEMACHINE71....
MACHINEJACKING73...................
STORAGEINFORMATION74.............

CONTENTS
515 MM420 (6--00)
2
Page
SPECIFICATIONS75.......................
GENERALMACHINE PERFORMANCE75. .
POWERTYPE 76........................
STEERING76...........................
BRAKINGSYSTEM76...................
TIRES 76...............................
MACHINEDIMENSIONS77...............
INDEX 78..................................

SAFETY PRECAUTIONS
3
515 MM420 (6--00)
SAFETY PRECAUTIONS
The following symbolsare used throughout this
manualasindicated intheirdescription:
WARNING:To warn ofhazardsor
unsafepractices thatcouldresultin
severepersonal injuryordeath.
FORSAFETY:To identify actionsthat
mustbefollowedforsafeoperation of
equipment.
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.Do notoperatemachine:
-- Unless trainedand authorized.
-- Unless operation manual isreadand
understood.
-- Inflammableorexplosive areas unless
designedforuse inthose areas.
-- Inareas with possiblefalling objects
unless equippedwith overhead guard.
2.Before starting machine:
-- Make sure all safetydevices arein
place and operateproperly.
-- Check brakes and steering forproper
operation.
3.Whenstarting machine:
-- Keepfooton brake and directional
pedal in neutral.
4.When using machine:
-- Use brakes tostop machine.
-- Goslowon inclines and slippery
surfaces.
-- Use carewhen backing machine.
-- Do notcarryriderson machine.
-- Always followsafety and trafficrules.
-- Reportmachinedamageorfaulty
operation immediately.
-- Followmixing and handling
instructionson chemicalcontainers.
5.Beforeleaving orservicing machine:
-- Stop on levelsurface.
-- Setparking brake.
-- Turn off machine and remove key.
6.Whenservicing machine:
-- Avoidmoving parts.Do notwearloose
jackets,shirts,orsleeves when
working on machine.
-- Block machinetires beforejacking
machineup.
-- Jack machineup atdesignated
locationsonly.Block machineup with
jack stands.
-- Use hoistorjack ofadequate capacity
tolift machine.
-- Weareye and earprotection when
using pressurizedairorwater.
-- Disconnectbattery connectionsbefore
working on machine.
-- Avoidcontactwith battery acid.
-- Use Tennantsupplied orequivalent
replacementparts.
7.Whenloading/unloading machine
onto/off truck ortrailer:
-- Turn off machine.
-- Use winch.Do notdrive themachine
onto/off thetruck ortrailerunless the
load heightis 380 mm (15 in)orless
fromtheground.
-- Setparking brake after machineis
loaded.
-- Block machinetires.
-- Tiemachinedowntotruck ortrailer.
WARNING:Batteries emithydrogen gas.
Explosion orfire canresult.Keep
sparks and openflame away.Keep
coversopenwhencharging.
WARNING:Flammablematerials can
cause anexplosion orfire.Do notuse
flammablematerialsintank(s).
WARNING:Flammablematerialsor
reactive metals cancause anexplosion
orfire.Do notpickup.

SAFETY PRECAUTIONS
515 MM420 (10--96)
4
The safetylabelsappearon the machine inthe
locationsindicated. If these oranylabelbecomes
damaged orillegible,install a new label inits
place.
10390
CLEANINGSOLUTIONLABEL-- LOCATEDON
THETANKSCOVER.
BATTERYCHARGINGLABEL-- LOCATEDON
THELINTEL.
FORSAFETYLABEL-- LOCATEDONTHE
MOTOR COVERPANEL.
FLAMMABLE SPILLSLABEL-- LOCATEDON
THEMOTOR COVERPANEL.

