Tennant 3640E Service Manual Download

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ELECTRICAL

4--1

3640E 330565 (5--00)

CONTENTS

Page

INTRODUCTION

4--3

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

ELECTRICAL SYSTEM

4--4

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

BATTERIES

4--5

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

TO CHARGE BATTERIES

4--6

. . . . . . . .

TO REPLACE BATTERIES

4--9

. . . . . . .

INSTRUMENT PANEL

4--11

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

BATTERY DISCHARGE INDICATOR

4--11

. . .

BATTERY DISCONNECT BUTTON

(OPTION)

4--11

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

HOURMETER

4--12

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

FILTER SHAKER MOTOR SWITCH

(OPTION)

4--12

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

IGNITION KEY SWITCH

4--12

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

CIRCUIT BREAKERS

4--13

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

TO REPLACE 15 AMP CIRCUIT

BREAKER

4--13

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

TO REPLACE 50 AMP CIRCUIT

BREAKER

4--16

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

TO REPLACE MAIN CONTACTOR

4--19

. .

TO REPLACE ELECTRICAL RELAY 4--22

ELECTRIC MOTORS

4--24

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

TO REMOVE MAIN DRIVE MOTOR 4--24

TO INSTALL MAIN DRIVE MOTOR

4--28

. .

TO REPLACE FILTER SHAKER

MOTOR (OPTION)

4--31

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

TO REPLACE SIDE BRUSH MOTOR 4--34

TO REPLACE SIDE BRUSH SWITCH 4--37

ELECTRIC MOTOR AMP DRAW

CHART

4--41

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

ELECTRICAL SCHEMATIC

4--42

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

TROUBLESHOOTING

4--43

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

MAIN MOTOR

TROUBLESHOOTING

4--44

. . . . . . . . . .

FILTER SHAKER

TROUBLESHOOTING

4--46

. . . . . . . . . .

Summary of Contents for 3640E

Page 1: ...330565 Rev 00 5 00 Service Manual 3640E ...

Page 2: ...ing machine storage chassis lubrication machine specifications and machine maintenance chart Chassis Tire wheel replacement caster replacement and transaxle repair Sweeping Hopper repair replacement brush repair replacement skirt seal repair replacement and sweeping troubleshooting Electrical Battery maintenance and replacement electric motor removal electrical schematics and electrical troublesho...

Page 3: ...E PERFORMANCE 1 5 POWER TYPE 1 6 TIRES 1 6 MACHINE DIMENSIONS 1 7 MAINTENANCE 1 8 MAINTENANCE CHART 1 8 PUSHING OR TOWING MACHINE 1 9 MACHINE TIE DOWNS 1 10 MACHINE STORAGE 1 10 STATIC DRAG CHAIN 1 12 HARDWARE INFORMATION 1 13 STANDARD BOLT TORQUE CHART 1 13 METRIC BOLT TORQUE CHART 1 13 BOLT IDENTIFICATION 1 13 THREAD SEALANT AND LOCKING COMPOUNDS 1 13 ...

Page 4: ...GENERAL INFORMATION 1 2 3640E 330565 5 00 ...

Page 5: ...tarting machine Keep directional lever in Park position 3 When using machine Go slowly on inclines and slippery surfaces Use care when reversing machine Do not carry riders on machine Always follow safety and traffic rules Report machine damage or faulty operation immediately 4 Before leaving or servicing machine Stop on level surface Move directional lever into Park position Turn off machine and ...

Page 6: ... or any labels become damaged or illegible install a new label in its place BATTERY CHARGING LABEL LOCATED ON THE UNDERSIDE OF THE BATTERY COMPARTMENT COVER FOR SAFETY LABEL LOCATED ON THE CONTROL PANEL BACK STRAIN LABEL LOCATED ON THE MOTOR COMPARTMENT COVER FLYING DEBRIS WARNING LABEL LOCATED ON THE MOTOR COMPARTMENT COVER 350842 ...

Page 7: ... 610 mm 24 in Sweeping path width main brush and one side brush 815 mm 32 in Sweeping path width main brush and two side brushes 1016 mm 40 in Hopper capacity Maximum 85 L 3 0 cu ft Hopper capacity Usable 42 5 L 1 5 cu ft Panel filter area 3 62 sq m 39 sq ft Bag filter volume 17 L 0 6 cu ft GENERAL MACHINE PERFORMANCE Item Measure Maximum forward speed first speed 1 3 kmh 0 8 mph Maximum forward s...

Page 8: ... 104 lb Type Use VDC Amp Kw hp Electric Motors Side brush es disk 24 V 2 4 A 0 075 kw 0 1 hp Electric Motors Main motor 24 V 43 A 0 75 kw 1 hp Type VDC Amp Hz Phase VAC Charger Smart 24 15 or 20 50 60 1 120 240 TIRES Location Type Size Front 2 Casters 35 mm wide x 127 mm OD 1 375 in wide x 5 in OD Rear 2 Solid 45 mm wide x 305 mm OD 1 75 in wide x 12 in OD ...

Page 9: ...GENERAL INFORMATION 1 7 3640E 330565 5 00 960 mm 37 7 in 820 mm 32 25 in 815 mm 32 in 1475 mm 58 in MACHINE DIMENSIONS ...

Page 10: ... 1 2 Skirts and seals Inspect 6 6 Bag filter Check Replace if full 1 6 Panel filter option Shake filter clean compartment door 1 50 Hours 1 Vacuum fan belt Check tension and wear 1 50 Hours 5 Main brush Rotate end for end and check brush pattern 1 1 Battery cells Check electrolyte level DW 3 100 Hours 6 Panel filter option Remove and clean 1 200 Hours 1 Battery terminals Clean and tighten 4 500 Ho...

Page 11: ...G MACHINE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Raise the main and side brushes 2 Place the shift lever in the neutral position between reverse and second gear 3 Push the machine using the handle assembly ...

Page 12: ...g it to the floor Place one strap over the hopper and secure it by the casters Place another strap over the motor compartment and secure it by the rear wheels Make sure the directional lever is in the park position MACHINE STORAGE When storing the machine for extended periods of time the following procedures must be followed 1 Raise the main and side brush es 2 Empty and clean the debris hopper ...

Page 13: ...GENERAL INFORMATION 1 11 3640E 330565 5 00 3 Fully charge the batteries 4 Disconnect the machine connector from the battery connector 5 Store the machine in a clean dry area 07224 ...

Page 14: ...ag chain prevents the buildup of static electricity in the machine The chain is attached to the backstop bracket Make sure the chain is always touching the floor Always use a internal tooth lock washer between the chain and rear guard to ensure a proper electrical connection ...

Page 15: ... 291 380 313 407 424 552 1 00 in 500 650 678 881 757 984 1026 1334 NOTE Decrease torque by 20 when using a thread lubricant METRIC BOLT TORQUE CHART Thread Size Class 8 8 Torque ft lb _Nm Class 10 9 Torque ft lb Nm 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...

Page 16: ...GENERAL INFORMATION 1 14 3640E 330565 5 00 ...

Page 17: ...ERS 2 6 TO REPLACE FRONT CASTERS 2 6 SHIFT CABLE 2 7 TO REPLACE SHIFT CABLE 2 7 TO ADJUST SHIFT CABLE 2 13 TRANSAXLE TRANSMISSION 2 15 TO REMOVE TRANSAXLE 2 15 TO INSTALL TRANSAXLE 2 19 TRANSAXLE BREAKDOWN 2 22 TO REPLACE FLAT DRIVE BELT 2 23 TO REPLACE DRIVE BELT IDLER CABLE clutch handle cable 2 26 TO REPLACE DRIVE BELT IDLER PULLEY 2 32 ...

