Tennant 96GR Operator'S Manual Download

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GENERAL INFORMATION

95GR MM199 (10---89)

Page

MAINTENANCE

3-1

. . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOMMENDED FIRST 50---HOUR

MACHINE INSPECTION

3-3

. . . . . . . . . . . . . .

MAINTENANCE CHART

3-4

. . . . . . . . . . . . . . . .

LUBRICATION

3-6

. . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE

3-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL SUPPORT PIVOT

3-6

. . . . . . .

STEERING GEAR

3-6

. . . . . . . . . . . . . . . . . . .

SIDE BRUSH PIVOT PINS

3-7

. . . . . . . . . . . .

STABILIZER LEG PIVOT PIN

3-7

. . . . . . . . . .

FRONT WHEEL BEARINGS

3-7

. . . . . . . . . . .

HYDRAULICS

3-8

. . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC FLUID

3-8

. . . . . . . . . . . . . . . . . .

HYDRAULIC FLUID RESERVOIR

3-8

. . . . . .

HYDRAULIC FLUID FILTER

3-9

. . . . . . . . . . .

TO REPLACE THE HYDRAULIC

FLUID FILTER ELEMENT

3-9

. . . . . . .

DIRECTIONAL CONTROL PEDAL

“NEUTRAL” POSITION ADJUSTMENT 3-9

SPEED LIMITER

3-10

. . . . . . . . . . . . . . . . . . . . .

HYDRAULIC FLUID LEAKS

3-10

. . . . . . . . . . .

HYDRAULIC SCHEMATIC

3-11

. . . . . . . . . . . .

HYDRAULIC SYSTEM

TROUBLESHOOTING

3-12

. . . . . . . . . . . . .

HYDRAULIC COMPONENTS

TROUBLESHOOTING

3-14

. . . . . . . . . . . . .

ENGINE

3-15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE LUBRICATION

3-15

. . . . . . . . . . . . . .

AIR INTAKE SYSTEM

3-16

. . . . . . . . . . . . . . . .

AIR FILTER RESTRICTION INDICATOR 3-16

AIR FILTER

3-17

. . . . . . . . . . . . . . . . . . . . . . . . .

TO REPLACE AIR FILTER ELEMENT 3-17

FUEL SYSTEM --- DIESEL

3-17

. . . . . . . . . . . .

DIESEL FUEL SYSTEM

3-17

. . . . . . . . . . . .

FUEL WATER TRAP

3-18

. . . . . . . . . . . . . . .

TO CLEAN WATER TRAP

3-18

. . . . . . .

FUEL FILTER

3-18

. . . . . . . . . . . . . . . . . . . . .

TO REPLACE THE FUEL FILTER 3-18

FUEL INJECTION PUMP

3-19

. . . . . . . . . . .

FUEL INJECTORS

3-19

. . . . . . . . . . . . . . . .

PRIMING THE FUEL SYSTEM

3-20

. . . . . .

DIESEL FUEL TROUBLESHOOTING

3-21

. . .

CYLINDER HEAD

3-22

. . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD

3-22

. . . . . . . . . . . . . . . . .

VALVE TAPPET CLEARANCE

ADJUSTMENT

3-22

. . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM

3-23

. . . . . . . . . . . . . . . . . .

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-23

ELECTRICAL SCHEMATIC

3-24

. . . . . . . . . . . .

ELECTRICAL SCHEMATIC,

ACCESSORIES

3-25

. . . . . . . . . . . . . . . . . .

BELTS AND CHAINS

3-26

. . . . . . . . . . . . . . . . . . . .

ENGINE FAN BELT

3-26

. . . . . . . . . . . . . . . . . .

STATIC DRAG CHAIN

3-26

. . . . . . . . . . . . . . . .

Page

DEBRIS HOPPER

3-27

. . . . . . . . . . . . . . . . . . . . . .

HOPPER DUST FILTERS

3-27

. . . . . . . . . . . . .

TO REMOVE HOPPER DUST FILTERS . .

3-27

TO INSTALL HOPPER DUST FILTERS 3-28

HOPPER FUSIBLE LINK

3-29

. . . . . . . . . . . . . .

TO REPLACE HOPPER FUSIBLE LINK . .

3-29

DEBRIS HOPPER

3-29

. . . . . . . . . . . . . . . . . . .

TO CHECK AND ADJUST HOPPER

FLOOR CLEARANCE

3-29

. . . . . . . . . . .

STABILIZER LEG

3-30

. . . . . . . . . . . . . . . . . . . .

TO ADJUST STABILIZER LEG

3-30

. . . . . .

BRUSHES

3-31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN BRUSH/WIRE BRUSH

3-31

. . . . . . . . . .

TO REPLACE MAIN BRUSH OR

WIRE BRUSH

3-31

. . . . . . . . . . . . . . . . .

TO CHECK AND ADJUST MAIN

BRUSH PATTERN

3-32

. . . . . . . . . . . . . .

