Tennant 5700XPS Service Manual Download Page 1

Page: 1 / 362

Service Manual

MM406

Rev. 10 (6--03)

5700XP/XPS

5680

5700

*MM406*

Summary of Contents for 5700XPS

Page 1: ...Service Manual MM406 Rev 10 6 03 5700XP XPS 5680 5700 MM406 ...

Page 2: ... drag chain adjustment Scrubbing Squeegee assembly replace and adjust Scrubber head replace and adjust Vacuum fan replacement Solution recovery tank replacement Scrubbing troubleshooting chart Power wand replacement and vacuum wand replacement Electrical Battery maintenance and replacement Charging instructions Circuit breaker relay replacement Instrument panel replacement Vacuum fan motor repair ...

Page 3: ...CHINE DIMENSIONS 1 7 MAINTENANCE 1 8 MAINTENANCE CHART 1 8 MACHINE JACKING 1 9 TO JACK UP THE MACHINE 1 10 MACHINE LIFTING 1 12 PUSHING AND TRANSPORTING THE MACHINE 1 13 PUSHING THE MACHINE 1 13 TRANSPORTING THE MACHINE 1 14 STORAGE INFORMATION 1 16 FREEZE PROTECTION 1 17 HARDWARE INFORMATION 1 18 STANDARD BOLT TORQUE CHART 1 18 METRIC BOLT TORQUE CHART 1 18 BOLT IDENTIFICATION 1 18 THREAD SEALANT...

Page 4: ...GENERAL INFORMATION 1 2 5680 5700 MM406 9 01 ...

Page 5: ...ined and authorized Unless operation manual is read and understood In flammable or explosive areas unless designed for use in those areas 2 Before starting machine Make sure all safety devices are in place and operate properly Check brakes and steering for proper operation if so equipped 3 When using machine Go slow on inclines and slippery surfaces Use care when backing machine Follow mixing and ...

Page 6: ...any label becomes damaged or illegible install a new label in its place BATTERY CHARGING LABEL LOCATED ON THE UNDERSIDE OF THE SOLUTION TANK FLAMMABLE SPILLS LABEL LOCATED THE OPERATOR CONSOLE FOR SAFETY LABEL LOCATED ON THE OPERATOR CONSOLE FLAMMABLE MATERIALS LABEL LOCATED ON THE UNDERSIDE OF THE SOLUTION TANK COVER 10066 ...

Page 7: ...ndrical brush length for 700 mm 28 in scrub head 695 mm 27 37 in Cylindrical brush length for 800 mm 32 in scrub head 795 mm 31 37 in Cylindrical brush length for 900 mm 36 in scrub head 900 mm 35 37 in Squeegee width for 700 mm 28 in scrub head 950 mm 37 5 in Squeegee width for 800 mm 32 in scrub head 1065 mm 42 in Squeegee width for 900 mm 36 in scrub head 1155 mm 45 5 in Scrubbing path width fo...

Page 8: ...5 20 hr rate 30 kg 67 lb 6 6 305 20 hr rate 47 kg 104 lb Type Use VDC Kw hp Electric Motors Scrub brush disk 36 0 45 0 60 Heavy duty scrub brush disk 36 0 75 1 Scrub brush cylindrical 36 0 56 0 75 Vacuum fan 36 0 63 0 85 Propelling 36 0 37 0 50 Propelling for power steering 2 36 0 19 0 25 Type VDC amp Hz Phase VAC Chargers Smart 36 20 60 1 115 36 30 60 1 115 Chargers Smart I t ti l 36 20 50 1 230 ...

Page 9: ... LPM 0 22 GPM Detergent pump 36 Volt DC Concentrate flow rate 0 9 CC Minute 0 03 Ounces Minute Concentrate to water dilution ratio 1 1000 Air pump 36 Volt DC 0 6 Maximum Amp draw Air pump flow rate 8 7 LPM 0 3 CFM open flow 1600 mm 63 in 1625 mm 64 in 1660 mm 65 25 in 1690 mm 66 5 in 950 mm 37 5 in 1065 mm 42 in 1155 mm 45 5 in 720 mm 28 25 in 1090 mm 43 in 10189 MACHINE DIMENSIONS ...

Page 10: ...St mode Clean 1 3 Vacuum fan filter Clean 1 Machine Check for leaks 1 6 Disk scrub head skirt Check adjustment 1 Check for damage and wear 1 6 Cylindrical scrub head Check adjustment 4 y skirts Check for damage and wear 4 50 Hours 5 Front tires Check air pressure 2 8 Cylindrical brushes Check taper and rotate front to rear 2 12 FaSTt Filter screen option Clean 1 100 Hours 4 Rear casters Lubricate ...

Page 11: ...t or jack that will support the weight of the machine Use a piece of wood to distribute the machine weight load Always stop the machine on a flat level surface and block the machine tires before jacking up the machine FOR SAFETY When servicing machine block machine tires before jacking machine up FOR SAFETY When servicing machine jack machine up at designated locations only Block machine up with j...

Page 12: ...Turn Off Machine And Remove Key 3 Block the machine tires that are not being jacked up to secure the machine position FOR SAFETY When Servicing Machine Block Machine Tires Before Jacking Machine Up 4 Use a jack that will support the weight of the machine Use a piece of wood to help spread out the load and position the jack anywhere under the recovery tank FOR SAFETY When Servicing Machine Jack Mac...

Page 13: ... the recovery tank to secure the machine 6 Lower the machine down on the jack stands 7 Check to make sure the machine is secure 8 When finished servicing the machine raise the machine off the jack stands 9 Remove the jack stands from under the machine 10 Lower the machine 11 Remove the blocks from the tires ...

Page 14: ...rs as shown 2 Remove the debris hopper on machines with cylindrical scrub head 3 Raise the scrub head 4 Empty the recovery and solution tanks Loop the straps around the front and rear of the machine as shown NOTE The machine can be lifted using two 1 wide braided lifting straps rated at 1000lb 454kg minimum STD XP ...

Page 15: ...rness before attempting to push a disabled machine The machine will become easier to maneuver when it is unplugged ATTENTION Do not push the machine for a long distance and without unplugging the drive motor or damage may occur to the propelling system Only push a disabled machine for a very short distance and do not exceed 3 2 kp h 2 mph It is NOT intended to be pushed for a long distance or at a...

Page 16: ...ushed onto the truck or trailer 3 To winch the machine onto the truck or trailer attach the winching chains to the rear tie down locations on either side of the machine frame by the rear casters 4 Unplug the drive motor from the electrical harness before attempting to winch the machine The machine will become easier to maneuver when it is unplugged FOR SAFETY When loading machine onto truck or tra...

Page 17: ...of the machine to prevent the machine from tipping The rear tie down locations are on either side of the machine frame by the rear casters 7 If the loading surface is not horizontal or is higher than 380 mm 15 in from the ground use a winch to unload machine If the loading surface is horizontal AND is 380 mm 15 in or less from the ground the machine may be pushed off the truck or trailer FOR SAFET...

Page 18: ...E INFORMATION The following steps should be taken when storing the machine for extended periods of time 1 Drain and clean the solution and recovery tanks 2 Park the machine in a cool dry area 3 Remove the batteries or charge them after every three months ...

Page 19: ... gal of pre mixed automotive type windshield washer solution into the solution tank 3 Turn the machine power on 4 Start the solution flow Start the power wand solution system or ESt system to circulate the washer solution through the components 5 The washer solution does not need to be drained from the solution tank ...

Page 20: ...0 291 380 313 407 424 552 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 b...

Page 21: ...tional 2 4 FRONT TIRES AND WHEELS 2 5 TO REPLACE FRONT TIRE AND WHEEL ASSEMBLY 2 5 PROPELLING TRANSAXLE 2 7 TO REMOVE PROPELLING TRANSAXLE 2 7 TO INSTALL PROPELLING TRANSAXLE 2 10 PROPELLING TRANSAXLE TEARDOWN 2 14 TO REPAIR PROPELLING TRANSAXLE 2 14 REAR CASTERS 2 18 TO REPLACE A REAR CASTER 2 18 ...

Page 22: ...CHASSIS 2 2 5680 5700 MM406 8 00 ...

Page 23: ...406 8 00 CHASSIS This section includes information on the main chassis related components These components include the tire and wheel assembly propelling transaxle and drive motor casters parking brake option and static chain ...

Page 24: ...e transaxle mount The chain should be in contact with the floor at all times PARKING BRAKE optional The parking brake option is set by pushing down on the pedal on the left side of the machine with your foot When the parking brake is activated the transaxle is locked The parking brake is released by pulling up on the red tipped release bar with your foot or finger ...

Page 25: ...ce a jack stand under machine Use a piece of wood on top of the jack stand to help spread out the load FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 2 Remove the three wheel nuts holding the rim to the machine axle 3 Remove the tire and wheel assembly from the machine 4 Position the new tire and wheel assembl...

Page 26: ...CHASSIS 2 6 5680 5700 MM406 8 00 5 Reinstall the three wheel nuts and tighten to 102 117 Nm 75 85 ft lb 6 Remove the jack stand and lower the machine ...

Page 27: ... or left hand side of the transaxle The lubricant should be up to the bottom edge of the hole Check the lubricant level every 1000 hours of operation Use SAE 90 weight gear lubricant The transaxle lubricant should never need changing TO REMOVE PROPELLING TRANSAXLE 1 Remove the front cover 2 Place a 50 mm 2 in tall block of wood between the scrub head lift bracket and the top of the srub head ...