Page 18: ...CHASSIS 2 2 3640E 330565 5 00 ...

Page 19: ...CHASSIS 2 3 3640E 330565 5 00 INTRODUCTION This section includes information on the main chassis related components for example the rear wheels casters and transaxle ...

Page 20: ...Stop On Level Surface Place Shifter In Park 1 Lift the rear of the machine by tipping the machine back and placing blocks under the machine frame in front of the wheels Let the go forward to contact the blocks The rear wheels will lift off the floor 2 Remove the flat head screw holding the hub cap to the drive wheel 3 Pull the hub cap off the drive wheel 4 Pull the tire and wheel assembly off the ...

Page 21: ...he drive axle Make sure the pin in the axle lines up with the slot in the black plastic hub NOTE Place machine in Neutral then rotate axle until cross pin is horizontal Put machine in Park and install hub wheel assembly 2 Install the hub cap on the drive wheel 3 Install the flat head screw in the end of the axle Tighten to 7 6 9 9 Nm 6 8 ft lb 4 Remove the blocks and lower the machine ...

Page 22: ...Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the debris hopper from the machine 2 Raise the front of the machine and install blocks under the frame 3 Remove the two hex screws holding the caster to the front of the machine frame Remove the caster from the machine 4 Position the new caster on the front of the machine 5 Install the two hex screws and tighten to 18 24 Nm ...

Page 23: ...e runs from the lever on the handle to the lever on the transaxle TO REPLACE SHIFT CABLE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the filter cover from the rear of the machine 2 Move the directional control lever to the park position 3 Remove the handle stop bracket from the upper left side of the filter compartment ...

Page 24: ...three screws holding the cover plate to the inside of the left side handle tower Remove the cover plate from the machine 6 Loosen the nut holding the directional control lever to the mount plate Move the directional control lever out away from the mount plate 7 Remove the cotter pin and clevis pin from the end of the shift cable ...

Page 25: ...the cable out of the slot 9 Go down to the transaxle and locate the shift link on the left side of the housing Pop the shift cable end off the ball end on the shift link 10 Remove the two hex screws holding the shift cable mount clamp to the machine frame 11 Remove the shift cable mounting clamp from the cable ...

Page 26: ...cable in the same orientation 14 Install the new cable assembly in the machine Make sure the end with the two larger jam nuts is positioned near the upper shift lever NOTE Start with the mounting jam nuts about half way down on the threads of the cable 15 Place the cable and jam nuts in the slot of the mount plate with 2 3 threads showing above the upper nut Firmly tighten the jam nuts ...

Page 27: ... to 7 6 9 9 Nm 6 8 ft lb 18 Make sure the upper shift lever is placed in the PARK position Snap the shift cable end over the ball end on the lower shift link Adjust the cable end in or out as needed so it is aligned with the ball end on the link Re tighten the jam nut against the cable ball end 19 Reinstall the left side handle assembly cover plate Tighten the three hex screws to 18 24 Nm 15 20 ft...

Page 28: ... of the four adjustment holes 21 Reinstall the filter cover and handle stop bracket 22 Start the machine and check the shift lever for proper gear selection and operation If the shift lever does not operate properly see TO ADJUST SHIFT CABLE instructions in this section ...

Page 29: ...vel Surface Place Shifter In Park 1 Pull the upper shift lever back until it is firmly in the park position hole 2 Go down to the shift link on the left side of the transaxle Pop the cable end off the ball end on the link 3 Once the cable end is off the ball end verify that the shift link is in the PARK detent ...

Page 30: ...nd to the shift cable end These two parts should line up perfectly if not loosen the cable end jam nut and move the cable end in or out to achieve the proper adjustment Re tighten the jam nut 5 If more adjustment is needed the shift cable can be adjusted at the two jam nuts behind the plastic handle cover or at the upper clevis ...

Page 31: ...rip handle The transmission can be shifted quickly between forward neutral and reverse by pushing or pulling the shift lever TO REMOVE TRANSAXLE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Lift the rear of the machine until the drive wheels are off the floor 2 Place blocks under the machine frame 3 Remove the rear cover from the drive belt 4 Slip th...

Page 32: ... to the drive wheels 6 Pull the hub cap and drive wheel off each side of the machine 7 Remove the hex screw sleeve and nut holding the left side of the brush shaft to the left side of the brush arm 8 Remove the two hex screws holding the shift cable mount clamp to the machine frame ...

Page 33: ...saxle 10 Remove the two hex screws holding the brush arm retaining plate to the left side of the machine frame Remove the retaining plate 11 Spread the left handle leg out far enough to drop it down past the end of the left axle shaft 12 Remove the left brush arm and wear ring from the machine frame ...

Page 34: ...e the five hex screws holding the transaxle to the machine frame 14 First drop the transaxle down out of the left side of the machine then pull it out of the right handle opening and right side brush arm Remove the transaxle from the machine ...

Page 35: ...e through the right handle opening and right brush arm then bring the left side of the transaxle up to the left side of the machine frame Reinstall the wear ring 2 Install the five hex screws that hold the transaxle to the bottom of the machine frame Tighten to 7 6 9 9 Nm 6 8 ft lb NOTE Install 3 flat washers under the transaxle where the 30mm hex screw goes 3 Position the left brush arm over the ...

Page 36: ...t hand brush arm retaining plate on the machine Tighten the hex screws to 7 6 9 9 Nm 6 8 ft lb 6 Reinstall the hex screw sheave and nut holding the left side of the brush shaft to the left brush arm NOTE The slot in the brush arm is used to adjust the taper of the main brush pattern 7 Reinstall the shift cable on the ball end on the shift lever ...

Page 37: ...11 Reinstall the rear drive wheels and hub caps Tighten the flat head screw to 7 6 9 9 Nm 6 8 ft lb NOTE Place machine in Neutral and rotate axle until cross pin is horizontal Put machine in Park Install hub wheel assembly 12 Remove the blocks and lower the machine Check for proper operation of the shifter and transaxle Also check the main brush pattern and adjust if tapered See TO CHECK AND ADJUS...

Page 38: ...TRANSAXLE BREAKDOWN CHASSIS 2 22 3640E 330565 5 00 ...

Page 39: ...ore Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the cover and engage the prop rod 2 Remove the rear cover from the drive belt at the transaxle sheave 3 Loosen the vacuum fan pivot bolt and remove the vacuum fan belt from the motor sheave ...

Page 40: ... belt 5 Slip the drive belt off the motor sheave Remove the drive belt 6 Install the new drive belt on the motor sheave 7 Install the new drive belt on the transaxle sheave NOTE Make sure the new belt is over the clutch idler pulley 8 Adjust the belt stop so it just clears the flat belt when it is tight This to stop the belt from moving when the machine is in neutral ...

Page 41: ...ght Check belt tension by applying a force 1 kg 2 lb at belt midpoint The proper deflection should be 5 mm 0 09 in Tighten the tension bolt to 18 24 Nm 15 20 ft lb 11 Reinstall the rear belt cover on the machine 12 Start the machine and operate the clutch bar Check for proper engagement of the new belt and smooth operation ...