TO CHECK AND ADJUST WIRE

BRUSH PATTERN

3-33

. . . . . . . . . . . . . .

SIDE BRUSH . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-33

TO REPLACE SIDE BRUSH

3-34

. . . . . . . .

TO ADJUST SIDE BRUSH

MAXIMUM HEIGHT

3-34

. . . . . . . . . . . .

TO ADJUST SIDE BRUSH ANGLE

3-35

. .

TO ADJUST SIDE BRUSH

BUMPER CLEARANCE

3-35

. . . . . . . . .

SKIRTS AND SEALS

3-36

. . . . . . . . . . . . . . . . . . . .

HOPPER LIP SKIRTS

3-36

. . . . . . . . . . . . . . . .

TO REPLACE HOPPER LIP

3-36

. . . . . . . .

HOPPER SIDE SEALS

3-37

. . . . . . . . . . . . . . .

TO REPLACE HOPPER SIDE SEALS 3-37

BRUSH DOOR SKIRTS

3-37

. . . . . . . . . . . . . . .

TO REPLACE AND ADJUST BRUSH

DOOR SKIRTS

3-37

. . . . . . . . . . . . . . . .

REAR SKIRTS

3-38

. . . . . . . . . . . . . . . . . . . . . . .

TO REPLACE AND ADJUST REAR

SKIRTS

3-38

. . . . . . . . . . . . . . . . . . . . . . .

HOPPER DUST DUMP DOOR SEAL

3-39

. . .

TO REPLACE DUST DUMP DOOR

SEAL

3-39

. . . . . . . . . . . . . . . . . . . . . . . . .

TO CHECK AND ADJUST HOPPER

DUST DUMP DOOR SEAL

3-40

. . . . . .

HINGED TOP HOPPER SEAL

3-40

. . . . . . . . .

TO REPLACE AND ADJUST HINGED

TOP HOPPER SEAL

3-40

. . . . . . . . . . . .

HOPPER DOOR HINGE SEAL

3-42

. . . . . . . . .

TO REPLACE HOPPER DOOR

HINGE SEAL

3-42

. . . . . . . . . . . . . . . . . .

BRAKES AND TIRES

3-43

. . . . . . . . . . . . . . . . . . .

SERVICE BRAKES

3-43

. . . . . . . . . . . . . . . . . . .

PARKING BRAKES

3-44

. . . . . . . . . . . . . . . . . .

TIRES

3-44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for 96GR

Page 1: ... Operator Manual ...

Page 2: ...maintained regularly per the maintenance instructions provided D 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 hand...

Page 3: ...dequate ventilation will cause asphyxiation Check exhaust system regularly for leaks WARNING Do not operate machine in flammable or explosive environment Machine is not designed for such an environment It could cause ignition of flammable or explosive materials WARNING Do not operate machine in areas with possible falling objects unless machine is equipped with overhead guard WARNING Dirt dust and...

Page 4: ...it WARNING Avoid moving parts of the machine Do not wear loose jackets shirts or sleeves when working on machine because of the danger of becoming caught in moving parts Keep shields and guards in position Wear approved eye protection If adjustments must be made while the engine is running use extreme caution around hot manifolds moving parts belts etc WARNING Always stop the machine on a level su...

Page 5: ...d If these or any labels become damaged or illegible install a new label in its place FOR SAFETY LABEL LOCATED ON DUST SHIELD ENGINE FAN LABEL LOCATED ON THE TOP AND SIDE OF THE RADIATOR FAN SHROUD HOPPER LIFT ARM LABEL LOCATED ON RIGHT AND LEFT SIDE LIFT ARMS TOXIC EMISSIONS LABEL LOCATED ON THE OPERATOR KICK PANEL 05544 ...

Page 6: ...GENERAL INFORMATION 95GR MM199 10 89 iv FALLING HOPPER LABEL LOCATED ON PUMP BAFFLE FALLING HOPPER LABEL LOCATED ON LEFT SIDE LIFT ARM AND ON HOPPER SUPPORT 05544 ...

Page 7: ...2 9 HAZARD LAMP SWITCH 2 9 TURN SIGNAL LEVER 2 9 CLOGGED DUST FILTER INDICATOR 2 9 DUST FILTER SHAKER PUSHBUTTON SWITCH 2 9 Page DUMP DOOR INDICATOR 2 9 FUEL LEVEL GAUGE 2 9 ENGINE COOLANT TEMPERATURE GAUGE 2 10 ENGINE OIL PRESSURE GAUGE 2 10 STEERING WHEEL 2 10 BRUSH PRESSURE INDICATOR 2 10 BATTERY CONDITION GAUGE 2 10 ENGINE HOUR METER 2 10 SIDE BRUSH SWITCH 2 10 DIESEL PRE HEAT INDICATOR 2 10 I...