Page 28: ...und the back of the machine and lifting with an overhead hoist or by using a floor jack under the center rear of the machine ATTENTION DO NOT lift the machine with the steering handle 5 If the machine is lifted with a floor jack make sure to support outside edges of the machine to keep it from tipping over 6 Lift the rear of the machine until the drive wheels are off the ground Remove the three wh...

Page 29: ... bracket to the back of the tank frame NOTE The transaxle should be supported with a floor jack before the next step is attempted 10 Remove the two M8 hex screws washers and two retainer brackets holding each side of the transaxle to the machine frame Make sure to retain the frame support bracket NOTE Care must used when removing the transaxle from the machine so the breather cap and drive motor b...

Page 30: ...ound the back of the machine and lifting with an overhead hoist or by using a floor jack under the center rear of the machine ATTENTION DO NOT lift the machine with the steering handle 2 If the machine is lifted with a floor jack make sure to support outside edges of the machine to keep it from tipping over 3 Make sure the two rubber isolators are in place at the end of each axle If new isolators ...

Page 31: ...axle is filled with lubricant before installing in the machine 5 Using a floor jack or some other lifting device lift the transaxle into position in the machine frame 6 Install the one frame support bracket two retainer brackets four M8 hex screws washers and nyloc nuts holding the axle housing in the machine frame Leave hardware loose for now 7 Reinstall the one M8 hex screw washer and isolator i...

Page 32: ...any adjustments are needed loosen the jam nut and turn the clevis in or out to align holes 10 Reconnect the drive motor s to the main electrical harness See schematic in the ELECTRICAL section of this manual 11 Position the tire and wheel assembly on the machines axle studs NOTE Make sure the taper on the rim is facing the center of the machine If the machine is equipped with pneumatic tires the v...

Page 33: ...s and tighten to 90 117 Nm 65 85 ft lb 13 Remove the jack stands and lower the machine 14 Raise the scrubber head and remove the wood block from under scrub head lift bracket 15 Reinstall the front cover and operate the machine Check the transaxle for proper operation ...

Page 34: ...ring and seal kit and a gear kit are available See 5680 5700 parts manual for repair part numbers TO REPAIR PROPELLING TRANSAXLE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Drain the lubricant out of the transaxle 2 Remove the transaxle from the machine See TO REMOVE PROPELLING TRANSAXLE instructions in this section ...

Page 35: ...e motor facing up 4 Remove the twelve M8 hex screws holding the two halves of the transaxle together 5 Use a large flat blade screw driver to pry the two halves apart NOTE There are two indentations provided in the transaxle housing for this purpose 6 Carefully lift the top half of the transaxle housing off the bottom half ...

Page 36: ...emble the transaxle in the reverse order Make sure that both mating surfaces are cleaned and free of any gasket material Apply a bead of oil resistant formable gasket material to one side 9 Assemble both halves together and tighten the twelve M8 hex screws to 18 24 Nm 15 20 ft lb 10 Fill the transaxle with 90W gear lube to the bottom of the plug ...

Page 37: ...CHASSIS 2 17 5680 5700 MM406 8 00 Drive motor 2 on XPS Housing Housing Motor seal C clip Motor gear Axle shaft Seal Bushing Bearing C clip Fill plug TRANSAXLE BREAKDOWN 5680 5700 5700 XP and 5700 XPS ...

Page 38: ...EGEE FRAME instructions in the SCRUBBING section of this manual 2 Jack up the rear of the machine Place a jack stand under machine FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands ATTENTION DO NOT lift the machine with the steering handle NOTE DO NOT remove both casters at the same time 3 Remove the four M8 hex ...

Page 39: ...t no 01433 1 6 Reinstall the squeegee frame See TO INSTALL SQUEEGEE FRAME instructions in the SCRUBBING section of this manual 7 Remove the jack stand lower the machine to the floor 8 Drive the machine and check to make sure the caster swivels properly NOTE If both casters are removed at the same time the squeegee pivot pin must be installed with the caster mounting plate left loose After the pin ...

Page 40: ...CHASSIS 2 20 5680 5700 MM406 8 00 ...

Page 41: ...EPLACE CYLINDRICAL SCRUB BRUSH DRIVE BELT 3 41 Page SQUEEGEE 3 45 TO REMOVE SQUEEGEE FRAME 3 45 TO INSTALL SQUEEGEE FRAME 3 47 TO REMOVE SQUEEGEE LIFT ASSEMBLY 3 48 TO INSTALL SQUEEGEE LIFT ASSEMBLY 3 50 TO REPLACE SQUEEGEE LIFT CABLE 3 52 TO ADJUST AUTO SQUEEGEE LIFT 3 54 SQUEEGEE BLADES 3 56 REPLACING OR ROTATING REAR SQUEEGEE BLADE 3 56 REPLACING OR ROTATING FRONT SQUEEGEE BLADE 3 59 TO ADJUST ...

Page 42: ...SCRUBBING 3 2 5680 5700 MM406 8 00 ...

Page 43: ... water flows from the solution tank through the pinch valve to the solution solenoid valve to the scrub brushes The brushes scrub the floor As the machine is moved forward the squeegee wipes the dirty solution off the floor which is then picked up and drawn into the recovery tank by the vacuum fan ...

Page 44: ... deposits do form on the bottom of the tank rinse with a strong blast of warm water NOTE The water must not be hotter than 55_ C 130_ F or tank damage may occur Do not use steam to clean the tank ESt Option The recovery tank should be partially filled with clean water after using the ESt Option and clean water should be run through the pump until it is clear of any deposits TO REMOVE SOLUTION TANK...

Page 45: ...ible hose to the solution tank drain nipple Pull the hose off the solution tank 5 If the machine is equipped with a power wand un plug the pump from the main harness 6 If the machine is equipped with ESt disconnect the hose coming from the pump and going to the front of the tank Loosen the collet at the tank and pull the hose out ...

Page 46: ...he top of the prop rod to the solution tank NOTE Make sure to hold the solution tank in the raised position when working with the prop rod attachment hardware 9 Close the solution tank 10 Remove the two M8 flat head screws holding the hinges to the outside of the solution tank 11 The solution tank can now be lifted off the machine ...

Page 47: ... the recovery tank Be careful not to damage the tank seals 2 Align the two hinges with the threaded inserts in the tank Install the two M8 flat head screws and tighten to 18 24 Nm 15 20 ft lb 3 Raise the solution tank to the open position Prop the solution tank open with a piece of wood or some other device NOTE Make sure to hold the solution tank in the raised position when working with the prop ...

Page 48: ...washer Tighten to 18 24 Nm 15 20 ft lb 5 Plug the vacuum fan s into the main electrical harness 6 Position the flexible hose on the solution drain nipple Hand tighten the worm drive clamp 7 If the machine is equipped with a power wand plug the power wand pump into the main electrical harness See schematic in the ELECTRICAL section of this manual ...

Page 49: ...tank Make sure the semi rigid tube is in place inside the soft hose before tightening the collet The semi rigid tube must extend up into the solution tank 10 Reach inside the solution tank and check to make sure the small push on filters are in place over the solution valve and the power wand pump 11 Close the solution tank and fill with water Check for leaks and proper operation of the water valv...

Page 50: ...ry tank is one of the machine s main frame components The recovery tank should be drained and cleaned daily NOTE The water must not be hotter than 55_ C 130_ F or tank damage may occur Do not use steam to clean the tank Rinse and wipe off the sensors daily on machines with optical sensors installed inside the recovery tank The magnetic float sensor is located inside the recovery tank ...

Page 51: ...serting a small pin or screwdriver into the lower square hole and pressing up on sensor ESt option The ESt filter should be cleaned daily NOTE Do not use steam to clean the tank A vacuum fan filter is located in the recovery tank for machines serial number 006956 and above Remove and clean this filter daily Clean by shaking dust or rinsing pleats with low pressure water For machines below serial n...

Page 52: ... scrub head so the scrub brushes are resting on the floor FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Raise the solution tank and engage the prop rod 4 Remove the four M8 hex screws holding the front cover to the machine Remove the cover ...

Page 53: ...6 Disconnect the battery connector from the machine connector ATTENTION Double check to make sure the batteries are disconnected from the machine 7 Disconnect the batteries from the control panel remove the battery cables and remove the batteries from the machine 8 Disconnect the squeegee lift cable from the lift handle ...

Page 54: ...ctions in this section NOTE Make sure to note the location of the actuator lift bracket hardware in the two slots 11 Remove the two M8 hex screws holding the scrub head lift actuator bracket to the front of the recovery tank Remove the bracket from the machine 12 Remove the four M8 hex screws holding the scrub head roller guide and brackets to the front of the recovery tank Remove the roller guide...

Page 55: ...nges to the recovery tank Remove the hinges from the machine 14 Remove the anti foam elbow from the recovery tank 15 Remove the drain hoses from the back of the recovery tank 16 Remove the M8 hex screws holding the rear electrical panel to the electrical mounting plate Tilt the panel out ...

Page 56: ... the frame and transaxle assembly to the bottom of the recovery tank Remove the recovery tank from the frame and transaxle assembly 19 Place the new tank on top of the frame and transaxle assembly Make sure the harness is routed in the same manner as it was removed 20 Align the four holes in the transaxle frame with the four threaded inserts in the tank Reinstall the four M8 hex screws and tighten...

Page 57: ...Reinstall the scrub head lift actuator bracket to the front of the recovery tank Tighten the two M8 hex screws to 18 24 Nm 15 20 ft lb NOTE Make sure to locate the bracket in the same position as it was removed from 23 Reinstall the scrub head roller guide and brackets to the front of the recovery tank Leave the hardware loose for now 24 Reinstall the scrub head See TO INSTALL SCRUB HEAD instructi...