Page 42: ...ore Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the filter cover from the rear of the machine 2 Remove the handle stop bracket from the upper left side of the filter compartment 3 Pull up on the two handle locks and move the handle assembly to its lowest position ...

Page 43: ...machine 5 Open the motor cover and engage the prop rod 6 Go to the area below the vacuum fan and locate the tension spring leading from the idler pulley arm to the end of the drive belt idler cable Disconnect the spring from the cable 7 Loosen the two jam nuts on the cable where it mounts to the bracket near the shaker motor Slip the cable out of the mount slot ...

Page 44: ...rea and locate the end of the drive belt idler cable Remove the cotter pin and clevis pin from the end of the clutch cable 10 Remove the nut holding the clutch cable clamp to the cable lever mount plate Note the position of the clamp and cable 11 Remove the cable from the machine by pulling it toward the vacuum fan ...

Page 45: ...chine Use the finger hole in the front left corner to guide the cable Then feed the cable up the left side arm to the clutch bar 13 Position the cable into the mount bracket slot near the shaker motor Tighten the two jam nuts 14 Connect the tension spring from the idler arm to the end of the new drive belt idler cable 15 Reinstall the cable in the clamp on the vacuum fan housing ...

Page 46: ... handle area Tighten to 7 6 9 9 Nm 6 8 ft lb 17 Reinstall the clevis pin and cotter pin in the end of the new cable and clutch bar 18 Reinstall the left side cover plate Tighten the three hex screws to 18 24 Nm 15 20 ft lb 19 Move the handle assembly up to one of the four adjustment holes ...

Page 47: ... rear of the machine 22 Close the motor cover 23 Start the machine and check the clutch bar for proper engagement If the new cable needs to be adjusted open the motor cover and loosen the two idler cable jam nuts Move the cable or cable bracket up or down and re tighten the jam nuts Close the cover and re check ...

Page 48: ...rvicing Machine Stop On Level Surface Place Shifter In Park 1 Open the motor cover and engage the prop rod 2 Slip the drive belt off the transaxle sheave and idler pulley 3 Remove the hex screw and nut holding the idler pulley to the idler arm Remove the idler pulley Retain the spring mount bracket ...

Page 49: ...r arm Make sure to reinstall the spring mount bracket Tighten the hex screw and nut to 7 6 9 9 Nm 6 8 ft lb 5 Slip the drive belt back over the transaxle sheave and the new idler pulley 6 Lower the motor cover and operate the machine Check the new idler for proper operation ...

Page 50: ...CHASSIS 2 34 3640E 330565 5 00 ...

Page 51: ...3 31 TO REPLACE STAINLESS STEEL BRUSH ARM WEAR RINGS 3 35 TO REMOVE MAIN BRUSH SHAFT 3 39 TO INSTALL MAIN BRUSH SHAFT 3 41 SIDE BRUSH 3 42 TO REPLACE LH OR RH SIDE BRUSH 3 42 TO REPLACE SIDE BRUSH LIFT CABLE 3 44 TO REPLACE SIDE BRUSH HOUSING 3 50 Page SKIRTS AND SEALS 3 54 HOPPER LIP SKIRT 3 54 TO REPLACE HOPPER LIP SKIRT 3 54 REAR SKIRT 3 56 TO REPLACE REAR SKIRT RECIRCULATION FLAP 3 56 UPPER HO...

Page 52: ...SWEEPING 3 2 3640E 330565 5 00 ...

Page 53: ...CTION This section includes information on the sweeping operation The side brush sweeps debris in front of the machine and the main brush sweeps the debris into the hopper The vacuum fan pulls air from the hopper and through the dust filter ...

Page 54: ...hine TO REMOVE DEBRIS HOPPER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Go to the front of the machine and grasp the molded handle 2 Lift on the handle and pull the hopper slightly up and forward 3 Use your other hand to lift the front of the hopper 4 Lift the hopper up and out of the machine frame ...

Page 55: ... Level Surface Place Shifter In Park 1 Position the hopper in the machine with the open end facing the main brush 2 Let the hopper rest on the machine front frame rails 3 Push the hopper back until the two frame knobs are lined up with the two indentations in the hopper The hopper is now in its correct position ...

Page 56: ... dump assist handle Place one foot on the hopper s pivot point Lift the hooper out of the machine and onto the wheels Transport the hopper to the location where debris is contained NOTE Do not attempt to lift the hopper when it is full of debris Dump the debris from the hopper into a pile on the floor near a trash can or dumpster then pick the debris up with a shovel ...

Page 57: ... Sentryt can be reset by pressing the red button on the end TO REPLACE THERMO SENTRYt FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the cover and engage the prop rod 2 Locate the Thermo Sentryton the back wall just above the filter shaker motor 3 Disconnect the wire from the terminals on the Thermo Sentryt ...

Page 58: ...ardware and lightly hand tighten 6 Reconnect the wires to the Thermo Sentryt See schematic in the ELECTRICAL section 7 Close the cover VACUUM WAND The vacuum wand uses the machine s vacuum system Use the vacuum wand to pick up debris in narrow or partially enclosed areas that cannot be swept by the machine NOTE The vacuum hose screws into the vacuum nozzle left hand thread Un screw to replace the ...

Page 59: ...e rear cover The standard filter is a bag style that is simply removed and discarded when full The optional filter is a panel style that can be cleaned and re used multiple times The optional filter also comes with a filter shaker system that can be used to shake the filter between cleanings Bag filter Panel filter ...

Page 60: ...ark 1 Go to the rear of the machine and un snap the two filter cover clamps Pull the vacuum wand out of the mount hole and hang it over the steering handle 2 Let the filter cover pivot down until it stops NOTE Remove the filter cover to empty any dirt that has collected 3 Pull the filter bag off the 90_ air horn Remove the filter bag from the machine ...

Page 61: ...of the 90_ air horn 5 Pivot the filter cover into position Make sure the upper portion of the vacuum wand hose is in the proper location 6 Reconnect the two filter clamps and snap them into the lock position Reinstall the vacuum wand in the mount hole 7 Start the machine and check the hopper filter area for any air leaks ...

Page 62: ...e Place Shifter In Park 1 Go to the rear of the machine and un snap the two filter cover clamps Pull the vacuum wand out of the mount hole and hang it over the steering handle 2 Let the filter cover pivot down until it stops NOTE Remove the filter cover to empty any dirt that has collected 3 Un snap the catch lock on the filter lock bars ...

Page 63: ...Make sure the air flow arrows point in toward the battery compartment 7 Pivot the filter lock bars over the new filter and reconnect the catch lock 8 Rotate the filter cover back into place Make sure the upper portion of the vacuum wand hose is in the proper location 9 Reconnect the two filter clamps and snap them into the lock position Reinstall the vacuum wand in the mount hole 10 Start the mach...

Page 64: ... bristles TO REPLACE MAIN BRUSH FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the debris hopper from the machine and drop the main brush to the full float position 2 Go to the left side of the machine and locate the main brush idler side knob pin This pin is located in the brush arm just ahead of the LH drive wheel ...

Page 65: ...move the main brush from the machine by pulling the left side of the brush forward then pull the brush off the drive plug on the right side 5 After the main brush has been removed from the machine remove the bearing assembly from the idler side end of the brush 6 Install the bearing assembly in either end of the new brush ...