Page 8: ...3 ELECTRICAL SCHEMATIC 3 24 ELECTRICAL SCHEMATIC ACCESSORIES 3 25 BELTS AND CHAINS 3 26 ENGINE FAN BELT 3 26 STATIC DRAG CHAIN 3 26 Page DEBRIS HOPPER 3 27 HOPPER DUST FILTERS 3 27 TO REMOVE HOPPER DUST FILTERS 3 27 TO INSTALL HOPPER DUST FILTERS 3 28 HOPPER FUSIBLE LINK 3 29 TO REPLACE HOPPER FUSIBLE LINK 3 29 DEBRIS HOPPER 3 29 TO CHECK AND ADJUST HOPPER FLOOR CLEARANCE 3 29 STABILIZER LEG 3 30 ...

Page 9: ...28 Front Wheels and Brakes Group 5 40 Fig 29 Rear Wheel Assembly 5 42 Fig 30 Rear Wheel Support Group 5 43 Fig 31 Hydraulic System 5 44 Fig 32 Side Brush Motor Group 5 46 Fig 33 Main Brush Control Valve Group 5 47 Fig 34 Hopper and Side Brush Control Valve Group 5 48 Fig 35 Hydraulic Reservoir Group 5 50 Fig 36 Hopper Dump Cylinder Group 5 52 Fig 37 Main Brush Cylinder Group 5 53 Fig 38 Hopper Lif...

Page 10: ... 16 Fig 13 Cylinder Breakdown 62710 7 17 ENGINE PARTS DIESEL 8 1 ORDERING REPAIR PARTS 8 3 Fig 1 Engine Block Group 8 4 Fig 2 Cylinder Head Group 8 6 Fig 3 Fuel System Group 8 8 Fig 4 Crankshaft Group 8 10 Fig 5 Piston Group 8 11 Fig 6 Camshaft Group 8 12 Fig 7 Oil Pump Group 8 13 Fig 8 Gear Cover Group 8 14 Fig 9 Flywheel and Starter Group 8 15 Fig 10 Intake and Exhaust Manifold Group 8 16 Fig 11...

Page 11: ...SPECIFICATIONS 1 3 POWER TYPE 1 3 POWER TRAIN 1 3 STEERING 1 3 HYDRAULIC SYSTEM 1 3 BRAKING SYSTEM 1 4 SUSPENSION SYSTEM 1 4 SYSTEM FLUID CAPACITIES 1 4 GENERAL MACHINE DIMENSIONS CAPACITIES 1 4 MACHINE WEIGHTS 1 4 GENERAL MACHINE PERFORMANCE 1 4 MACHINE DIMENSIONS 1 5 ...

Page 12: ...SPECIFICATIONS 95GR MM199 10 89 1 2 ...

Page 13: ...ump 20 8 gpm 80 L min 2400 rpm Propelling system rated pressure 4500 psi 31 030 kPa Main brush pump variable displacement piston pump 20 8 gpm 80 L min 2400 rpm Main brush system rated pressure 4500 psi 31 030 kPa Accessories pump gear pump 2 gpm 30 L min 2400 rpm Accessories system rated pressure 2000 psi 13 790 kPa Dump cylinder system rated pressure 500 psi 3450 kPa Propelling motor internal ge...

Page 14: ...n 1805 mm Height without overhead guard 59 in 1500 mm Height with overhead guard 81 5 in 2070 mm Height with overhead guard and hazard light 90 5 in 2300 mm Track front 60 5 in 1535 mm Wheel base 48 9 in 1240 mm Main brush sweeping 16 in 405 mm tubular length 50 in 1270 mm Main brush wire diameter 15 in 380 mm length 50 in 1270 mm Side brush rotary diameter 26 in 660 mm Sweeping path width without...

Page 15: ...SPECIFICATIONS 1 5 95GR MM199 10 89 MACHINE DIMENSIONS TOP VIEW SIDE VIEW 01431 71 in 1805 mm 111 5 in 2830 mm 108 in 2745 mm 60 5 in 1535 mm 90 5 in 2300 mm 81 5 in 2070 mm ...

Page 16: ...SPECIFICATIONS 95GR MM199 10 89 1 6 ...

Page 17: ...COOLANT TEMPERATURE GAUGE 2 10 ENGINE OIL PRESSURE GAUGE 2 10 STEERING WHEEL 2 10 BRUSH PRESSURE INDICATOR 2 10 BATTERY CONDITION GAUGE 2 10 ENGINE HOUR METER 2 10 SIDE BRUSH SWITCH 2 10 DIESEL PRE HEAT INDICATOR 2 10 IGNITION SWITCH 2 10 PARKING BRAKE 2 11 SIDE BRUSH HEIGHT ADJUSTMENT KNOB 2 11 HOPPER SUPPORT BAR 2 11 TO ENGAGE HOPPER SUPPORT BAR 2 11 TO DISENGAGE HOPPER SUPPORT BAR 2 11 HYDRAULI...

Page 18: ...OPERATION 95GR MM199 10 89 2 2 ...