OPERATION
5
515 MM420 (1--96)
OPERATION
OPERATOR RESPONSIBILITY
-The operator’sresponsibilityistotakecare
of the dailymaintenance and checkupsof
the machine tokeep itin good working
condition.The operator mustinform the
servicemechanicorsupervisorwhen the
maintenanceintervalsarerequired as stated
inthe MAINTENANCEsection of this
manual.
-Read thismanualcarefullybefore operating
thismachine.
FORSAFETY:Do notoperatemachine,
unless operation manual isreadand
understood.
-Check the machine forshipping damage.
Check tomakesurethe machine is
complete pershipping instructions.
-Keep your machine regularlymaintained by
following the maintenanceinformation inthis
manual.Werecommend taking advantage
ofaregularly scheduled servicecontract
fromyourTennantrepresentative.
-Orderpartsand suppliesdirectlyfromyour
authorized Tennantrepresentative.Usethe
partsmanualprovided when ordering parts.
-Afterthe first50 hoursofoperation, follow
the recommended procedures stated inthe
MAINTENANCECHART.
07324

OPERATION
515 MM420 (12--96)
6
MACHINECOMPONENTS
A
B
D
E
F
G
J
I
K
L
H
C
DE
F
C
K
10641
10390
A. Operatorseat
B.Steering wheel
C.Machine cover
D.Recoverytank
E.Solution tank
F.Tank cover
G. Rearsqueegee
H.Side squeegee
I. Solution tankdrain
J.Recoverytankdrain
K.Rearwheel
L.Seatsupport

OPERATION
7
515 MM420 (1--96)
SYMBOLDEFINITIONS
Thesesymbolsidentify controls,displays,and
featureson the machine:
Battery charging systemHeadlights
Hour meterSolution flow
Recoverytankfull Circuitbreaker#1
EStCircuitbreaker#2
Scrub brush edge clean Circuitbreaker#3
Squeegee downCircuitbreaker#4
Down pressureCircuitbreaker#5
Scrub brush down and on Circuitbreaker#6
HornCircuitbreaker#7
Key switchCircuitbreaker#8
Jack-point

OPERATION
515 MM420 (9--98)
8
CONTROLSAND INSTRUMENTS
B
C
D
EFG
H
I
JK
L
M
N
O
P
A
10639
A.Brake pedal
B.Directionalpedal
C.Steering wheel
D.Solution lever
E.Batterydischargeindicator
F.Hour meter
G. Recoverytankfull indicator
H.EStswitch(Option)
I. Edge scrub switch
J.Rearsqueegee switch
K.Scrub switch
L. On-off key switch
M.Horn button
N. Operating lights switch/revolving lightswitch
O. Parking brake
P.Powerwand switch(Option)

OPERATION
9
515 MM420 (1--96)
BRAKE PEDAL
The brake pedalstopsthe machine.
Stop:Takeyourfootoff the directionalpedaland
letitreturntothe neutralposition.Step on the
brake pedal.
DIRECTIONALPEDAL
The directionalpedalcontrolsdirection of travel
and the propelling speed of the machine.You
change the speed of the machine withthe
pressure ofyourfoot; the harderyou press the
fasterthe machine travels.
The machine will coast forashortdistance before
changing direction when itismoving,and the
direction isreversed withthe directionalpedal.
Usethe brake pedaltostop the machine.
Forward:Press the top of the directionalpedal
withthe toe ofyourfoot.
Reverse:Press the bottomof the directional
pedal withthe heelofyourfoot.

OPERATION
515 MM420 (1--96)
10
Neutral:Takeyourfootoff the directionalpedal
and itwill returntothe neutralposition.
STEERINGWHEEL
The steering wheelcontrolsthe machine’s
direction.The machine is veryresponsivetothe
steering wheelmovements.
Left: Turnthe steering wheeltothe left.
Right: Turnthe steering wheeltothe right.
SOLUTIONLEVER
The solution levercontrolsthe amountofsolution
flowtothe floor.
Increase:Movethe leverup.
Decrease:Movethe leverdown.
Stop:Movethe leverall the waydown.

OPERATION
11
515 MM420 (1--96)
BATTERYDISCHARGEINDICATOR
The batterydischarge indicatorshowsthe charge
levelof the batterieswithasegmented display.
When the batteriesarefully charged,all the
segmentsarelit. Asthe batteriesdischarge, the
segments shutoff.
The batteries shouldberecharged when all the
segmentshaveshutoff. At thispoint, the
scrubbing functionswill automatically shutoff to
alert the operatorof the battery condition.The
squeegee and vacuumcan be operated,withthe
rearsqueegee switch, foran additional30
secondsto pick up anyexcess water.
NOTE:Do notcharge the batteriesmore often
than isnecessaryto prolong the life of the
batteries.Do notcharge the batterieswitha“top
off”charge if thereisenough remaining charge in
the batteriesforthe nextmachine use.Discharge
the batteriesto a 20%level,when the battery
discharge indicatorsegments shutoff, beforefully
charging the batteries.Do notallowthe batteries
to becomecompletelydischarged asthiswill also
damage the batteries.See BATTERIES inthe
MAINTENANCEsection.
HOURMETER
The hourmeter recordsthe numberofhoursthe
machine hasbeen operating.Thisinformation is
useful when maintaining the machine.
10658
10659