Page 66: ...m Push the pin in until the two ribs on the pin line up with the two slots in the brush arm NOTE You may have to move the free end of the main brush around to help line up the pin and bearing 9 Push the pin in and turn it until it locks in position A detent type lock should be felt 10 Reinstall the debris hopper and operate the machine Check the taper of the main brush and adjust if needed See TO ...

Page 67: ...achine Move the machine off the test area 4 Check the pattern the main brush left on the floor The brush pattern should be even all the way across If the pattern is even no adjustment is needed If the brush pattern has any taper go to the next step 5 Go to the back of the machine and locate the left hand brush arm Loosen the hex screw and nut holding the left brush arm to the brush shaft Move the ...

Page 68: ...Remove the filter cover from the rear of the machine Remove the handle stop bracket from the upper left side of the filter compartment 2 Pull up on the two handle locks and move the handle assembly to its lowest position 3 Remove the three hex screws holding the cover plate to the inside of the right side handle tower Remove the cover plate from the machine ...

Page 69: ...d clevis pin from the end of the main brush lift cable where it attaches to the main brush lift lever 6 Remove the nut from the clamp holding the main brush cable to the mount plate 7 Open the battery cover and remove the left hand battery Locate the end of the main brush lift cable where it attaches to the mount bracket below the vacuum fan Remove the cotter pin and clevis pin from the lift cable...

Page 70: ...of the machine from the lower end by the vacuum fan 11 Route the new lift cable through the hole in the front center of the frame Push the cable toward the front right corner Next reach into the corner finger hole to guide the cable to the rear of the machine frame and up into the side arm and the lift handle NOTE Add a cable tie around the new main brush lift cable and the existing side brush lif...

Page 71: ...tion and orientation 13 Position the new cable in the lower mount slot and tighten the jam nuts 14 Install the clevis pin and cotter pin in the end of the new cable where it attaches to the main brush lift arm 15 Go up to the main brush lift lever and install the nut on the main brush lift cable mount clamp Tighten the nut to 7 6 9 9 Nm 6 8 ft lb ...

Page 72: ...n the end of the new cable where it attaches to the main brush lift lever 17 Reinstall the pivot plate assembly and clutch bar pivot 18 Reinstall the right side handle assembly cover plate Tighten the three hex screws to 18 24 Nm 15 20 ft lb 19 Reinstall the left hand battery ...

Page 73: ...ll the filter cover and the handle stop bracket 22 Start the machine and check the main brush lift cable for proper operation If the main brush cable needs to be adjusted loosen the two jam nuts at the lower mount bracket move the cable forward or backward and re tighten the jam nuts 23 Close the battery cover ...

Page 74: ...Place Shifter In Park 1 Remove the main brush See TO REPLACE MAIN BRUSH instructions 2 Raise the right side of the machine and install a block under the frame 3 Remove the flat head screw holding the hub cap and drive wheel to the axle Pull the tire and wheel assembly off the drive axle Be careful not to loose pin from axle cross hole ...

Page 75: ...and tension on the brush belt will be released NOTE The pressure on the belt tensioner must be released before the drive belt can be replaced 6 Remove the old brush belt from the motor sheave belt tensioner sheaves and main brush drive plug sheave Remove the drive belt from the machine 7 Position the new drive belt in the machine First loop it over the motor sheave then over the main brush drive p...

Page 76: ...tall the belt drive plate 10 Reinstall the right side drive wheel and hub cap Tighten the flat screw to 7 6 9 9 Nm 6 8 ft lb NOTE Place machine in Neutral then rotate axle until cross pin is horizontal Put machine in Park and install hub wheel assembly 11 Install the main brush See TO REPLACE MAIN BRUSH instructions Lower the machine and operate the main brush Check for proper operation ...

Page 77: ...urface Place Shifter In Park 1 Remove the main brush See TO REPLACE MAIN BRUSH instructions 2 Raise the right side of the machine and install a block under the frame 3 Remove the flat head screw holding the hub cap and drive wheel to the axle Pull the tire and wheel assembly off the drive axle Be careful not to loose pin from axle cross hole ...

Page 78: ...ft lever in the up position The screw driver will hold the idler from moving and tension on the brush belt will be released NOTE The pressure on the belt tensioner must be released before the drive belt can be replaced 6 Remove the old brush belt from the motor sheave belt tensioner sheaves and main brush drive plug sheave 7 Remove the hex nut or hex screw holding the idler pulley to the idler arm...

Page 79: ... the correct idler pulley grooved or smooth 9 Reinstall the main brush drive belt 10 Place the main brush lift lever in the down position 11 Remove the screw driver from the brush arm Place the main brush lift lever in the up position Reinstall the belt drive plate Engine motor sheave Main brush drive sheave Idler pulleys Front of machine Flat belt ...

Page 80: ...at screw to 7 6 9 9 Nm 6 8 ft lb NOTE Place machine in Neutral then rotate axle until cross pin is horizontal Put machine in Park and install hub wheel assembly 13 Install the main brush See TO REPLACE MAIN BRUSH instructions 14 Lower the machine and operate the main brush Check for proper operation ...

Page 81: ... Place Shifter In Park 1 Remove the main brush See TO REPLACE MAIN BRUSH instructions 2 Raise the right side of the machine and install a block under the frame 3 Remove the flat head screw holding the hub cap and drive wheel to the axle Pull the tire and wheel assembly off the drive axle Be careful not to loose pin from axle cross hole ...

Page 82: ...brush lift lever in the up position The screw driver will hold the idler from moving and tension on the brush belt will be released NOTE The pressure on the belt tensioner must be released before the drive belt can be replaced 6 Remove the brush belt from the motor sheave belt tensioner sheaves and main brush drive plug sheave 7 Remove the screw holding the brush drive plug to the pulley shaft Rem...

Page 83: ...Press the new sheave and shaft into the brush arm 10 Reinstall the square key and drive plug on the shaft Reinstall the screw and tighten to 7 6 9 9 Nm 6 8 ft lb 11 Reinstall the main brush drive belt Engine motor sheave Main brush drive sheave Idler pulleys Front of machine Flat belt ...

Page 84: ...tall the belt drive plate 14 Reinstall the right side drive wheel and hub cap Tighten the flat screw to 7 6 9 9 Nm 6 8 ft lb NOTE Place machine in Neutral then rotate axle until cross pin is horizontal Put machine in Park and install hub wheel assembly 15 Install the main brush See TO REPLACE MAIN BRUSH instructions 16 Lower the machine and operate the main brush Check for proper operation ...

Page 85: ...eaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the main brush See TO REPLACE MAIN BRUSH instructions 2 Remove both rear tires See TO REMOVE REAR TIRE instructions in the CHASSIS section 3 Remove the hex screw sleeve and nut holding the brush shaft to both brush arms ...

Page 86: ...he wear ring is loose use RTV sealant between the ring and the frame Reinstall the left brush arm 7 RH BRUSH ARM Place a screw driver in the 1 4 in hole in the brush arm behind the idler arm Place the main brush lift lever in the up position The screw driver will hold the idler from moving and tension on the brush belt will be released Remove the main brush drive belt from the idler pulleys Remove...

Page 87: ...ition 10 Remove the screw driver from the RH brush arm Place the main brush lift lever in the up position Reinstall the belt drive plate 11 Spread the handle legs out far enough to reinstall them up past the end of the transaxle shafts Engine motor sheave Main brush drive sheave Idler pulleys Front of machine Flat belt ...