Page 58: ...ion drain hose to the scrub head 26 Tilt the electrical panel back in position and reinstall the M8 hex screws and washers Hand tighten the hardware 27 Reconnect the squeegee lift cable to the lift handle Hand tighten to allow cable to pivot 28 Reinstall the two hinges to the recovery tank and tighten the two M8 hex screws to 18 24 Nm 15 20 ft lb ...

Page 59: ...ment and cable arrangement 31 Reinstall the solution tank See TO INSTALL SOLUTION TANK instructions in this section NOTE After the batteries have been connected the scrub head lift actuator adjustment procedure must be followed This procedure can be found in the TO INSTALL SCRUB HEAD instructions in this section 32 Position the scrub head roller guide so the roller is at the top of the slot Tighte...

Page 60: ...SCRUBBING 3 20 5680 5700 MM406 8 00 33 Reinstall the front cover 34 Close the solution tank and fill with water NOTE Check for leaks and proper operation of the machine and all the components ...

Page 61: ...e floor all the way around when the scrub head is lowered Check the disk brush scrub head skirt for damage or wear daily Check the cylindrical brush scrub head side skirts for damage daily 5680 high down pressure strap Pulling this strap forward when the scrub head lift actuator is in the raised position will allow the scrub head to be used in a floor stripping mode The actuator will return to the...

Page 62: ...ition a block of wood in front of each drive tire 2 Lower the scrub head to the floor FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Raise the solution tank until the prop rod is engaged 4 Remove the four M8 hex screws holding the front cover to the machine Remove the cover ...

Page 63: ...ire harness to the main harness NOTE Do not disconnect the scrub brush motors from scrub head harness 7 Mark the location of the actuator tube on the actuator shaft with a piece of tape or a colored marking pen NOTE Be sure to mark the actuator position to keep the scrub head adjustment set correctly 8 Remove the cotter pin and clevis pin from the bottom of the head lift actuator ...

Page 64: ...ove the clevis pin and the roller from the scrub head roller guide bracket 10 Remove the two hair pins and two clevis pins connecting the scrub head to the scrub head lift arms 11 The scrub head can now be pulled out and away from the machine ...

Page 65: ... And Remove Key 1 If machine is equipped with the optional parking brake engage it at this time If not position a block of wood in front of each drive tire 2 Position the scrub head in front of the machine 3 Align the mounting holes in the rear of the scrub head with the holes in the end of the scrub head lift arms Install the two clevis pins and two hair pins ...

Page 66: ...ator with the hole in the scrub head actuator mount bracket Install the clevis and cotter pin 7 On the 5680 5700 machine check the actuator by raising the scrub head until the top of the actuator tube is 9 mm 3 8 in from the bottom of the actuator head If the actuator tube does not stop at that dimension with the brush switch on remove the bottom clevis pin and turn the tube to achieve the proper ...

Page 67: ... and adjust the roller guide bracket so the roller just touches or is slightly away from the end of the slot Re tighten the screws to 18 24 Nm 15 20 ft lb 10 Reconnect the solution hose running from the scrub head to the bottom of the solution tank 11 Reinstall the front cover using the four M8 hex screws Tighten to 18 24 Nm 15 20 ft lb 12 Lower the solution tank operate the machine check for prop...

Page 68: ...e key Remove the front cover NOTE On the 5680 push the scrubbing switch forward The scrub head will lower tom the floor Turn off the key switch FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 The scrub head levelness is checked by measuring from the top of the scrub head to the floor at the four outside corners Adjust if nece...

Page 69: ...rn the propel handles just enough to allow the scrub head to lower and operate but not enough to cause the machine move forward NOTE Make sure the side skirts on the scrub head are not holding the scrub head and brushes up off the floor when checking the brush pattern You may have to adjust them up or pull them to the side 4 Lower the scrub head allowing the brushes to spin on the floor in one spo...

Page 70: ... go to step 6 6 Turn off the machine and remove the key Remove the front cover Remove the idler plate on the brush that showed a taper FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 7 Put a open end wrench on the flat of the idler eccentric shaft loosen the flat head screw with a 7 32 in allen wrench and turn eccentric shaft to raise or lower that end of the ...

Page 71: ...tained NOTE Make sure to install the idler doors on the side they were removed from to avoid having to re adjust the brush taper 9 If the brush patterns are not both 40 5 mm 1 5 0 25 in wide then use a 17mm wrench on the M10 hex screw located on the pivot bracket to adjust the angle of the scrub head Make sure to re tighten the M10 jam nut ...

Page 72: ...2 Turn the machine power off FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 3 Check to see if the scrub head skirt touches the floor all the way around the scrub head 4 If the skirt is off the ground at any point around the scrub head loosen the skirt strap and pull the skirt down in that area 5 Once the skirt is touching the floor all the way around tighten ...

Page 73: ...On Level Surface Turn Off Machine 3 Loosen the skirt strap remove and discard the torn or worn out skirt 4 Position the new skirt around the scrub head Make sure the notches are in the correct place under the scrub head rollers Make sure the skirt is touching the floor all the way around the scrub head 5 Pull the strap tight attach the velcro end of the strap to the velcro strip re check the skirt...

Page 74: ...ower off FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 3 Check to see if the four scrub head skirts touch the floor all the way around the scrub head 4 Loosen the two M8 flat head screws holding each of the four skirts and retainers to the scrub head 5 Adjust the skirt down so it lightly contacts the floor Hand tighten the M8 flat head screws 6 Operate the m...

Page 75: ...vicing Machine Stop On Level Surface Turn Off Machine 3 Remove the two M8 flat head screws holding each skirt and retainer to the scrub head Remove the skirt 4 Position a new skirt under the skirt retainer and reinstall the two M8 flat head screws 5 Adjust the skirt down so it lightly contacts the floor Hand tighten the M8 flat head screws 6 Operate the machine and check the scrub head skirts for ...

Page 76: ...ub brushes should be replaced if large amounts of bristles are missing or if the remaining bristles length is less than 10 mm 0 38 in NOTE Be sure to replace brushes in sets Otherwise one brush will be more aggressive than the other Cleaning pads must be placed on pad drives before they are ready to use The cleaning pad is held in place by a pad holder Cleaning pads need to be cleaned with soap an...

Page 77: ...On Level Surface Turn Off Machine 2 Open the access cover on the side of the scrub head over the brush that needs changing 3 Turn the brush until you can see the brush retaining spring clip 4 Pinch the two brush retaining spring clips together and drop the brush down and off the drive hub Remove the brush from the machine 5 Slide the new scrub brush under the scrub head ...

Page 78: ...n it until the hub in the brush lines up with the brush drive hub 7 Push the brush up until the brush retaining spring clips snap over the edge of the drive hub 8 Close the access door lower the scrub head scrub with the machine checking for proper brush operation ...

Page 79: ...n Off Machine 2 The scrub brush must be removed from the end opposite the drive motor 3 The brush idler plate is held in place with a spring clip To remove the idler plate the spring clip must be pressed down flat to the top of the scrub head 4 With the spring clip pressed down flat to the top of the scrub head pull the bottom of the idler plate out of the end of the brush and off the spring clip ...

Page 80: ...r plug into the other end of the scrub brush 9 Position the idler plate on the scrub head making sure that the notches on the idler plate engage the lip of the scrub head 10 Push the spring clip down until the slot is positioned under the clip on the idler plate Release the spring 11 Start the brushes and check for proper brush pattern See TO CHECK CYLINDRICAL BRUSH PATTERN instructions NOTE Every...

Page 81: ...n Off Machine And Remove Key 1 Raise the solution tank until the prop rod is engaged Remove the four M8 hex screws holding the front cover to the machine Remove the cover 2 Remove the scrub brush from the motor that the belt needs to be changed See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this section 3 Loosen the front and rear pivot bolts on the brush motor ...

Page 82: ...pped off the motor pulley Push the drive belt down toward the lower pulley in the brush area NOTE Make sure the scrub head is in the raised position before attempting to remove the drive plug rubber seal 6 Using a needle nose pliers pull the rubber seal off the brush drive plug 7 Pull the drive belt off the bottom drive pulley NOTE It is a tight fit for the belt in the area of the lower belt cover...

Page 83: ...hex screw located under the brush motor tension the belt by applying 2 5 2 7 lbs of force per belt at the middle of the span that is opposite the belt travel with a deflection of 0 10 inch 10 Tighten the two pivot bolts to 18 24 Nm 15 20 ft lb Re check the belt tension 11 Reinstall the belt cover two M6 hex screws and washers Tighten to 11 14 Nm 7 10 ft lb Use a small amount of RTV on the flange o...

Page 84: ... the scrub brush See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this section 13 Reinstall the front cover using the four M8 hex screws Tighten to 18 24 Nm 15 20 ft lb 14 Lower the solution tank operate the machine check for proper operation ...

Page 85: ... can be adjusted for leveling and deflection The deflection and leveling of the squeegee blades should be checked daily or when scrubbing a different type of floor The squeegee can be removed from the squeegee pivot so the squeegee will not be damaged during transport of the machine TO REMOVE SQUEEGEE FRAME FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn...

Page 86: ...gee frame 4 Locate the two plastic thumb screws on the squeegee frame These are located near the vacuum hose 5 Loosen the two plastic thumb screws 2 3 turns Do not remove the thumb screws 6 Remove the squeegee frame by pulling it straight back off the the lift linkage assembly ...