OPERATION
515 MM420 (1--96)
12
CONTROLPANELMESSAGEDISPLAY
The hour meterand batterydischarge indicator
displayalsologsand displays messagestothe
operator.When a scheduled maintenanceinterval
haspassed, the controlpanel will internallylog the
eventand displayamessage the next timethe
machine ispowered on.See the chartbelowfor
the normaloperating messages.Ifanymessages
appearotherthan thoselisted inthe chart, contact
yourservice personnel.
MessageDescription
Tanks Full The auto-fill hasturned off. The
tanks arefilled tothe proper
level.
Rec.TankFull Recoverytankisfull.
XX hourcheck Check the MaintenanceChart
forthe scheduled maintenance
at the numberofhours stated in
the message.
XX hourlube Check the MaintenanceChart
forthe scheduled maintenance
at the numberofhours stated in
the message.
BreakerCB3Brushcircuitbreakerhas
tripped forthe rightbrushmotor.
The circuitbreaker mustbe
resetbeforeresuming
scrubbing.
BreakerCB4Brushcircuitbreakerhas
tripped forthe left brushmotor.
The circuitbreaker mustbe
resetbeforeresuming
scrubbing.
BreakerCB5Brushcircuitbreakerhas
tripped forthe centerbrush
motor (MaxProt1200 option).
The circuitbreaker mustbe
resetbeforeresuming
scrubbing.
Toremovethe message fromthe hour meterand
batterydischarge indicatordisplay, turnthe
machine poweroff and then back on again.
The message displaylanguage can be changed.
The availablelanguagesare:
EnglishSwedish
DutchDanish
Italian Norwegian
SpanishFinnish
FrenchPortuguese
German Japanese
10660

OPERATION
13
515 MM420 (3--98)
CHANGINGMESSAGEDISPLAY LANGUAGE
1.Withthe machine powered off, press and
holdthe scrub and edge scrub switches.
2.Turnthe machine poweron.
3.Continue pressing the scrub and edge scrub
switchesfor5moreseconds.
4.Releasethe scrub and edge scrub switches.
5.Press the EStswitchtoscroll through the
listoflanguagesuntil the desired language
isdisplayed.
6.Turnthe machine poweroff, and the new
language will be stored inthe controlpanel.
RECOVERYTANK FULL INDICATOR
The recoverytankfull indicatorcomeson when
the recoverytankisfull.
If the recoverytankfull indicatorstays on for more
than 7 seconds, the “Rec.TankFull” message will
appearinthe hourmeterdisplay.The scrub
brushesand vacuumwill shutoff, and the rear
squeegee will raise.
To pick up excess waterafterthe vacuumhas
shutoff and the rearsqueegee hasraised,press
and holdthe rearsqueegee switch.
Note:Do notoverfill the recoverytank. Overfilling
the recoverytankmaydamage the vacuumfans.
10734
10662
10661

OPERATION
515 MM420 (1--96)
14
EStSWITCH (OPTION)
The EStswitchturnson and off the solution
recycling system.
On:Press the switch.The indicatorwill light.
Off: Press the switch.
EDGE SCRUB SWITCH
The edge scrub switch extendsthe scrub head to
the right to allowclose edge scrubbing.
On:Press the switch during normalscrubbing.
The indicatorwill light.
Off: Press the switch again.
REAR SQUEEGEE SWITCH
The rearsqueegee switch,along withthe direction
of travel,controlsthe rearsqueegee position and
scrubbing vacuumfan.
Lowersqueegee and startvacuum:Press the
switch.The indicatorwill light.
Raisesqueegee and stop vacuum:Press the
switch.
The rearsqueegee liftswhen the machine travels
inreverse.Thispreventsthe rearsqueegee from
being damaged when reversing the machine.The
rearsqueegee will loweragainwhen the machine
travelsforward.
10662
10663
10880