Page 88: ...s Tighten the flat screw to 7 6 9 9 Nm 6 8 ft lb NOTE Place machine in Neutral then rotate axle until cross pin is horizontal Put machine in Park and install hub wheel assembly 14 Install the main brush See TO REPLACE MAIN BRUSH instructions 15 Lower the machine and operate the main brush Check for proper operation ...

Page 89: ...ng Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Lower the main brush to the float position 2 Go to the back of the machine and locate the brush shaft running between the left and right brush arms 3 Remove the tension spring from the right side of the brush shaft ...

Page 90: ...65 5 00 4 Remove the two hex screws sleeves and nuts holding the brush shaft to the brush arms 5 Remove the two hex screws sleeves and nuts holding the brush shaft to the upper pivot bar Remove the brush shaft from the machine ...

Page 91: ...o 18 24Nm 15 20 ft lb 2 Line up the lower holes in the brush shaft with the holes in the rear of both brush arms Install the two hex screws sleeves and nuts Tighten to 18 24Nm 15 20 ft lb 3 Reconnect the tension spring to the right side of the brush shaft and machine frame 4 Start the machine and check the main brush pattern See TO CHECK AND ADJUST MAIN BRUSH PATTERN instructions 5 Raise and lower...

Page 92: ... with an electric motor TO REPLACE LH OR RH SIDE BRUSH FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Make sure the side brush lever is in the raised position 2 Go under the side brush and locate the hair pin clip on the bottom of the side brush motor shaft Pull the pin out NOTE Some early models have two spacer washers under the hairpin ...

Page 93: ... front of the machine in the area of the side brush motor 5 Lift the side brush up and onto the side brush motor shaft Make sure the slots in the top of the side brush line up with the pin on the side brush motor shaft 6 Reinstall the hair pin clip in the bottom of the side brush motor shaft 7 Start the machine and check the side brush for proper operation ...

Page 94: ...Remove the filter cover from the rear of the machine Remove the handle stop bracket from the upper left side of the filter compartment 2 Pull up on the two handle locks and move the handle assembly to its lowest position 3 Remove the three hex screws holding the cover plate to the inside of the right side handle tower Remove the cover plate from the machine ...

Page 95: ...e and handle assembly to be pulled away from the plastic arm for easy access 5 Remove the cotter pin and clevis pin from the end of the side brush lift cable where it attaches to the side brush lift lever 6 Remove the nut from the clamp holding the side brush cable to the mount plate 7 Remove the debris hopper from the machine ...

Page 96: ...ding the side brush lift cable lower mount bracket to the machine frame Pull the mount bracket out of the hole in the frame Pull the side brush cable out of mount slot 10 Remove the two hex screws holding the side brush lift cable spring assembly to the right side of the machine frame out near the right side brush 11 Pull the spring and cable assembly out of the machine frame ...

Page 97: ...hole in the main frame and down to the right side of the frame Next reach in the frame hole and grab the cable NOTE Add a cable tie around the new side brush cable and the existing stiff main brush lift cable This will prevent the new side brush lift cable from drooping down and rubbing on the brush drive pulley 14 Reconnect the cable to the side brush spring assembly Reinstall the spring assembly...

Page 98: ...the two hex screws to 8 24Nm 15 20 ft lb 16 Go up to the main brush lift lever and install the nut on the main brush lift cable mount clamp Tighten the nut to 7 6 9 9 Nm 6 8 ft lb 17 Install the clevis pin and cotter pin in the end of the new cable where it attaches to the side brush lift lever 18 Position the brush lift lever assembly back onto the right handle arm ...

Page 99: ...ate Tighten the three hex screws to 18 24 Nm 15 20 ft lb 20 Move the handle assembly up to one of the four adjustment holes 21 Reinstall the filter cover and the handle stop bracket 22 Start the machine and check the side brush lift cable for proper operation 23 Close the battery cover ...

Page 100: ...Stop On Level Surface Place Shifter In Park 1 Remove the hopper from the machine See TO REMOVE DEBRIS HOPPER instructions 2 Lower the side brush s 3 Remove the side brush es See TO REPLACE LH OR RH SIDE BRUSH instructions in the SWEEPING section 4 Un plug the side brush motor s from the main electrical harness ...

Page 101: ... motor s and gear box s to the side brush housing 6 Remove the side brush motor s and gear box s from the machine 7 Remove the two screws holding the side brush lift cable assembly to the side brush housing 8 Remove the hex screw and sleeve from the left side of the side brush housing ...

Page 102: ...or now 11 Go the right side arm of the housing and position the tension spring in the opening where the sleeve is inserted Once the spring is positioned correctly place the sleeve through the arm holes and the center of the tension spring Bring that end up carefully making sure the spring is pulled back and one end placed down the main machine frame Line up the hole in the sleeve with the threaded...

Page 103: ... holes in the side brush motor 14 Reinstall the hex screws and tighten to 7 6 9 9 Nm 6 8 ft lb 15 Reconnect the side brush motor s to the main harness See schematic in the ELECTRICAL section 16 Reinstall the side brush es See TO REPLACE LH OR RH SIDE BRUSH instructions in the SWEEPING section 17 Operate the machine and check the side brush for proper operation ...

Page 104: ...e hopper lip skirt deflects debris from the main brush and into the hopper It allows debris to pass under the hopper and into the rotating main brush Inspect the hopper lip skirt every time the hopper is dumped TO REPLACE HOPPER LIP SKIRT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the hopper from the machine See TO REMOVE DEBRIS HOPPER instr...

Page 105: ... skirt and retainer from the machine Discard the skirt 5 Position the new skirt and existing retainer on the hopper Reinstall the hardware and tighten to 7 6 9 9 Nm 6 8 ft lb 6 Reinstall the debris hopper See TO INSTALL DEBRIS HOPPER instructions ...

Page 106: ...ear skirt should be adjusted slightly off the ground to allow air flow and avoid any dusting problems TO REPLACE REAR SKIRT RECIRCULATION FLAP FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the hopper from the machine See TO REMOVE DEBRIS HOPPER instructions 2 Remove the main brush See TO REPLACE MAIN BRUSH instructions ...

Page 107: ...ecirculation flap on the machine Lift the rear skirt recirculation flap and install the five bolt plates through the rear skirt recirculation flap and the machine frame Install the five nuts and lightly tighten 6 Reinstall the main brush See TO REPLACE MAIN BRUSH instructions 7 Reinstall the hopper in the machine See TO INSTALL DEBRIS HOPPER instructions 8 Operate the machine and check for proper ...

Page 108: ...debris from being expelled outside the brush compartment area TO REPLACE UPPER HOPPER SEAL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the hopper from the machine See TO REMOVE DEBRIS HOPPER instructions 2 Lift the upper hopper seal up slightly and locate the plastic rivets holding the seal to the machine ...

Page 109: ...eal from the machine 5 Position the new upper hopper seal on the machine Line up the holes in the seal with the mount holes in the machine frame 6 Install the plastic rivets in the mount holes Start by placing the body of the rivet in the hole first then screw the center pin into the body until it snaps in place 7 Reinstall the hopper in the machine See TO INSTALL DEBRIS HOPPER instructions ...

Page 110: ...sh to the sides of the brush compartment TO REPLACE LEFT BRUSH SEAL idler side FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the hopper from the machine See TO REMOVE DEBRIS HOPPER instructions 2 Remove the main brush See TO REPLACE MAIN BRUSH instructions ...