Page 19: ...draulic fluid level in the hydraulic fluid reservoir using the sight gauge provided TENNANTr hydraulic fluid is recommended If TENNANTr hydraulic fluid is not available use only new approved hydraulic fluid See Hydraulics in the Maintenance section 4 Check the engine oil level 5 Check the radiator coolant level WARNING If the coolant is hot or if the engine has been operating let the engine cool H...

Page 20: ... CONTROLS A B C D E F G H I J 05544 MACHINE COMPONENTS A Operator Seat F Hopper Inspection Door B Instrument Panel G Side Brush C Overhead Guard H Side Brush Height Adjustment Knob D Engine Cover I Hopper Support Bar E Hopper J Main Brush Access ...

Page 21: ...uge E Main Brush Speed Lever V Steering Wheel F Main Brush Power Lift Lever W Brush Pressure Indicator G Throttle Lever X Battery Condition Gauge H Main Brush Pressure Knob Y Engine Hour Meter I Side Brush Lever Z Side Brush Switch J Hopper Door Lever AA Diesel Preheat Indicator K Vacuum Fan and Hopper Lift Lever BB Ignition Switch L Main Brush Lift Lever CC Parking Brake M Operating Lamps Switch ...

Page 22: ...ted in Directional Pedal Neutral Position Adjustment in the Maintenance section WARNING Always use the brake pedal for normal stopping and controlling machine speed on downgrades to prevent loss of machine control MAIN BRUSH HEIGHT ADJUSTMENT KNOB The main brush height adjustment knob is located behind an access door next to the operator s left foot It limits the main brush lift linkage travel The...

Page 23: ...Brush Position MAIN BRUSH POWER LIFT LEVER The main brush power lift lever raises and lowers the wire brush It has three positions up hold and down To raise the wire brush push the lever into the up position To keep the brush at its present height pull the lever into the hold position To lower the brush pull the lever into the down position NOTE The power lift lever will not interfere with the mai...

Page 24: ...s also operating HOPPER DOOR LEVER The hopper door lever controls the hopper door position Pushing the control lever away from the operator into the open position opens the hopper door into the operating position Pulling the control lever back into the close position closes the hopper door so the hopper may be raised without allowing the debris in the hopper to spill Always sweep with the hopper d...

Page 25: ...mp on Flip the switch toggle down to turn the lamp off TURN SIGNAL LEVER The turn signal lever controls the turn signal lights Pushing the lever forward signals a turn to the right Pulling the lever back signals a turn to the left CLOGGED DUST FILTER INDICATOR The clogged dust filter indicator lights when the dust filters become clogged and excessively restrict vacuum air flow Lower the hopper shu...

Page 26: ... brush down pressure by turning the main brush pressure knob clockwise Watch the hydraulic pressure gauge BATTERY CONDITION GAUGE The battery condition gauge indicates the present voltage potential of the battery Normal battery voltage is 10 to 14 volts If the battery voltage exceeds 14 volts it may be overcharging If the battery voltage falls below 10 volts it may not be accepting or getting a ch...

Page 27: ...the operator s side of the hopper It holds the hopper up when work is to be done under the hopper Do not rely on the machine hydraulic system to keep the hopper raised WARNING Always engage the hopper support bar before working under a raised hopper Do not rely on the machine hydraulic system to keep the hopper in the raised position The hydraulic system may leak internally allowing the hopper to ...

Page 28: ...TRACTED STABILIZER LEG A Machine Frame B Stabilizer Leg FUSES AND CIRCUIT BREAKERS Fuses are a one time circuit protection device designed to stop the flow of current in the event of a circuit overload Never substitute higher value fuses than those specified in this manual Circuit breakers are reusable circuit protection devices designed to stop the flow of current in the event of a circuit overlo...

Page 29: ...tion and with a foot on the brake pedal or with the parking brake engaged WARNING Before operating the machine make sure all safety devices are in place and operate properly Check the foot and parking brakes and the steering control for proper operation Do not start the machine unless you are in the operator s seat with a foot on the brake pedal or have the parking brake engaged and the directiona...

Page 30: ...h position switch into the down position 5 Push the vacuum fan and hopper lift lever into the vacuum on position 6 Adjust the main brush pressure knob to suit the floor conditions 7 Sweep as required TO DUMP HOPPER 1 Pull the main brush lift lever back into the raise position 2 Press the side brush position switch back into the up position 3 Move the main brush power lift lever into the up positio...

Page 31: ...ng brake 10 Turn the ignition switch key to the off position Remove the key from the switch WARNING Always stop the machine on a level surface stop the engine and engage the parking brake before leaving the machine unattended to keep it from rolling POST OPERATION CHECKLIST ENGINE STOPPED Check skirts for damage wear and adjustment Check for wire or string tangled on brushes Check for leaks OPERAT...