Page 87: ...nd Remove Key 1 Make sure the squeegee lift linkage assembly is in the raised position 2 Place the squeegee frame under the squeegee pivot 3 Line up the slots in the squeegee frame with the plastic thumb screws on the lift assembly 4 Push the squeegee frame all the way forward in the slot Hand tighten the thumb screws 5 Reinstall the vacuum hose on the squeegee frame ...

Page 88: ...g Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Remove the squeegee frame from the machine See TO REMOVE SQUEEGEE FRAME instructions in this section 2 Lower the squeegee lift handle 3 Disconnect the squeegee lift cable from the squeegee assembly ...

Page 89: ...ocate the squeegee assembly pivot pin at the front center of the lift assembly Remove the hair pin from the pivot pin 5 Pull the pivot pin straight down and out of the machine 6 The squeegee lift assembly can now be removed from the machine ...

Page 90: ...ing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Position the lift assembly at the back of the machine 2 Align the hole in the aluminum pivot casting with the hole in the frame mounting bracket 3 Push the pivot pin up into the bracket and casting Reinstall the hair pin ...

Page 91: ... will allow the squeegee frame to be lifted higher with the handle Reinstall the cable into the hole it was removed from 6 Operate the machine and check the squeegee for proper operation See TO ADJUST SQUEEGEE instructions in this section NOTE If both casters are removed at the same time the squeegee pivot pin must be installed with the caster mounting plate left loose After the pin is installed a...

Page 92: ... Lower the squeegee assembly to the floor 2 Remove the M8 flat head screw plastic bumper washer sleeve and M8 nyloc nut holding the squeegee lift cable to the lift handle 3 Remove the M5 hex screw and nyloc nut holding the lift cable to the squeegee frame NOTE Make a note of which hole the bottom of the cable is installed in 4 The squeegee lift cable can now be removed from the machine ...

Page 93: ...e lift cable Re use the M5 hex screw There are two holes in the squeegee lift bracket Using the lower hole will allow the squeegee frame to be lifted higher with the handle Reinstall the cable into the hole it came out of 7 Reinstall the M8 flat head screw plastic bumper washer sleeve and nyloc nut in the lift handle end Hand tighten to allow the cable to pivot freely 8 Raise the squeegee ...

Page 94: ...blades are rolled over 3 Turn off the machine with the squeegee in the down position FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 Check the gap between the top of the roller on the auto squeegee and the bottom of the Y bar on the squeegee arms This gap should be 0 125 to 0 250 in ...

Page 95: ...ss than 125 in the three hex screws holding the actuator mount bracket to the frame must be loosened and the bracket slid back until the gap is correct 6 Tighten the three hex screws to 18 24 Nm 15 20 ft lb 7 Operate the machine and check the squeegee lift for proper operation ...

Page 96: ...end for end To use the next wiping edge rotate the top edges down bottom edges up To use the last edge rotate the blade end for end REPLACING OR ROTATING REAR SQUEEGEE BLADE 1 Make sure the squeegee is raised off the floor 2 Turn the machine power off and set the parking brake if your machine has this option FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Tur...

Page 97: ...MM406 8 00 3 Loosen the two retention knobs one at each the end on the squeegee 4 Pull off the rear retaining band 5 Pull off the rear squeegee blade 6 Insert the rotated or new squeegee blade and then insert the retainer band ...

Page 98: ...SCRUBBING 3 58 5680 5700 MM406 8 00 7 Tighten the two retention knobs ...

Page 99: ...brake if your machine has this option FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Remove the squeegee from the machine See TO REMOVE SQUEEGEE FRAME instructions in this section 4 Remove the rear squeegee blade and retainer See REPLACING OR ROTATING THE REAR SQUEEGEE BLADE instructions in this section ...

Page 100: ... Pull the retainer plate back and pull off the front squeegee blade 7 Insert the rotated or new front squeegee blade in the squeegee frame lining up the slots in the blade with the tabs on the retainer plate 8 Push the retainer plate forward Tighten the two outside knobs on top of the squeegee assembly ...

Page 101: ...d retainer Tighten the two rear blade retention knobs 10 Install the squeegee assembly on the squeegee pivot See TO INSTALL SQUEEGEE FRAME instructions in this section 11 Adjust the squeegee blade leveling and deflection See TO ADJUST SQUEEGEE instructions in this section ...

Page 102: ...ake sure this adjustment is done on an even level floor TO LEVEL SQUEEGEE 5700 5700XP 5700XPS only 1 Park the machine on a level surface 2 Lower the squeegee FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Make sure the squeegee is level with the floor over the full length of the squeegee blade ...

Page 103: ... to increase the deflection at the ends of the squeegee NOTE Turn the squeegee leveling knob clockwise to decrease the deflection at the ends of the squeegee blade 5 Raise and lower the squeegee blade again to check level with the floor 6 Drive the machine forward to check the squeegee blade deflection 7 Adjust the squeegee blade deflection if necessary ...

Page 104: ... of curl the squeegee blade has when the machine moves forward with the squeegee lowered to the floor The best deflection is when the squeegee wipes the floor just dry with a minimum amount of deflection TO ADJUST SQUEEGEE BLADE DEFLECTION 1 Turn the machine power on 2 Lower the squeegee ...

Page 105: ... FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 5 To adjust the amount of deflection turn the squeegee deflection cams counter clockwise to decrease the blade deflection Turn the squeegee deflection cams clockwise to increase blade deflection 6 Drive the machine forward again to check the squeegee blade deflection 7 Readjust t...

Page 106: ...he squeegee blade end should be farther away from the wall when the floor curves up to the wall TO ADJUST SQUEEGEE GUIDE ROLLERS 1 Lower the squeegee assembly to the floor 2 Drive the machine forward and up against a wall until the squeegee blades are rolled over 3 Loosen the nut at the top of the guide roller and move the roller in or out to adjust how close the end of the squeegee blade comes to...

Page 107: ...to the recovery tank through the vacuum hose The vacuum fan inlet filter in the solution tank should be cleaned daily TO REPLACE VACUUM FAN S FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Make sure the solution tank is empty 2 Raise the solution tank until the prop rod is engaged ...

Page 108: ...he machine is equipped with the dual fan option the vacuum fans are bolted to a mounting plate then to the solution tank To remove the problem fan follow the instructions for single fan removal NOTE The orientation of the vacuum fan exhaust tube before removing it from the machine 5 Prepare the new fan by installing a new seal on it s inlet side with the adhesive side to the fan 6 Position the new...

Page 109: ...acuum fan mounting brackets M8 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 8 Plug the vacuum fan into the main harness See electrical schematic in the ELECTRICAL section if this manual 9 Start the machine and check the vacuum fan for proper operation ...

Page 110: ...re is a quick release fitting in the tank of the machine under the cover on the solution tank where the power wands hose plugs in The power wand handle and hose are stored on the machine solution tank TO REPLACE POWER WAND PUMP FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Make sure the solution tank is empty 2 Raise the so...

Page 111: ...ll worm drive clamp and hose leading from the power wand pump to the fitting on the solution tank Note the orientation of the pump inlet pipe 5 Remove the power wand pump by turning counter clockwise Remove the pump from the machine 6 Place thread sealant RTV on the threads before installing the new pump ...

Page 112: ...g sure the inlet pipe lines up with the fitting in the solution tank 8 Reinstall the hose leading from the pump to the fitting on the solution tank Hand tighten worm drive clamp 9 Plug the power wand pump into the main harness See schematic in the ELECTRICAL section of this manual ...

Page 113: ... through the ESt system after it used in the scrubbing operation TO REPLACE EStPUMP FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key NOTE Any light that enters the front of the recovery tank with the solution tank in the raised position and reaches the liquid level sensor may cause the EStpump to run erratically 1 Make sure the ...

Page 114: ... harness 4 Loosen the worm drive clamps holding the two solution hoses to the pump Disconnect the hoses from the pump 5 Loosen the large worm drive clamp holding the ESt pump to the bottom of the frame Remove the pump from the machine 6 Position the new pump back under the frame Reinstall the large worm drive clamp and hand tighten tight ...

Page 115: ... the two solution hoses to the EStpump Hand tighten the clamps 8 Plug the EStpump into the main electrical harness See schematic in the ELECTRICAL section of this manual 9 Operate the machine and check the ESt pump for proper operation or any leaks ...

Page 116: ...ee TO REPLACE ESt PUMP instructions in this section 2 Remove the six screws holding the end on the pump 3 Disassemble the pump until the diaphragm is exposed 4 See the 5680 5700 parts manual for repair kit part number 5 Re assemble the ESt pump using the parts illustration 6 Reinstall the pump in the machine See TO REPLACE ESt PUMP instructions in this section 7 Operate the machine checking the ES...

Page 117: ...R VALVE CABLE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Make sure the solution tank is empty 2 Raise the solution tank until the prop rod is engaged 3 Loosen the swivel on the cable at the water valve end ...

Page 118: ... valve closed by hand With the pinch valve in the closed position tighten down on the cable swivel 6 Close the solution tank and fill with water 7 Open and close the valve handle Check to make sure the pinch valve is properly controlling the solution flow NOTE The water solenoid valve will only allow water to flow when the machine is in the forward propel mode ...

Page 119: ... on and off Drain recovery tank Little or no solution flow to the floor Solution tank empty Fill solution tank Solution control cable broken or out of adjustment Replace and or adjust cable Solution flow turned off Turn solution flow on Solution supply lines plugged Flush solution supply lines Solution supply line filter dirty Clean filter Solution solenoid clogged or stuck Clean or replace ESt mo...