Page 111: ...ivet Lift the body of the rivet out of the hole Repeat on all of the rivets 4 Remove the old seal from the machine 5 Install the new left dust seal on the machine Line up the holes in the new seal with the mount holes in the machine frame 6 Install the seven plastic rivets in the mount holes Start by placing the body of the rivet in the hole first then push the center pin into the body until it sn...

Page 112: ...SWEEPING 3 62 3640E 330565 5 00 7 Reinstall the main brush See TO REPLACE MAIN BRUSH instructions 8 Reinstall the hopper in the machine See TO INSTALL DEBRIS HOPPER instructions ...

Page 113: ...Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the hopper from the machine See TO REMOVE DEBRIS HOPPER instructions 2 Remove the main brush See TO REPLACE MAIN BRUSH instructions 3 Remove the hex screw holding the main brush drive plug to the shaft Pull the drive plug off the shaft ...

Page 114: ...f the rivet out of the hole Repeat this on all rivets 6 Remove the old seal from the machine 7 Remove the small cap retainer holding the inside plate to the right seal Remove the inside plate and install it on the new right seal in the same orientation Reinstall the small cap retainer 8 Install the new right dust seal and plate assembly on the machine Line up the holes in the new seal with the mou...

Page 115: ...the center pin into the body until it snaps in place 10 Reinstall the main brush drive plug on the shaft Make sure the key is in place on the shaft Reinstall the hex screw and tighten to 7 6 9 9 Nm 6 8 ft lb 11 Reinstall the main brush See TO REPLACE MAIN BRUSH instructions 12 Reinstall the hopper in the machine See TO INSTALL DEBRIS HOPPER instructions ...

Page 116: ...after it becomes full The panel filter optional can be cleaned with the filter shaker or can be removed and cleaned outside of the machine TO REMOVE VACUUM FAN ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the battery cover 2 Remove the air duct running from the top of the vacuum fan to the front wall of the dust filter ...

Page 117: ...he tension bolt and slotted bracket on the side of vacuum fan opposite the V belt pulley Remove the tension bolt 5 Let the vacuum fan drop down Remove the V belt from the pulley on the fan 6 Remove the hex screw and nut holding the vacuum fan assembly to the pivot mount bracket Remove the vacuum fan from the machine ...

Page 118: ...er In Park 1 Open the battery cover 2 Position the vacuum fan assembly in the machine Line up the mount hole in the pivot bracket with the pivot mount on the fan housing Install the hex screw and nut Tighten so the vacuum fan can pivot freely for belt tensioning 3 Install the bolt in the tension slot and vacuum fan housing Leave loose for now ...

Page 119: ...he vacuum fan assembly until the V belt is tight Tighten the tension bolt to 18 24 Nm 15 20 ft lb See TO TENSION VACUUM FAN V BELT 6 Reinstall the clamp and cable on the top of the vacuum fan housing 7 Reinstall the air duct running from the top of the vacuum fan to the front wall of the dust filter ...

Page 120: ...SWEEPING 3 70 3640E 330565 5 00 8 Close the battery cover 9 Start the machine and check the vacuum fan for proper operation ...

Page 121: ...ace Place Shifter In Park 1 Remove the vacuum fan assembly from the machine See TO REMOVE VACUUM FAN ASSEMBLY instructions 2 Remove the smaller hex screws holding the vacuum fan housing to the bearing backing plate Pull the housing off the backing plate 3 Hold the impeller from turning Remove the hex nut from the impeller shaft ...

Page 122: ...on the impeller shaft Make sure the key is in place on the shaft 6 Hold the impeller from turning Install the hex nut on the impeller shaft Tighten to 18 24Nm 15 20 ft lb 7 Reinstall the vacuum fan housing on the bearing backing plate Hand tighten the smaller hex screws 8 Reinstall the vacuum fan assembly in the machine See TO INSTALL VACUUM FAN ASSEMBLY instructions 9 Start the machine and check ...

Page 123: ... Surface Place Shifter In Park 1 Remove the vacuum fan assembly from the machine See TO REMOVE VACUUM FAN ASSEMBLY instructions 2 Remove the smaller hex screws holding the vacuum fan housing to the bearing backing plate Pull the housing off the backing plate 3 Hold the impeller from turning Remove the hex nut from the impeller shaft ...

Page 124: ...bearing and pulley assembly to the backing plate Remove the bearing assembly 6 Loosen the set screws on the impeller belt pulley Slide the pulley off the impeller shaft NOTE Make sure to mark the location of the pulley on the impeller shaft for proper re assembly 7 Use a press to remove the impeller shaft and inner bearing from the bearing housing Press the bearing and shaft in the direction of th...

Page 125: ...mpeller shaft into the new bearing Note the impeller side of the shaft must be on the flange side of the bearing housing 11 Press the second bearing into the housing over the impeller shaft Press the bearing in until the snap ring contacts the housing 12 Reinstall the bearing assembly on the backing plate Reinstall the hardware and tighten to 7 6 9 9 Nm 6 8 ft lb ...

Page 126: ... on the impeller shaft Make sure the key is in place on the shaft 15 Hold the impeller from turning Install the hex nut on the impeller shaft Tighten to 18 24Nm 15 20 ft lb 16 Reinstall the vacuum fan housing on the bearing backing plate Hand tighten the smaller hex screws 17 Reinstall the vacuum fan assembly in the machine See TO INSTALL VACUUM FAN ASSEMBLY instructions 18 Start the machine and c...

Page 127: ...he battery cover 2 Locate the tension bolt and slotted bracket on the side of vacuum fan opposite the V belt pulley Loosen the tension bolt 3 Pull up on the vacuum fan assembly until the V belt is tight Check belt tension by applying a force 1 kg 2 lb at belt midpoint The proper deflection should be 5 mm 0 09 in Tighten the tension bolt to 18 24 Nm 15 20 ft lb ...

Page 128: ...SWEEPING 3 78 3640E 330565 5 00 4 Close the battery cover 5 Start the machine and check the vacuum fan for proper operation ...

Page 129: ...djust main brush down pressure Debris caught in main brush drive mechanism Remove debris from drive mechanism Main brush drive failure Contact Tennant service Side brush drive failure Contact Tennant service Hopper full Empty hopper Hopper brush skirts worn or damaged Replace skirts Wrong sweeping brush Use yellow black brush w 75 mm 3 in dia tube for floor sweeping Use black brush w 125 mm 5 in d...

Page 130: ...SWEEPING 3 80 3640E 330565 5 00 ...

Page 131: ...H 4 12 CIRCUIT BREAKERS 4 13 TO REPLACE 15 AMP CIRCUIT BREAKER 4 13 TO REPLACE 50 AMP CIRCUIT BREAKER 4 16 TO REPLACE MAIN CONTACTOR 4 19 TO REPLACE ELECTRICAL RELAY 4 22 ELECTRIC MOTORS 4 24 TO REMOVE MAIN DRIVE MOTOR 4 24 TO INSTALL MAIN DRIVE MOTOR 4 28 TO REPLACE FILTER SHAKER MOTOR OPTION 4 31 TO REPLACE SIDE BRUSH MOTOR 4 34 TO REPLACE SIDE BRUSH SWITCH 4 37 ELECTRIC MOTOR AMP DRAW CHART 4 4...

Page 132: ...ELECTRICAL 4 2 3640E 330565 5 00 ...