Page 32: ...bristles worn Replace brushes Brushes not adjusted properly Adjust brushes Debris caught in brush Free mechanism of debris drive mechanism Main brush drive failure See Hydraulic System Trouble shooting Main brush turns slowly or not at all Side brush drive failure See Hydraulic System Trouble shooting Side brush turns slowly or not at all Hopper not adjusted properly Adjust hopper floor clearance ...

Page 33: ...ne s position WARNING Always block the machine tires before jacking the machine up to keep it from rolling off jack 4 Use a scissors or hydraulic type jack of adequate capacity to raise the machine Jack up the machine only at the designated locations WARNING Jack machine up only at the designated locations to keep it from tipping The front jacking locations are the bottom edge of the machine frame...

Page 34: ...res MACHINE TIE DOWNS The machine may be tied down at each of the four corners of the machine at the locations specified To tie the machine down use the tie down lug provided A B 01456 FRONT TIE DOWN LUG RIGHT SIDE SHOWN A Machine Frame B Tie Down Lug A B 01455 REAR TIE DOWN LUG LEFT SIDE SHOWN A Machine Frame B Tie Down Lug When transporting the machine on a trailer or in a truck be sure to engag...

Page 35: ...of rust sludge and other undesirable deposits from forming 1 Empty the debris hopper 2 Change engine oil 3 Place the main brush height control lever in the raise position 4 Park the machine in a cool and dry area 5 Stop the engine 6 Fill the hydraulic reservoir with hydraulic fluid to the full mark on the sight gauge to prevent excessive condensation from forming in the reservoir ...

Page 36: ...OPERATION 95GR MM199 10 89 2 20 ...

Page 37: ... TO CLEAN WATER TRAP 3 18 FUEL FILTER 3 18 TO REPLACE THE FUEL FILTER 3 18 FUEL INJECTION PUMP 3 19 FUEL INJECTORS 3 19 PRIMING THE FUEL SYSTEM 3 20 DIESEL FUEL TROUBLESHOOTING 3 21 CYLINDER HEAD 3 22 CYLINDER HEAD 3 22 VALVE TAPPET CLEARANCE ADJUSTMENT 3 22 ELECTRICAL SYSTEM 3 23 BATTERY 3 23 ELECTRICAL SCHEMATIC 3 24 ELECTRICAL SCHEMATIC ACCESSORIES 3 25 Page BELTS AND CHAINS 3 26 ENGINE FAN BEL...

Page 38: ...RUSH DOOR SKIRTS 3 37 REAR SKIRTS 3 38 TO REPLACE AND ADJUST REAR SKIRTS 3 38 HOPPER DUST DUMP DOOR SEAL 3 39 TO REPLACE DUST DUMP DOOR SEAL 3 39 TO CHECK AND ADJUST HOPPER DUST DUMP DOOR SEAL 3 40 HINGED TOP HOPPER SEAL 3 40 TO REPLACE AND ADJUST HINGED TOP HOPPER SEAL 3 40 HOPPER DOOR HINGE SEAL 3 42 TO REPLACE HOPPER DOOR HINGE SEAL 3 42 BRAKES AND TIRES 3 43 SERVICE BRAKES 3 43 PARKING BRAKES ...

Page 39: ... are recommended 1 Check the brush pattern for correct brush adjustment 2 Change the hydraulic fluid filter 3 Check the torque of the engine cylinder head cap screws 4 Perform all 50 hour interval lubrication and maintenance procedures listed in the Maintenance chart 5 Check the valve tappet clearance after the first 250 hours of operation ...

Page 40: ...brush Check for damage wear and adjustment 1 4 Main brush Check for damage wear and adjustment 1 50 Hours 12 Engine fan belt Check tension 1 14 Engine crankcase Change oil and filter EO 1 17 Hopper Check floor clearance 1 4 Main brush Rotate end for end and check adjustment 1 100 Hours 6 Parking brake Check adjustment 1 11 Radiator Check coolant level WG 1 Check core exterior for debris and clean ...

Page 41: ...fluid reservoir Change hydraulic fluid HYDO 1 7 Hydraulic fluid filter Change filter element 1 3 Brake master cylinder Check fluid level BF 1 800 Hours 8 Hydraulic reservoir strainer Replace 1 11 Cooling system Flush WG 1 BF Brake fluid EO Engine oil HYDO Tennant Company or approved hydraulic fluid MPGM Multipurpose water resistant lithium base moly disulphide EP grease WG Water and permanent type...

Page 42: ...peratures involved The engine oil capacity is 7 qt 6 6 L with filter REAR WHEEL SUPPORT PIVOT There is a grease fitting which is used to lubricate the rear wheel support pivot bearing Access to the grease fitting is through the center rear access door Apply a general purpose water resistant lithium base moly disulphide EP grease after every 200 hours of operation A B C 01452 REAR WHEEL SUPPORT PIV...

Page 43: ...ion A B 01459 SIDE BRUSH PIVOT PINS A Pivot Pin B Side Brush Motor STABILIZER LEG PIVOT PIN The stabilizer leg pivot pin should be lubricated with a general purpose water resistant lithium base moly disulphide EP grease after every 200 hours of operation 01440 STABILIZER LEG FRONT WHEEL BEARINGS The front wheel bearings should be repacked with a good quality wheel bearing grease after every 2000 h...