Page 120: ...SCRUBBING 3 80 5680 5700 MM406 8 00 ...

Page 121: ...ERS 4 71 TO REPLACE SCRUB HEAD LIFT ACTUATOR 4 74 TO REPLACE SQUEEGEE LIFT ACTUATOR XP XPS 4 78 Page ELECTRIC MOTORS 4 81 TO REPLACE STANDARD DISK SCRUB BRUSH MOTOR 4 81 TO REPLACE HEAVY DUTY DISK SCRUB BRUSH MOTOR 4 85 TO REPLACE CYLINDRICAL SCRUB BRUSH MOTOR 4 89 TO REPLACE DISK SCRUB BRUSH STANDARD MOTOR BRUSHES 4 94 TO REPLACE DISK SCRUB BRUSH HEAVY DUTY MOTOR BRUSHES 4 97 TO REPLACE CYLINDRIC...

Page 122: ... 179 ESt PUMP CIRCUIT 4 182 NO ESt PUMP 4 183 SOLUTION SOLENOID CIRCUIT 4 184 NO SOLUTION FLOW 4 185 HOURMETER CIRCUIT 4 186 NO HOURMETER 4 187 BDI CIRCUIT 4 188 BDI MALFUNCTION 4 189 SOLID STATE LEVEL CIRCUIT 4 190 LEVEL TESTING 4 191 INITIAL TESTING 4 193 POWER UP CIRCUIT 4 194 NO POWER 4 195 PROPEL STEERING CIRCUIT 4 197 STEERING MALFUNCTION 4 198 SQUEEGEE VAC FAN CIRCUIT 4 201 NO SQUEEGEE OR V...

Page 123: ... SYSTEM The 5680 5700 electrical system consists of the batteries electrical drive motors scrub brush motors vacuum fan motors power control panel and related components This section includes information on these components and their troubleshooting ...

Page 124: ...ll metallic objects off the top of the batteries which may cause a short circuit Replace any worn or damaged wires Check the electrolyte level in each battery cell before and after charging and after every 50 hours of operation Do not charge the batteries unless the fluid is slightly above the battery plates If needed add just enough distilled water to cover the plates Never add acid to the batter...

Page 125: ...harged 1 148 25 Charged 1 110 Discharged 1 223 75 Charged NOTE If the readings are taken when the battery electrolyte is any temperature other than 27_ C 80_ F the reading must be temperature corrected Add or subtract to the specific gravity reading 0 004 4 points for each 6_ C 10_ F above or below 27_ C 80_ F ...

Page 126: ...ake optional Turn Off Machine And Remove Key 3 Lift up the solution tank to get access to the batteries NOTE The solution tank must be empty 4 Check the water level in all the battery cells 5 If the level is low add just enough distilled water to cover the plates DO NOT OVERFILL The batteries can overflow during charging due to expansion NOTE Make sure the battery caps are in place while charging ...

Page 127: ...will start automatically When the batteries are fully charged the TENNANT charger will automatically turn off 9 After the charger has turned off unplug the charger from the wall outlet 10 Unplug the charger connector from the battery connector on the machine FOR SAFETY When maintaining or servicing machine avoid contact with battery acid 11 Check the electrolyte level in each battery cell after ch...

Page 128: ...ELECTRICAL 5680 5700 MM406 9 01 4 8 ...

Page 129: ...ELECTRICAL 4 9 5680 5700 MM406 9 01 ...

Page 130: ...ELECTRICAL 5680 5700 MM406 9 01 4 10 ...

Page 131: ...ELECTRICAL 4 11 5680 5700 MM406 9 01 ...

Page 132: ...ELECTRICAL 5680 5700 MM406 9 01 4 12 ...

Page 133: ... latch This panel can be adjusted up and down by the operator The inner panel contains the key circuit breakers hour meter and any optional switches The optional 5700 XP instrument panel consists of a circuit board a touch panel and a water dust resistant plastic enclosure Its touch panel controls various machine functions while its indicator lights keep the operator informed on the machine perfor...

Page 134: ...n Off Machine And Remove Key 1 Make sure the solution tank is empty Raise the solution tank and engage the safety arm NOTE Disconnect the negative battery cable from the battery nearest the back of the machine before servicing any electrical components 2 Remove the M8 hex screws holding the rear electrical panel to the electrical mounting plate Tilt the panel out ...

Page 135: ... 9 01 3 Tilt the instrument panel assembly back until it is resting against the lanyard strap 4 All of the electrical components that are contained in the instrument panel and on the electrical mount panel can now be easily accessed ...

Page 136: ...he instrument panel assembly back up to the electrical mount panel Reinstall the two M8 hex screws and hand tighten NOTE Make sure all the wires are out of the way of any pinch points when pivoting the instrument panel back into position 2 Re connect the negative battery cable to the battery nearest the back of the machine 3 Close the solution tank and operate the machine checking for proper opera...

Page 137: ...optional Turn Off Machine And Remove Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Locate the power contactor on the bottom left side of the electrical mount panel ATTENTION Double check to make sure the batteries are disconnected from the machine 3 Disconnect the wire harness from the power contactor ...

Page 138: ...e 5 Position the new power contactor on the electrical mount panel Reinstall the two M6 hex screws and tighten to 8 10 Nm 5 7 ft lb 6 Reconnect the wire harness to the power contactor See the electrical schematic in this section 7 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 8 Operate the machine checking for proper operation ...

Page 139: ... optional Turn Off Machine And Remove Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Locate the 36 volt contactor on the top left side of the electrical mount panel ATTENTION Double check to make sure the batteries are disconnected from the machine 3 Disconnect the wire harness from the 36 volt contactor ...

Page 140: ...ller white contactor 5 Remove the two M6 thread rolling screws holding the 36 volt contactor to the electrical mount panel Remove the contactor from the machine 6 Position the new 36 volt contactor onto the electrical mount panel Reinstall the two M6 thread rollers and tighten to 8 10 Nm 5 7 ft lb 7 Reconnect the wire harness to the power contactor See the electrical schematic in this section ...

Page 141: ... white contactor to the electrical mount panel Reinstall the two M6 thread rollers and tighten to 8 10 Nm 5 7 ft lb 9 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 10 Operate the machine checking for proper operation ...

Page 142: ...f Machine And Remove Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Locate the white SPST contactor on the left side of the electrical mount panel Its the white contactor on the far left ATTENTION Double check to make sure the batteries are disconnected from the machine 3 Disconnect the wire harness from the SPST contactor ...

Page 143: ...5 Position the new SPST contactor onto the electrical mount panel Reinstall the two M6 thread rollers and tighten to 8 10 Nm 5 7 ft lb 6 Reconnect the wire harness to the SPST contactor See the electrical schematic in this section 7 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 8 Operate the machine checking for proper operation ...

Page 144: ...e Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Locate the control relays on the right hand side of the electrical mount panel ATTENTION Double check to make sure the batteries are disconnected from the machine 3 Remove the faulty relay by pulling it straight up NOTE A small flat screw driver can be used to help pry the relay from mounting base ...

Page 145: ...lay base Make sure the male terminals line up with the female slots in the base 5 Push the relay down into the base connecters 6 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 7 Operate the machine checking for proper operation ...

Page 146: ...chine And Remove Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Locate the speed controller under the rubber shield in the center of the electrical mount plate Pull the rubber flap up and out of the way ATTENTION Double check to make sure the batteries are disconnected from the machine 3 Disconnect the wire harness from the speed controller ...

Page 147: ... shield and the four M4 hex screws Tighten to 223 290 Ncm 19 25 in lb 6 Reconnect the speed control to the main harness See ELECTRICAL SCHEMATIC in this section ATTENTION On the 5700 when reconnecting the six pin connector to the controller make sure the GREEN lead is on the right and the RED WHITE and BLACK leads are on the left 7 Put a small amount of dielectric grease on the terminals of this l...

Page 148: ...ELECTRICAL 5680 5700 MM406 9 01 4 28 9 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 10 Operate the machine checking for proper operation ...

Page 149: ...e Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Locate the electronic control circuit board under the plastic cover on the lower right side of the electrical mount plate 3 Remove the four M4 hex screws holding the plastic cover to the electrical mount plate Remove the cover ATTENTION Double check to make sure the batteries are disconnected from the...

Page 150: ...age will occur to the controller if the ribbon cable removed from terminal P1 is accidentally placed on terminal P6 NOTE The flat connector on the ribbon cable has a tight fit to the circuit board Use two hands when carefully pulling it off the pins 6 Using a small needle nose pliers compress the tang on each of the circuit board clips holding the board to the electrical mount plate Remove the boa...

Page 151: ...S instructions in this section 10 Put a small amount of dielectric grease on the terminals of this low voltage circuit to protect it against condensation and corrosion part 86385 NOTE The flat connector on the ribbon cable has a tight fit to the circuit board Use two hands when carefully pushing it onto the pins 11 Reinstall the plastic cover over the electronic control circuit board Tighten the f...

Page 152: ...d Remove Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Locate the propelling control circuit boards under the plastic cover in the center of the electrical mount plate ATTENTION Double check to make sure the batteries are disconnected from the machine 3 Remove the four M4 hex screws holding the plastic cover to the electrical mount plate Remove the...

Page 153: ...ace the two M4 hex screws through the circuit board and through the spacers Align the hex screws with the mounting holes in the electrical mount plate Lightly hand tighten 7 Reconnect the propelling control circuit board to the main harness See electrical schematic in this section 8 Put a small amount of dielectric grease on the terminals of this low voltage circuit to protect it against condensat...