Page 133: ...ELECTRICAL 4 3 3640E 330565 5 00 INTRODUCTION This section includes information on machine electrical components such as relays circuit breakers switches and wiring harness ...

Page 134: ...he model 3640E consists of two 12V deep cycle batteries main drive motor filter shaker motor side brush motor s circuit breakers relays and switches The batteries on the model 3640E is a 12 volt wet deep cycle style They are located in the main motor compartment under the cover ...

Page 135: ...l can potentially short circuit the batteries Keep all metallic objects off the batteries Replace any worn or damaged wires Check the electrolyte level in each battery cell after charging and after every 50 hours of operation Never add acid to the batteries Add distilled water only Always keep the battery caps on except when adding water or taking hydrometer readings Using a hydrometer measure the...

Page 136: ... well ventilated 2 Turn the machine power off FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 3 Move the directional control lever into the PARK position 4 Lift the battery cover to access the batteries The support arm automatically engages when the cover is lifted all the way up ...

Page 137: ...vicing machine avoid contact with battery acid 6 Unplug the machine connector from the batteries 7 Plug the charger connector into the battery connector WARNING Batteries emit hydrogen gas Explosion or fire can result Keep sparks and open flame away Keep covers open when charging 8 Plug the battery charger into the wall outlet NOTE If the red ABNORMAL CYCLE lamp lights when the TENNANT charger is ...

Page 138: ...r the charger has turned off unplug the charger from the wall outlet 11 Unplug the charger connector from the battery connector on the machine FOR SAFETY When maintaining or servicing machine avoid contact with battery acid 12 Connect the machine connector to the battery connector 13 Lower the battery cover by slightly raising it while pushing the support arm inward 07224 ...

Page 139: ...FETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the battery cover and engage the prop rod 2 Unplug the connector on the battery harness from the machine connector 3 Disconnect the battery cables from the battery posts ...

Page 140: ...ry hold down brackets from the battery Remove the batteries 5 Install new batteries in the machine Note the orientation of the positive and negative posts 6 Reconnect the cables on the posts 7 Plug the battery harness connector into the machine connector ...

Page 141: ...hen the second indicator from the far left flashes When two indicators on the left flash the machine will gradually slow down then stop Drive or push the machine in neutral to the battery charging area and charge the batteries immediately after the battery discharge indicator s begin to flash NOTE The reading on the battery discharge indicator may not be accurate when the machine is first powered ...

Page 142: ...is information as a guide as to when to perform routine maintenance FILTER SHAKER MOTOR SWITCH OPTION IGNITION KEY SWITCH The ignition switch starts and stops the motor using a key Start Turn the motor key clockwise as far as it will go Release the key as soon as the motor starts Stop Turn the motor key counterclockwise ...

Page 143: ...breakers The circuit breakers are located on the battery cover in the instrument panel TO REPLACE 15 AMP CIRCUIT BREAKER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the battery cover and engage the prop rod 2 Unplug the connector on the battery harness from the machine connector ...

Page 144: ...l lock ring from the back of the circuit breaker Remove the circuit breaker 6 Install the new circuit breaker with the correct 15 amp rating in the mount hole Install the lock ring and rubber boot NOTE The mount hole in the battery cover is D shaped Make sure to install the circuit breaker in the correct orientation 7 Reconnect the wires to the back of the new circuit breaker See schematic in this...

Page 145: ...ELECTRICAL 4 15 3640E 330565 5 00 8 Plug the battery harness connector into the machine connector 9 Close the battery cover Start the machine and check the new circuit breaker for proper operation ...

Page 146: ...SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the battery cover and engage the prop rod 2 Unplug the connector on the battery harness from the machine connector 3 Locate the 50 amp circuit breaker on the left side of the cover ...

Page 147: ...r 5 Remove the two hex screws and nuts holding the 50 amp circuit breaker to the battery cover Remove the circuit breaker 6 Install the new 50 amp circuit breaker on the battery cover Note the orientation of the number 50 on the face of the reset button 7 Install the two hex screws and nuts Lightly tighten ...

Page 148: ...ct the wires to the back of the new circuit breaker See schematic in this section 9 Plug the battery harness connector into the machine connector 10 Close the battery cover Start the machine and check the new circuit breaker for proper operation ...

Page 149: ...eaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the battery cover and engage the prop rod 2 Unplug the connector on the battery harness from the machine connector 3 Locate the main contactor on the front of the filter wall behind the main drive motor ...

Page 150: ...he top of the main contactor 5 Remove the rear filter cover and dust filter 6 Remove the two hex screws and nuts holding the main contactor to the wall of the filter area Remove the contactor 7 Install the new contactor in the machine on the back wall of the filter area ...

Page 151: ...ts Firmly tighten 9 Reconnect the wires to the top of the new main contactor See schematic in this section 10 Plug the battery harness connector into the machine connector 11 Close the battery cover Start the machine and check the new main contactor for proper operation ...

Page 152: ...Y Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the battery cover and engage the prop rod 2 Unplug the connector on the battery harness from the machine connector 3 Locate the relay block on the back wall behind the main drive motor ...

Page 153: ...o pry the relay out of the terminals 5 Install the new relay in the relay block Note the direction of the terminals on the relay for proper installation Push the relay in all the way 6 Plug the battery harness connector into the machine connector 7 Close the battery cover Start the machine and check the new relay for proper operation ...

Page 154: ... fan and main brush drive The shaker motor has an eccentric weight on the shaft that causes the filter area to move when the motor rotates The side brush motor s are attached to right angle gear boxes that drive the side brush when activated TO REMOVE MAIN DRIVE MOTOR FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the battery cover and engage the prop...

Page 155: ... of the main drive motor 4 Disconnect the wires leading to the two studs on the main drive motor 5 Loosen the adjustment screw on the vacuum fan Let the vacuum fan drop down and remove the V belt from the motor sheave 6 Slip the flat drive belt off the motor sheave ...

Page 156: ...emove the tension on the main brush drive belt and slip it off the motor sheave 9 Remove the main brush from the machine See TO REPLACE MAIN BRUSH instructions in the SWEEPING section 10 Remove the two front motor mount bolts Access this hardware by going into the brush wrap area and locating the two hardware dimples in the roof of the frame ...

Page 157: ...to the rear of the machine and locating the two hardware dimples in front of the brush arm mount bracket and above the transaxle 12 The main drive motor can now be removed from the machine 13 Remove the drive sheaves from both sides of the old motor and install them on the new motor in the same orientation ...

Page 158: ...r on the mount plate 2 Install the two front motor mount bolts Access this hardware by going into the brush wrap area and locating the two hardware dimples in the roof of the frame 3 Install the two rear motor mount bolts Access this hardware by going to the rear of the machine and locating the two hardware dimples in front of the brush arm mount bracket and above the transaxle ...

Page 159: ...e sheave on the right side of the motor See TO REPLACE MAIN BRUSH DRIVE BELT instructions in the SWEEPING section 6 Reinstall the right side drive wheel assembly See TO INSTALL REAR TIRE instructions in the CHASSIS section 7 Reinstall the flat transaxle drive belt over the sheave on the left side of the drive motor See TO REPLACE FLAT DRIVE BELT instructions in the CHASSIS section ...

Page 160: ...structions in the SWEEPING section 9 Reconnect the wires on the two studs on the main drive motor See schematic in the ELECTRICAL section 10 Reinstall the front battery in the machine 11 Plug the battery harness connector into the machine connector 12 Close the battery cover Start the machine and check the new main drive motor for proper operation ...