Page 44: ...the hydraulic fluid used must match closely the viscosity specifications given in the chart for TENNANT Hydraulic Fluid as well as the other features described Do not substitute automatic transmission fluid for hydraulic fluid ATTENTION Hydraulic components depend on system hydraulic fluid for internal lubrication If dirt or other contaminants are allowed to enter the hydraulic system malfunctions...

Page 45: ...or leaks Correct any leaks found 7 Check the hydraulic fluid reservoir level and fill as required 8 Close the engine access door DIRECTIONAL CONTROL PEDAL NEUTRAL POSITION ADJUSTMENT After replacing the hydraulic pump or pump linkages the pump control linkages must be adjusted 1 Stop the engine and engage the machine parking brake WARNING Always stop the machine on a level surface stop the engine ...

Page 46: ...ble One threaded end of the cable is located on the right lift arm The other end of the cable which is also threaded is located on a flat sided sheave next to the directional control pedal Tighten the cable to reduce the machine speed when the hopper is raised Loosen the cable to increase the machine speed when the hopper is raised A B C D 01463 SPEED LIMITER CABLE A Speed Limiter Cable B Flat Sid...

Page 47: ...MAINTENANCE 3 11 95GR MM199 10 89 04307 HYDRAULIC SCHEMATIC ...

Page 48: ...Troubleshooting Side brush turns slowly Hydraulic control valve See Hydraulic Components or not at all failure Troubleshooting Hydraulic motor failure See Hydraulic Components Troubleshooting Relief valve in control Clean or replace relief valve sticking valve Gear pump failure See Hydraulic Components Troubleshooting Poor or no vacuum to Hydraulic control valve See Hydraulic Components brush comp...

Page 49: ...shooting Gear pump failure See Hydraulic Components Troubleshooting Lift arms binding Replace and or adjust lift arm linkage Hopper door will not roll out Hydraulic control valve See Hydraulic Components failure Troubleshooting Lift cylinder failure See Hydraulic Components Troubleshooting Gear pump failure See Hydraulic Components Troubleshooting Lift arms binding Replace and or adjust lift arm l...

Page 50: ...Gerotor worn Replace gerotor set Output shaft failure Replace output shaft and bearings Hydraulic gear pump Pump leaking Install seal kit pump failure Gear set failure Replace gear set Shaft failure Replace gear set Flow divider failure Replace back plate assembly Engine to pump coupling Replace coupling failure Hydraulic piston pump Pump leaking Install seal kit failure Relief valve stuck Clean o...

Page 51: ...remove the heavy deposits of sludge rust and scale The reverse flow flushing should be performed immediately after draining the cleaning solution Flush the radiator first then the engine to allow the engine to cool as much as possible Engine overheating may also be caused by dirty radiator fins The exterior fins of the radiator can be cleaned with an air hose Check them for clogging after every 10...

Page 52: ... than good Removing the air filter element more often than is needed allows contaminants to enter the engine unnecessarily Clean or replace the air filter element only when the restriction indicator indicates excessive restriction in the system AIR FILTER RESTRICTION INDICATOR The air filter restriction indicator signals when to change the air filter element Check the restriction indicator daily T...

Page 53: ...he air filter element out of the filter housing Discard it do not attempt to clean the filter element 6 Slide a new filter element into the filter housing rounded end first A B C 01469 INSTALLING AIR FILTER ELEMENT A Filter Housing B Air Filter Element C Pre Cleaner 7 Position the pre cleaner on the filter housing 8 Position the pre cleaner cover on the pre cleaner with the air filter clamps 9 Tig...

Page 54: ... 00210 WATER TRAP A Water Trap B Bowl Retaining Bolt C Drain Spigot 4 Lower the bowl from the water trap head 5 Thoroughly clean the water trap bowl in cleaning fluid NOTE Do not use gasoline to clean the bowl 6 After cleaning the water trap bowl fill the bowl with clean fuel Hold the water trap bowl in position under the water trap head 7 Secure the bowl retaining bolt 8 Prime the fuel system as ...

Page 55: ...e attempted FUEL INJECTORS When replacing injectors in the cylinder head it is essential that a new correct type heat shield washer be fitted between the nozzle cap and the cylinder head Care should be used when replacing the fuel injectors to prevent loosening the injector leak off nipples Be sure to cut a relief in the inside of your socket for clearance This will prevent an interference between...

Page 56: ...ion Pump B Top Vent Valve C Fuel Pump Inlet D Governor Housing Vent Connection 2 Continue operating the fuel lift pump priming lever while loosening the top vent valve and the vent screw on the governor housing When fuel flows free of air tighten the connections Stop operating the priming lever and place it in the vertical position NOTE Leaving the priming lever in the horizontal position will loc...