Page 154: ...ELECTRICAL 5680 5700 MM406 9 01 4 34 10 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 11 Operate the machine checking for proper operation ...

Page 155: ...move Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Locate the electronic circuit board under the plastic cover on the lower right side of the electrical mount plate ATTENTION Double check to make sure the batteries are disconnected from the machine 3 Remove the four M4 hex screws holding the plastic cover to the electrical mount plate Remove the co...

Page 156: ...oard to the electronic control board below it Remove the board 6 Position the new electronic circuit board on the electronic control board Gently push the circuit board onto the clips 7 Reconnect the electronic control circuit board to the main harness See electrical schematic in this section 8 Put a small amount of dielectric grease on the terminals of this low voltage circuit to protect it again...

Page 157: ...stic cover over the electronic control circuit board Tighten the four M4 hex screws to 223 290 Ncm 19 25 in lb 10 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 11 Operate the machine checking for proper operation ...

Page 158: ...TRUMENT PANEL instructions in this section ATTENTION Double check to make sure the batteries are disconnected from the machine 2 Remove the wires leading to the faulty circuit breaker 3 The 2 5A and 10A circuit breakers are held in with a round spring clip Use a small flat screw driver and a needle nose pliers to remove the spring clip off the circuit breaker If the clip is damaged when its remove...

Page 159: ... The circuit breaker has a D shape and will only install one way 7 Push the new locking ring all the way on the barrel of the circuit breaker Reinstall the clear rubber boot 8 Reconnect the wires to the circuit breaker See the electrical schematic in this section 9 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 10 Operate the machine checking for proper...

Page 160: ...eries are disconnected from the machine 2 Remove the wires leading to the faulty circuit breaker 3 Remove the two pan head screws holding the circuit breaker to the instrument panel Remove the circuit breaker 4 Position the new circuit breaker on the instrument panel Reinstall the two pan head screws and hand tighten 5 Reconnect the wires to the circuit breaker See the electrical schematic in this...

Page 161: ...Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section ATTENTION Double check to make sure the batteries are disconnected from the machine 2 Remove the M8 hex nut and star washer holding the shroud locking bracket to the adjustable handle assembly Remove the locking bracket from the machine 3 Push the adjustable handle assembly all the way down in its slot ...

Page 162: ...ustable handle assembly up in its slot until the shield plate is completely exposed 6 Remove the two M3 flat head screws holding the shield plate to the adjustable handle assembly Remove the shield plate 7 Unplug the touch panel flat film cable from the machine ribbon cable NOTE The flat connector on the ribbon cable has a tight fit Use two hands when carefully pulling the two cables apart ...

Page 163: ...from the machine 9 Place the touch panel in the plastic bezel before installing it on the machine This will correctly locate the touch panel and plastic bezel Remove the cover over the adhesive 10 Install the touch panel and bezel on the adjustable handle assembly Be sure to route the flat film cables carefully through the slot 11 Reinstall the six pinch clips on the studs on the touch panel mount...

Page 164: ...t 86385 NOTE The flat connector on the ribbon cable has a tight fit Use two hands when carefully pushing the two cables together 14 Reinstall the shield plate to the adjustable handle assembly Reinstall the two M3 flat head screws and hand tighten 15 Push the adjustable handle assembly all the way down in its slot 16 Reinstall the touch panel drain cable and machine ground strap to the center hole...

Page 165: ...king bracket to the adjustable handle assembly Reinstall the M8 hex nut and star washer Tighten to 12 16 Nm 9 12 ft lb 18 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 19 Operate the machine checking for proper operation ...

Page 166: ...nd Remove Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section ATTENTION Double check to make sure the batteries are disconnected from the machine 2 Remove the M8 hex nut and star washer holding the shroud locking bracket to the adjustable handle assembly Remove the locking bracket from the machine 3 Push the adjustable handle assembly all the way down in i...

Page 167: ...e 5 Pull the adjustable handle assembly all the way up in its slot 6 Remove the wires from the gauge terminals 7 Remove the two small hex nuts holding the gauge retainer bracket to the gauge Remove the gauge and bracket from the machine 8 Position the new gauge back in the instrument panel Make sure gauge face can be read properly from the operators area ...

Page 168: ...the electrical schematic in this section 11 Pull the adjustable handle assembly far enough up in its slot so the shield plate can be reinstalled Reinstall the two M3 flat head screws and hand tighten 12 Push the adjustable handle assembly all the way down in its slot 13 Reinstall the shroud locking bracket to the adjustable handle assembly Reinstall the M8 hex nut and star washer Tighten to 12 16 ...

Page 169: ...ELECTRICAL 4 49 5680 5700 MM406 9 01 14 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 15 Operate the machine checking for proper operation ...

Page 170: ...STRUMENT PANEL instructions in this section ATTENTION Double check to make sure the batteries are disconnected from the machine 2 Disengage the lock on the steering console and push it all the way down 3 Remove the left hand rubber grip from the steering handle NOTE The rubber grip has a very tight fit on the steering handle You may have to cut the grip to remove it Refer to the 5680 5700 parts ma...

Page 171: ...steering handle NOTE The orientation of the speed control gear torsion spring and washer when removing the steering handle 5 Slide the steering handle to the right of the machine Reach in and hold the white plastic speed control gear spring and washer while pulling the handle out Remove the handle spring and gear from the machine ...

Page 172: ...the steering console 2 While pushing the steering handle into the console slip the washer spring and speed control gear onto the shaft The spring must be positioned with one ear on each side of the plastic boss inside the panel NOTE Make sure the teeth on the speed control gear mesh with the teeth on the potentiometer gear when pushing the steering handle in 3 Align the hole in the steering handle...

Page 173: ...k of the machine 6 Turn on the machine and check for proper neutral centering If the machine creeps in either direction grasp the body of the potentiometer and rotate it forward or backward until neutral is obtained 7 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 8 Reconnect the batteries turn on the machine and check the steering handle for proper ope...

Page 174: ...y 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section ATTENTION Double check to make sure the batteries are disconnected from the machine 2 Remove the steering handle See TO REMOVE STEERING HANDLE instructions in this section 3 Locate the wire harness coming from the potentiometer Lift the rubber flap and un plug the white connector from the top left hand side...

Page 175: ...tic wire ties that are holding the potentiometer wire harness to the main harness 6 Loosen the jam nut that is holding the potentiometer to the steering console 7 Pull the potentiometer straight out of the slot Remove the potentiometer from the machine 8 Loosen the set screw holding the gear to the potentiometer Remove the gear ...

Page 176: ... under the jam nut ATTENTION Do not over tighten the jam nut Lightly hand tighten only 11 Route the wire harness back to the propel controller Plug the white connector into the upper left hand side of the controller and the green wire back onto the B terminal Position the rubber flap back under the plastic tie 12 Put a small amount of dielectric grease on the terminals of this low voltage circuit ...

Page 177: ...e 15 Re connect the negative battery cable to the battery nearest the back of the machine 16 Turn on the machine and check for proper neutral centering If the machine creeps in either direction grasp the body of the potentiometer and rotate it forward or backward until neutral is obtained 17 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section ...

Page 178: ...Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section ATTENTION Double check to make sure the batteries are disconnected from the machine 2 Remove the steering handle See TO REMOVE STEERING HANDLE instructions in this section 3 Locate the wire harness coming from the potentiometer and leading to the circuit board on the lower right hand side of the electrica...

Page 179: ...n the right hand side of the circuit board 6 Cut any of the plastic wire ties that are holding the potentiometer wire harness to the main harness 7 Loosen the jam nut that is holding the potentiometer to the steering console 8 Pull the potentiometer straight out of the slot Remove the potentiometer from the machine 9 Loosen the set screw holding the gear to the potentiometer Remove the gear ...

Page 180: ...NTION Do not over tighten the jam nut Lightly hand tighten only 12 Route the wire harness back to the circuit board Plug the small red potentiometer harness connector back onto the right hand side of the circuit board NOTE The red connector will only install with the two tabs pointing up and the wire pointing down Do not force it on 13 Put a small amount of dielectric grease on the terminals of th...

Page 181: ...ry cable to the battery nearest the back of the machine 17 Turn on the machine and check for proper neutral centering If the machine creeps in either direction grasp the body of the potentiometer and rotate it forward or backward until neutral is obtained ATTENTION Do not over tighten the jam nut Lightly hand tighten only 18 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructio...

Page 182: ... Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section ATTENTION Double check to make sure the batteries are disconnected from the machine 2 Remove the steering handle See TO REMOVE STEERING HANDLE instructions in this section 3 Locate the wire harness coming from the potentiometer and leading to the circuit board on the lower right hand side of the electric...

Page 183: ...tom center of the smaller power steering circuit board 6 Cut any of the plastic wire ties that are holding the potentiometer wire harness to the main harness 7 Loosen the set screw holding the gear to the potentiometer Remove the gear 8 Loosen the jam nut holding the potentiometer to the mount bracket 9 Pull the potentiometer straight out of the mount bracket Remove the potentiometer from the mach...

Page 184: ...NTION Do not over tighten the jam nut Lightly hand tighten only 12 Route the wire harness back to the circuit board Plug the small red potentiometer harness connector back onto the right hand side of the circuit board NOTE The red connector will only install with the two tabs pointing up and the wire pointing down Do not force it on 13 Put a small amount of dielectric grease on the terminals of th...