OPERATION
15
515 MM420 (1--96)
SCRUB SWITCH
The scrub switchcontrolsthe scrubbing
operations.The scrub switch alsosetsthe scrub
brush pressure.
The scrubbing operationsinclude the following.
The scrub head lowersand the brushesturn on.
The rearsqueegee will lowerand the vacuumwill
start. Also, the optionalEStsystemwill start.
Startscrubbing:Press the switch.The indicators
will light tothe presetbrush pressure.The
scrubbing systemwill startwhen the machine
movesforward.
NOTE:The brush pressuresetting, the edge
scrub,and the EStsystemwill default tothe last
setting used when the scrubbing operationsare
started again.
Stop scrubbing:Press the switch.The indicators
will go off. First the scrub brusheswill stop and
raise, then the rearsqueegee will raise and the
vacuumwill shutoff.
Scrub brush pressure:Press and holdthe scrub
switch.The brush pressurewill scroll through the
foursettings.Whateverpressuresetting is
selected when the switchisreleased,will be the
newdefaultbrush pressuresetting.
The brush pressure hasfourpositions.Under
normalconditions, the brush pressureshould be
setinthe minimumsettings.Underheavy grime
conditions, the brush pressureshouldbesetin
the maximumsettings.Travelspeed and floor
conditionswill affect the scrubbing performance.
NOTE:The rearsqueegee will raise and the
vacuumwill shutoff when the machine travelsin
reverse.The squeegee will lowerand the vacuum
startsagainwhen the machine travelsforward.
NOTE:The scrub brusheswill stop when the
machine is stopped forashort time.The brushes
will startagainwhen the machine travelsforward.
10881

OPERATION
515 MM420 (1--96)
16
ON-OFF KEY SWITCH
The on-off key switchcontrolsmachine power
withakey.
On:Turnthe key clockwise all the way.
Off: Turnthe key counter-clockwise.
HORN BUTTON
The horn button operatesthe horn.
Sound:Press the button.
OPERATINGLIGHTS SWITCH (OPTION)
The operating lights switch powerson and off the
headlights, taillights,and hazardlightoption.
On:Press the top of the switch.
Off: Press the bottomof the switch.
10906

OPERATION
17
515 MM420 (1--96)
PARKINGBRAKE
The parking brakeleversetsand releasesthe
rearwheelbrakes.
Set: Pull the parking brakeleverup.
FORSAFETY:Beforeleaving orservicing
machine;stop on levelsurface,setparking
brake,turn off machine and remove key.
Release:Pushthe parking brakeleverdown.
POWERWAND SWITCH (OPTION)
The powerwand switchturnson and off the
powerwand solution system.
On:Press the top of the switch.The switchwill
lightup.
Off: Press the bottomof the switch.

OPERATION
515 MM420 (1--96)
18
CIRCUITBREAKERS
The circuitbreakersareresetable electricalcircuit
protection devices.They stop the flowofcurrent
inthe eventofacircuitoverload. Onceacircuit
breakeristripped,resetitmanuallybypressing
the resetbutton afterthe breakerhas cooled
down.
If the overload thatcaused the circuitbreakerto
tripis still there, the circuitbreakerwill continue to
stop current flowuntil the problemis corrected.
The fuseisa one-timecircuitprotection device
designed tostop the flowofcurrentinthe eventof
acircuitoverload.Neversubstitute highervalue
fusesthan thosespecified inthismanual.
The circuitbreakersarelocated tothe left of the
operator’s compartmentnearthe machine and
battery connectorsand on the controlboxes.The
fusesarelocated inthe maincontrolbox.
The chartshowsthe circuitbreakersand fuses,
and the electricalcomponentstheyprotect.
Circuit
BreakerRating CircuitProtected
CB1 20 A Scrubbing vacuumfan motor
CB2 20 A Scrubbing vacuumfan motor
CB3 40 ARightscrub brushmotor
CB3 50 AHeavy dutyrightscrub brushmotor
(option)
CB4 40 ALeft scrub brushmotor
CB4 50 AHeavy dutyleft scrub brushmotor
(option)
CB5 40 ACenterscrub brushmotor (option)
CB6 2.5AControl Circuit
CB7 15 AControlpanel
CB8 15 AHorn,hazard and operating lights
(option)