Page 57: ...er in fuel Drain water trap Fuel too thick Change fuel grade Clogged fuel nozzle Clean or replace nozzle Low compression Repair engine Engine overheating Check radiator Check lubricating system Timing wrong Check timing Valve clearance wrong Adjust valves Fuel pressure wrong Adjust pressure Injection pump worn Repair or replace pump Engine stops suddenly Fuel leak Check fuel system Out of fuel Fil...

Page 58: ...d brought up to proper operating temperatures To re torque cap screws follow the correct sequence Loosen one head cap screw or riser at a time one quarter turn 90 degrees then re torque it to the correct value Check the valve tappet clearance NOTE Power wrench torque limit must be held at least 10 ft lb 14 Nm below hand torque specification then hand torque to the specifications VALVE TAPPET CLEAR...

Page 59: ...ter or taking hydrometer readings WARNING Avoid contact with battery acid Battery acid can cause severe burns Wash immediately and get medical attention if contact with battery acid occurs 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 NOTE Do not take readings immediately af...

Page 60: ...MAINTENANCE 95GR MM199 10 89 3 24 04309 ELECTRICAL SCHEMATIC ...

Page 61: ...MAINTENANCE 3 25 95GR MM199 10 89 01502 ELECTRICAL SCHEMATIC ACCESSORIES ...

Page 62: ...0 hours of operation Proper belt deflection is obtained when the belt deflects 0 5 in 13 mm from a force of 10 to 12 lb 4 5 to 5 4 kg applied at the midpoint of the longest span A B 00577 ENGINE FAN BELT A Fan Belt B 0 5 in 13 mm STATIC DRAG CHAIN A static drag chain is provided to prevent the buildup of static electricity in the machine The chain is attached to the machine by a rear brush skirt r...

Page 63: ... the arrows This may be done with the dust filters in the machine 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 dust filter do not use compressed air NOTE Be sure the dust filters are dry before reinstalling them in the machine TO REMOVE HOPPER DUST FILTERS 1 Stop the ...

Page 64: ...S 1 Place the cleaned or new dust filters in the hopper dust filter frames with the arrows pointing up A B 01482 INSTALLING DUST FILTER A Dust Filter B Dust Filter Frame 2 Place the four shaker shims in position 3 Slide the dust filter shaking assemblies in position over the dust filters 4 Thread the two allen head socket bolts through the mounting springs and into the dust filter frames of each f...

Page 65: ...pins A B C D 01483 FUSIBLE LINK INSTALLATION A Fire Door B Retaining Clip C Fusible Link D Fire Door Hook 5 Push the link retaining clips onto the mounting pins 6 Open the fire door 7 Place the fire door hook over the middle of the fusible link 8 Close the hopper inspection door DEBRIS HOPPER The debris hopper collects debris swept up by the main brush The hopper has one regularly scheduled adjust...

Page 66: ...s in the operating position Check for proper operation daily Lubricate the leg pivot pin after every 200 hours of operation TO ADJUST STABILIZER LEG 1 Place the hopper in the operating position 2 Make sure the front bumper is not resting on the stabilizer leg assembly If it is loosen the leg assembly mounting bolts slide the assembly down and retighten the bolts 3 Loosen the activating arm pinch b...

Page 67: ...h slide the wire brush dolly into position under the wire brush 4 Place the main brush lever in the free float position CAUTION Wear gloves when replacing the main brush to protect your hands 5 Disconnect the clevis from the brush arm 6 Remove the brush idler arm retaining bolt from the arm hub A B C 01486 MAIN BRUSH IDLER ARM A Brush Idler Arm B Plastic Screw C Arm Retaining Bolt 7 Pull the brush...

Page 68: ...brush in the raised position position the main brush over the chalked area 3 Start the main brush rotating while keeping a foot on the brakes to keep the machine from moving 4 Lower the main brush to the floor for 15 to 20 seconds NOTE If no chalk or other material is available allow the brushes to spin for two minutes 5 Raise the main brush after it has been spinning on the chalk marks for 15 to ...

Page 69: ... floor Be sure to use the hydraulic pressure gauge It should read between 1800 and 2200 psi 12 410 and 15 510 kPa SIDE 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 should be replaced when the remaining brush bristle measures 2 5 in 65 mm in length The side brush has four adjustment...

Page 70: ...ght as described in Side Brush Height Adjustment TO ADJUST SIDE BRUSH MAXIMUM HEIGHT 1 Empty the hopper 2 Park the machine on a level surface and engage the parking brake 3 Raise the hopper engage the hopper support bar and lower the hopper onto the support bar 4 Stop the engine WARNING Always engage the hopper support bar before working under a raised hopper Do not rely on the machine hydraulic s...

Page 71: ...le if the application requires 5 Tighten the two side brush angle bolts TO ADJUST SIDE BRUSH BUMPER CLEARANCE 1 Empty the hopper 2 Park the machine on a level surface and engage the parking brake 3 Raise the hopper engage the hopper support bar and lower the hopper onto the support bar 4 Stop the engine WARNING Always engage the hopper support bar before working under a raised hopper Do not rely o...