Page 185: ...ry cable to the battery nearest the back of the machine 17 Turn on the machine and check for proper neutral centering If the machine creeps in either direction grasp the body of the potentiometer and rotate it forward or backward until neutral is obtained ATTENTION Do not over tighten the jam nut Lightly hand tighten only 18 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructio...

Page 186: ...On Level Surface Set parking brake optional Turn Off Machine And Remove Key 1 Remove the instrument panel See TO REMOVE INSTRUMENT PANEL instructions in this section 2 Remove the M6 hex screw holding the steering potentiometer clamp bracket to the steering pivot bracket Remove clamp 3 Disconnect the potentiometer from the circuit board ...

Page 187: ... the set screw holding the gear to the potentiometer Remove the gear 6 Remove the clamp bracket Pull the potentiometer straight out of the hole and remove it from the machine 7 Position the new potentiometer back on the mounting hole Reinstall the clamp bracket Tighten the M6 hex screw to 11 14 Nm 7 10 ft lb NOTE Make sure the washer is in position ...

Page 188: ...ire harness back to the circuit board 10 Secure the potentiometer wire harness to the main harness routing with wire ties or electrical tape 11 Put a small amount of dielectric grease on the terminals of this low voltage circuit to protect it against condensation and corrosion part 86385 12 Reinstall the instrument panel See TO INSTALL INSTRUMENT PANEL instructions in this section 13 Re connect th...

Page 189: ...The scrub heads are available in two brush type and three widths The scrub heads are interchangeable when the scrub brush motor circuit breakers installed in the operator console match the circuit breakers needed as shown in the circuit breaker chart ...

Page 190: ...ator console Interchanging the scrub heads without changing the scrub brush motor circuit breakers will cause the scrub brush motors or circuit breakers to fail NOTE When you change to a different width scrub head be sure to install the appropriate width squeegee and machine front cover The front cover for the cylindrical brush scrub head has a cutout on both sides for clearance when the head is i...

Page 191: ...battery cable from the battery nearest the back of the machine before servicing any electrical components FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set parking brake optional Turn Off Machine And Remove Key 2 Remove the two M8 hex screws holding the top of the instrument panel to the electrical panel 3 Tilt the instrument panel assembly back until the lanyard strap is ti...

Page 192: ...the machine 6 Pull the original circuit breaker out and disconnect the 60A 60B yellow and 62A blue wires on all models On the 5700 machine disconnect the remaining 64A grey wire On the 5700XP and 5700XPS machines disconnect the remaining 64A purple wire Remove both of the scrub head circuit breakers from the machine 7 Reconnect the wires in the reverse order to the new circuit breakers 8 Position ...

Page 193: ...Reinstall the two M8 hex screws and tighten NOTE Make sure all the wires are out of the way of any pinch points when pivoting the instrument panel back into position 10 Reconnect the battery cable to the rear battery 11 Lower the solution tank and operate the machine checking for proper scrub brush operation ...

Page 194: ...SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set parking brake optional Turn Off Machine And Remove Key 2 Raise the solution tank until the prop rod is engaged 3 Remove the four M8 hex screws holding the front cover to the machine Remove the cover 4 Unplug the scrub head lift actuator from the main harness ...

Page 195: ...Be sure to mark the actuator position to keep the scrub head adjustment set correctly 6 Remove the cotter pin and clevis pin from the bottom of the head lift actuator 7 Remove the cotter pin and clevis pin from the top of the head lift actuator 8 The head lift actuator can now be removed from the machine NOTE Be careful not to rotate the actuator tube ...

Page 196: ...et Install the clevis and cotter pin 11 Plug the actuator into the main harness See the schematic in this section NOTE Make sure the actuator tube lines up with the mark made earlier on the shaft of the actuator that was removed If not turn the actuator tube until it does 12 Align the mounting hole in the bottom of the scrub head lift actuator with the hole in the scrub head actuator mount bracket...

Page 197: ... the propel circuit is lightly activated Press the scrub brush up and off button When the scrub brush stops going up press the scrub brush up and off button once more This will properly adjust the actuator 15 The scrub head guide roller should now be almost at the top of the slot on the roller guide bracket If the roller is not at the top of the slot loosen the four M8 hex screws and adjust the ro...

Page 198: ...Stop On Level Surface Set parking brake optional 1 Lower the squeegee to the floor Turn off the machine 2 Locate the squeegee lift actuator on the lower right side of the machine Un plug the actuator from the main harness 3 Remove the two hair pins and two clevis pins holding the squeegee lift actuator to the mounting bracket ...

Page 199: ...om the machine with the actuator inside it 5 Remove the actuator from the mounting bracket 6 Position the new lift actuator in the mounting bracket with the motor facing forward and down 7 Position the actuator mount bracket on the machine Reinstall the three M8 hex screws Leave the hardware loose for now 8 Reinstall the two clevis pins and hair pins ...

Page 200: ...he gap between the top of the roller on the auto squeegee and the bottom of the Y bar on the squeegee arms This gap should be 0 125 to 0 250 in 13 If the gap is more than 0 250 in or less than 125 in the three hex screws holding the actuator mount bracket to the frame must be loosened and the bracket slid back until the gap is correct 14 Tighten the three hex screws to 18 24 Nm 15 20 ft lb 15 Star...

Page 201: ... be inspected after every 1000 hours of machine operation TO REPLACE STANDARD DISK SCRUB BRUSH MOTOR 1 Raise the solution tank until the prop rod is engaged FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set parking brake optional Turn Off Machine And Remove Key 2 Remove the four M8 hex screws holding the front cover to the machine Remove the cover 3 Unplug the brush motor fr...

Page 202: ...ttom of the brush motor shaft 6 Slide the brush drive plug off the brush motor shaft Be careful not to lose the square key on the shaft NOTE The right side motor is mounted in slotted holes When removing this motor mark the position so the proper brush overlap is maintained 7 Remove the four 0 25 in hex screws and Belleville washers holding the brush motor to the scrub head NOTE The orientation of...

Page 203: ...te 242 blue and tighten to 11 14 Nm 7 10 ft lb NOTE The right side motor is mounted in slotted holes When installing this motor make sure that a slight amount of brush overlap is maintained for proper scrubbing performance 12 Apply a small amount of EMB lubriplate water proof grease to the brush motor shaft part 01433 1 Make sure that the square key is in place and slide the brush drive plug onto ...

Page 204: ...the scrub brush motor into the scrub head harness See the schematic in this section 16 Start the machine and check the scrub head for proper brush rotation and overlap 17 Reinstall the front cover using the four M8 hex screws Tighten to 18 24 Nm 15 20 ft lb 18 Lower the solution tank operate the machine check for proper operation proper rotation ...

Page 205: ...ke optional Turn Off Machine And Remove Key 1 Raise the solution tank until the prop rod is engaged FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set parking brake optional Turn Off Machine And Remove Key 2 Remove the four M8 hex screws holding the front cover to the machine Remove the cover 3 Unplug the brush motor from the scrub head harness ...

Page 206: ...ush drive plug and spacer off the brush motor shaft Be careful not to lose the square key on the shaft NOTE The right side motor is mounted in slotted holes When removing this motor mark the position so the proper brush overlap is maintained 7 Remove the four M8 hex screws washers and nyloc nut holding the brush motor and adapter to the scrub head NOTE The orientation of the wires coming out of th...

Page 207: ... the center of the scrub head 12 Align the four holes in the scrub head with the holes in the motor adapter plate Reinstall the four M8 hex screws washers and nyloc nuts Tighten to 18 24 Nm 15 20 ft lb 13 Apply a small amount of EMB lubriplate water proof grease to the brush motor shaft part 01433 1 14 Make sure that the spacer ring and square key are in place Slide the brush drive plug on the bru...

Page 208: ...atic in the ELECTRICAL section of this manual 18 Start the machine and check the scrub head for proper brush rotation and overlap 19 Reinstall the front cover using the four M8 hex screws Tighten to 18 24 Nm 15 20 ft lb 20 Lower the solution tank operate the machine check for proper operation proper rotation ...

Page 209: ... Set parking brake optional Turn Off Machine And Remove Key 1 Raise the solution tank until the prop rod is engaged 2 Remove the four M8 hex screws holding the front cover to the machine Remove the cover 3 Remove the scrub brush from the motor that needs to be changed See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in the SCRUBBING section ...

Page 210: ...crews holding the belt cover on the motor that needs changing Remove the cover from the scrub head 6 Loosen the M8 hex nut on the belt tension bolt under the motor Turn the tension bolt down far enough to slip the belt off the pulley 7 Unplug the brush motor from the scrub head harness Main harness Unhook here Unhook here ...

Page 211: ...ush motor shaft Slide the pulley off the shaft Make sure not to loose the square key 10 Reinstall the square key and cogged pulley on the shaft of the new motor 11 Position the brush motor on the scrub head Align the mounting holes on the motor with the holes in the mounting bracket on the scrub head Reinstall the one M8 flat head screw one M8 hex screw and two M8 nyloc nuts Snug the hardware for ...

Page 212: ...e M8 hex screw located under the brush motor tension the belt by applying 2 5 2 7 lbs of force per belt at the middle of the span that is opposite the belt travel with a deflection of 0 10 inch 15 Tighten the two pivot bolts to 18 24 Nm 15 20 ft lb Re check the belt tension 16 Plug the scrub brush motor into the scrub head harness See the schematic in this section 2 5 2 7 lbs Main harness connect ...