Page 161: ...FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the battery cover and engage the prop rod 2 Unplug the connector on the battery harness from the machine connector 3 Locate the shaker motor on the back wall behind the battery ...

Page 162: ...acket Remove the shaker motor from the machine 6 Loosen the two set screw holding the weight to the motor shaft Slide the weight off and install it on the new motor in the same orientation Firmly tighten the set screws 7 Install the new shaker motor in the machine Position it on the frame bracket and install the mount bracket Tighten the hex screws to 18 24 Nm 15 20 ft lb ...

Page 163: ...he new shaker motor into the main electrical harness See schematic in this section 9 Plug the battery harness connector into the machine connector 10 Close the battery cover Start the machine and check the new shaker motor for proper operation ...

Page 164: ...g Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Open the battery cover and engage the prop rod 2 Unplug the connector on the battery harness from the machine connector 3 Remove the RH side brush See TO REPLACE LH OR RH SIDE BRUSH instructions in the SWEEPING section ...

Page 165: ... Remove the four hex screws holding the side brush motor and gear box to the machine frame 6 Remove the side brush motor and gear box from the machine 7 Position the new side brush motor and gear box in the machine Line up the mount holes in the machine frame with the mount holes in the side brush motor ...

Page 166: ...motor to the main harness See schematic in the ELECTRICAL section 10 Reinstall the side brush See TO REPLACE LH OR RH SIDE BRUSH instructions in the SWEEPING section 11 Plug the battery harness connector into the machine connector 12 Close the battery cover Start the machine and check the new RH side brush motor for proper operation ...

Page 167: ... Or Servicing Machine Stop On Level Surface Place Shifter In Park 1 Remove the filter cover from the rear of the machine 2 Remove the handle stop bracket from the upper left side of the filter compartment 3 Pull up on the two handle locks and move the handle assembly to its lowest position ...

Page 168: ...er Remove the cover plate from the machine 5 Remove the hardware and pull the brush handle mount plate away from the right plastic handle 6 Mark and disconnect the wires leading to the side brush switch 7 Remove the two screws and nuts holding the switch to the brush handle mount plate Remove the side brush switch from the machine ...

Page 169: ...tall the two screws and nuts Hand tighten lightly 9 Reconnect the wires to the new side brush switch See schematic in this section 10 Position the brush handle mount plate against the right plastic handle Reinstall the hardware 11 Reinstall the right side handle assembly cover plate Tighten the three flat screws to 18 24 Nm 15 20 ft lb ...

Page 170: ...e the handle assembly up to one of the four adjustment holes 13 Reinstall the filter cover 14 Reinstall the handle stop bracket 15 Start the machine and check the side brush for proper operation when the handle is placed in the down position ...

Page 171: ... BRUSH UP APPROX 26 DC AMPS F SIDE BRUSH MOTOR NO LOAD APPROX 1 5 DC AMPS F SIDE BRUSH MOTOR FREE FLOAT ON URETHANED CONCRETE APPROX 2 DC AMPS F ENTIRE MACHINE BRUSH IN FREE FLOAT ON URETHANED CONCRETE B F 1 ST GEAR APPROX 32 DC AMPS F 2 ND GEAR APPROX 34 DC AMPS F 3 RD GEAR APPROX 38 DC AMPS F REVERSE APPROX 33 DC AMPS ...

Page 172: ...EL 16 GRY 14 BLU FILTER SHAKER WILL ONLY RUN WHEN THE MAIN MOTOR IS OFF B A S4 9 GRN 9A GRN 11 BRN M2 4 2 7 PUR 4B YEL 7A BLU 7B BLU 7 PUR 4D YEL 15 AMP CB 1 9C GRN 14A BLU S2 4C YEL M1 RIGHT SIDE BRUSH MOTOR STANDARD BATTERIES ARE RATED AT 130 AMP HOURS HEAVY DUTY BATTERIES ARE RATED AT 215 AMP HOURS FILTER SHAKER MOTOR 3 1 D1 40 AMP FOR EE MACHINE THERMAL SENTRY OPENS AT 140 F 12 VOLT BATTERY ST...

Page 173: ...3640E 330565 5 00 TROUBLESHOOTING The troubleshooting charts that follow are organized so they lead you through the circuits They include flow charts and instructions for you as to where to insert your test instruments ...

Page 174: ...LTAGE BETWEEN ANY 4 YEL AND ANY 13 BLK WIRE BATTERY VOLTAGE 0 VOLTAGE RESET OR REPLACE CB1 HOLD THE KEY SWITCH IN THE START POSITION AND CHECK FOR BATTERY VOLTAGE BE TWEEN ANY 6 BLU AND ANY 13 BLK WIRE 0 VOLTAGE REPLACE THE KEY SWITCH BATTERY VOLTAGE 0 VOLTAGE REPLACE THE THERMAL SENTRY BATTERY VOLTAGE IS THERE BATTERY VOLTAGE BETWEEN ANY 4 YEL WIRE AND ANY 7 PUR WIRE 0 VOLTAGE RESET THE STOP SWIT...

Page 175: ... 330565 5 00 CHECK MOTOR REPAIR OR REPLACE CONTINUED FROM PREVIOUS PAGE IS THERE BATTERY VOLTAGE BETWEEN 3 ORA AND ANY 13 BLK WIRE AFTER THE KEY SWITCH IS STARTED AND IN THE RUN POSITION 0 VOLTAGE BATTERY VOLTAGE REPLACE M1 ...

Page 176: ...AKER OK CHECK FOR BATTERY VOLTAGE BETWEEN ANY 2 BRN AND ANY 13 BLK DOES THE FILTER SHAKER MOTOR RUN FOR 15 SECONDS AFTER THE SHAKER MOTOR SWITCH IS PRESSED WHEN THE KEY SWITCH IS IN THE OFF POSITION NO YES NO YES IS THE KEY SWITCH IN THE OFF POSITION TURN THE KEY SWITCH TO THE OFF POSITION DOES THE FILTER SHAKER WORK NOW SHAKER OK DOES THE FILTER SHAKER MOTOR RUN WHILE PRESSING THE FILTER SHAKER S...

Page 177: ...ave regarding our machine manuals If you find an error or have a suggestion please complete this postage paid form and mail it to us Thank you for helping us make zero defects a way of life at Tennant Manual No Rev No Publish Date Page Machine Report Error Suggestion Name Date Customer Number Company Address City State Zip Code ...

Page 178: ...GE NECESSARY IF MAILED IN THE UNITED SATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 94 MINNEAPOLIS MN POSTAGE WILL BE PAID BY ADDRESSEE Technical Publications 15 701 North Lilac Drive P O Box 1452 Minneapolis MN 55440 9947 TENNANT COMPANY ...

Page 179: ...ave regarding our machine manuals If you find an error or have a suggestion please complete this postage paid form and mail it to us Thank you for helping us make zero defects a way of life at Tennant Manual No Rev No Publish Date Page Machine Report Error Suggestion Name Date Customer Number Company Address City State Zip Code ...

Page 180: ...GE NECESSARY IF MAILED IN THE UNITED SATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 94 MINNEAPOLIS MN POSTAGE WILL BE PAID BY ADDRESSEE Technical Publications 15 701 North Lilac Drive P O Box 1452 Minneapolis MN 55440 9947 TENNANT COMPANY ...

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