Page 72: ... WARNING Always stop the machine on a level surface stop the engine and engage the parking brake before working on the machine to keep it from rolling 5 Remove the hopper lip retaining strip mounting bolts A B 01487 HOPPER LIP SKIRT A Retaining Strip B Hopper Lip Skirts 6 Remove the hopper lip retaining strip and worn or damaged hopper lip segments 7 Thread the retaining strip mounting bolts throu...

Page 73: ...ning strip mounting bolts through the retaining strip the hopper side seal and into the machine frame 8 Tighten the mounting bolts 9 Start the engine 10 Raise the hopper lower the hopper support bar and lower the hopper 11 Stop the engine BRUSH DOOR SKIRTS The brush door skirts are located on the bottom of each of the two brush compartment doors These skirts seal the brush compartment The seals sh...

Page 74: ...ne on a level surface stop the engine and engage the parking brake before working on the machine to keep it from rolling 3 Open the two brush compartment doors A B C D E 01486 REAR SKIRTS A Brush Idler Arm B Brush Contact Skirt C Skirt Mounting Bracket D Rear Floor Skirt E Skirt Retaining Strip 4 Remove the main brush as described in Main Brush Replacement 5 Remove the front skirt mounting bracket...

Page 75: ... hopper support bar before working under a raised hopper Do not rely on the machine hydraulic system to keep the hopper in the raised position The hydraulic system may leak internally allowing the hopper to lower crushing anything under it 4 Stop the engine and engage the machine parking brake WARNING Always stop the machine on a level surface stop the engine and engage the parking brake before wo...

Page 76: ...ame To adjust the cam position loosen the cam arm stop bolt adjust the position and retighten Use care when making adjustments If the cam strikes the main frame at too low an angle it may be damaged If the cam strikes the main frame at too high an angle the dust dump door will not close fully HINGED TOP HOPPER SEAL The hinged top hopper seal is located on the top of the rear hopper opening It keep...

Page 77: ... hopper 10 Open the right brush door 11 Remove the main brush 12 Looking through the right brush door opening check to make sure approximately three fourths of the top seal is making contact with the machine frame If three fourths of the seal is not making contact raise the hopper engage the hopper support bar loosen the shell cam jam nut and turn the adjustment bolt counterclockwise to increase t...

Page 78: ... a raised hopper Do not rely on the machine hydraulic system to keep the hopper in the raised position The hydraulic system may leak internally allowing the hopper to lower crushing anything under it 4 Stop the engine WARNING Always stop the machine on a level surface stop the engine and engage the parking brake before working on the machine to keep it from rolling 5 Remove the two seal retainers ...

Page 79: ...dy paint Brake pads will be permanently damaged requiring replacement Body paint can be damaged also unless you wipe the area with a clean cloth and wash it with soapy solution immediately 1 Make sure that the brake fluid reservoir is full and that the vent in the cap is open 2 Connect a plastic or rubber tube to the bleeder valve on the left front wheel Suspend the other end of the tube in a jar ...

Page 80: ...the knurled knob on the end of the parking brake clockwise If the knob adjustment is inadequate fully loosen the knob loosen the brake cable mounting nuts thread the lower nuts closer to the end of the cable and retighten the top nuts Be sure to thread the nuts out the same number of turns Adjust the parking brake enough to make the parking brake slightly resist being engaged A B C 01496 PARKING B...

Page 81: ...T 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 ...

Page 82: ...APPENDIX 95GR MM199 10 89 4 2 ...

Page 83: ...__ M4 2 3 3 4 M5 4 5 6 8 M6 7 9 10 14 M8 18 24 25 34 M10 32 43 47 64 M12 58 79 83 112 M14 94 127 133 180 M16 144 195 196 265 M20 260 352 336 455 M24 470 637 664 900 NOTE Decrease torque by 20 when using a thread lubricant Exceptions to the above chart Brake unit to hub sockethead screw 9 to 12 ft lb 12 to 16 Nm with Locktite 242 blue Front wheel nut 10 to 12 ft lb 14 to 16 Nm while turning wheel t...

Page 84: ...__________ 0 25 0 44 20 9 ft lb 12 Nm 0 38 0 56 18 20 ft lb 27 Nm 0 50 0 75 16 30 ft lb 41 Nm 0 62 0 88 14 40 ft lb 54 Nm 0 75 1 12 12 70 ft lb 95 Nm 1 0 1 31 12 90 ft lb 122 Nm HYDRAULIC O RING FITTING TORQUE CHART Tube Thread Minimum Maximum O D in Size Torque Torque ______________________________________________________________ 0 25 0 44 20 6 ft lb 8 Nm 9 ft lb 12 Nm 0 38 0 56 18 13 ft lb 18 Nm...

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Tennant 96GR, Operator'S Manual

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