Page 213: ...er to keep dust out 18 Reinstall the scrub brush See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in the SCRUBBING section 19 Start the machine and check the scrub head for proper brush rotation 20 Reinstall the front cover using the four M8 hex screws Tighten to 18 24 Nm 15 20 ft lb 21 Lower the solution tank operate the machine and check for proper operation proper rotation ...

Page 214: ...rking brake optional Turn Off Machine And Remove Key 1 Lift the solution tank and engage the prop rod 2 Disconnect the batteries from machine NOTE Disconnect the negative battery cable from the battery nearest the back of the machine before servicing any electrical components 3 Remove the four M8 hex screws holding the front cover on the machine Remove the cover ...

Page 215: ...g the four motor brushes into the slots 6 Remove the pan head screws holding the wire leads coming from the brushes to the motor plate 7 Remove the brushes from the motor 8 Position the new brushes in the slots 9 Position the spring clips back on top of the brushes 10 Reinstall the four wire leads to the motor plate using the four pan head screws Hand tighten tight ...

Page 216: ...ighten to 11 14 Nm 7 10 ft lb 12 Reinstall the front cover Reinstall the four M8 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 13 Re connect the negative battery cable to the battery nearest the back of the machine 14 Close the solution tank and operate the scrub head checking the scrub brush motor for proper operation ...

Page 217: ...arking brake optional Turn Off Machine And Remove Key 1 Lift the solution tank and engage the prop rod 2 Disconnect the batteries from machine NOTE Disconnect the negative battery cable from the battery nearest the back of the machine before servicing any electrical components 3 Remove the four M8 hex screws holding the front cover on the machine Remove the cover ...

Page 218: ...x screws holding the end plate to the top of motor 6 Carefully remove the end plate The brushes and spring clips are attached to the end plate NOTE There are marks on the motor and on the end plate that must line up when re assembling brush motor 7 Undo the spring clips holding the four motor brushes in the slots ...

Page 219: ... on top of the brushes 12 Reinstall the four wire leads to the end plate using the four pan head screws Hand tighten tight NOTE There are marks on the motor and on the end plate that must line up when re assembling brush motor 13 Reinstall the end plate and brushes back on the motor Reinstall the two long hex screws and tighten to 11 14 Nm 7 10 ft lb NOTE The brushes must be pushed back in the slo...

Page 220: ...s section 15 Reinstall the front cover Reinstall the four M8 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 16 Re connect the negative battery cable to the battery nearest the back of the machine 17 Close the solution tank and operate the scrub head checking the scrub brush motor for proper operation ...

Page 221: ...Surface Set parking brake optional Turn Off Machine And Remove Key 1 Remove the cylindrical scrub brush motor from the machine See TO REPLACE CYLINDRICAL SCRUB BRUSH MOTOR instructions in the SCRUBBING section of this manual 2 Remove the four plastic caps covering the brushes 3 Remove the four allen screws that are holding the brushes in the motor ...

Page 222: ...new brushes back in the motor 6 Reinstall the four allen screws that retain the brushes in their slot Lightly hand tighten 7 Reinstall the scrub brush motor to the scrub head See TO REPLACE CYLINDRICAL SCRUB BRUSH MOTOR instructions in the SCRUBBING section of this manual 8 Reinstall the front cover Reinstall the four M8 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb ...

Page 223: ...03 5680 5700 MM406 9 01 9 Re connect the negative battery cable to the battery nearest the back of the machine 10 Close the solution tank and operate the scrub head checking the scrub brush motor for proper operation ...

Page 224: ... Remove the transaxle from the machine See TO REMOVE PROPELLING TRANSAXLE instructions in the CHASSIS section 2 After the transaxle is removed from the machine place it in a large vice with the drive motor facing up 3 Remove the three M8 hex screws holding the electric drive motor to the transaxle housing 4 Pull the drive motor straight out of the transaxle NOTE Note the orientation of the motor t...

Page 225: ...einstall the C clip 7 Position the new motor back on the transaxle Make sure the teeth on the motor gear line up with the teeth on the transaxle gear NOTE Note the orientation of the motor to the housing 8 Reinstall the three M8 hex screws and tighten to 18 24 Nm 15 20 ft lb 9 Reinstall the transaxle in the machine See TO INSTALL PROPELLING TRANSAXLE instructions in the CHASSIS section 10 Operate ...

Page 226: ...e black plastic cover from on the top of the fan assembly by spreading the clips on both sides and lifting straight off 3 Remove the two pan head screws holding the brush retaining U clip to the fan motor Remove the U clip 4 Pull the green plastic housing back until the wire lead is exposed Pull the wire lead connector straight out of the green plastic housing 5 Push the wire lead connector in the...

Page 227: ...ap the black plastic cover back on the top of the motor 8 Reinstall the vacuum fan motor into the machine See TO REPLACE VACUUM FAN S instructions in the SCRUBBING section of this manual 9 Operate the vacuum fan s and check for proper operation ...

Page 228: ...ELECTRICAL 5680 5700 MM406 6 03 4 108 Electrical Schematic 5680 000000 012929 1 2 3 4 5 6 7 8 353412 5680 ...

Page 229: ...ELECTRICAL 4 109 5680 5700 MM496 6 03 Electrical Schematic 5680 000000 012929 1 2 3 4 5 6 7 8 353412 5680 ...

Page 230: ...ELECTRICAL 5680 5700 MM406 6 03 4 110 Electrical Schematic 5680 012930 1 2 3 4 5 6 7 8 353412 374231 ...

Page 231: ...ELECTRICAL 4 111 5680 5700 MM496 6 03 Electrical Schematic 5680 012930 1 2 3 4 5 6 7 8 353412 374231 ...

Page 232: ...ELECTRICAL 5680 5700 MM406 6 03 4 112 Electrical Schematic 5700 000000 021999 2 3 4 1 10282 5700 NA JP CE ...

Page 233: ...ELECTRICAL 4 113 5680 5700 MM496 6 03 Electrical Schematic 5700 000000 021999 2 3 4 1 10282 5700 NA JP CE ...

Page 234: ...ELECTRICAL 5680 5700 MM406 6 03 4 114 Electrical Schematic 5700 022000 2 3 1 534040 397904 5700 NA JP CE ...

Page 235: ...ELECTRICAL 4 115 5680 5700 MM496 6 03 Electrical Schematic 5700 022000 2 3 1 354040 397904 5700 NA JP CE ...

Page 236: ...ELECTRICAL 5680 5700 MM406 6 03 4 116 Electrical Schematic 5700EE 2 3 4 1 10433 EE NA ...

Page 237: ...ELECTRICAL 4 117 5680 5700 MM496 6 03 Electrical Schematic 5700EE 10433 EE NA 3 4 2 1 ...

Page 238: ...ELECTRICAL 5680 5700 MM406 6 03 4 118 Electrical Schematic 5700XP 000000 021999 2 3 1 10283 XP NA CE ...

Page 239: ...ELECTRICAL 4 119 5680 5700 MM496 6 03 Electrical Schematic 5700XP 000000 021999 10283 XP NA CE 2 3 1 ...

Page 240: ...ELECTRICAL 5680 5700 MM406 6 03 4 120 Electrical Schematic 5700XP 022000 8 1 2 3 4 6 7 5 354041 397910 XP NA CE ...

Page 241: ...ELECTRICAL 4 121 5680 5700 MM496 6 03 Electrical Schematic 5700XP 022000 1 2 3 4 5 6 7 8 354041 397910 XP NA CE ...

Page 242: ...ELECTRICAL 5680 5700 MM406 6 03 4 122 Electrical Schematic 5700XPS 2 3 1 10284 XPS NA JP CE ...

Page 243: ...ELECTRICAL 4 123 5680 5700 MM496 6 03 Electrical Schematic 5700XPS 10284 XPS NA JP CE 2 3 1 ...

Page 244: ...ELECTRICAL 5680 5700 MM406 6 03 4 124 Wire Harness Group 5680 000000 012929 1 of 2 SEE NEXT PAGE SEE NEXT PAGE ...

Page 245: ...ELECTRICAL 4 125 5680 5700 MM496 6 03 Wire Harness Group 5680 000000 012929 2 of 2 ...

Page 246: ...ELECTRICAL 5680 5700 MM406 6 03 4 126 Wire Harness Group 5680 012930 1 of 3 ...

Page 247: ...ELECTRICAL 4 127 5680 5700 MM496 6 03 Wire Harness Group 5680 012930 2 of 3 ...

Page 248: ...ELECTRICAL 5680 5700 MM406 6 03 4 128 Wire Harness Group 5680 012930 3 of 3 ...

Page 249: ...SHUNT 62A BLU 62B BLU 87A CLR 13S BLK 56 PUR ES PUMP 13M BLK 47A GRY 30 PUR 31 BRN 64A GRY 13EE BLK 13DD BLK 13U BLK 13V BLK 88A BLK 66A GRN UPPER TANK LEVEL SWITCH LOWER TANK ES LEVEL SWITCH 13R BLK 54 BRN 53 GRN 13G BLK 40 GRN 18C YEL 66B GRN 64B BLU LEFT BRUSH MOTOR RIGHT BRUSH MOTOR SOLUTION SOLENOID VALVE 44 PUR 45 GRY 46 GRY 13T BLK 58 BLU GRN BLU BLK RED POWER WAND PUMP HEADLIFT ACTUATOR PR...

Page 250: ...T SWITCH KEY SWITCH POWER ON LIGHT HOURMETER SCRUB LIGHT BRUSH HEADLIFT SWITCH TANK FULL LIGHT LIGHTED ES SWITCH STOP 9C GRN 9 GRN 5 ORG 6 BLU SHIELDED CABLE DOWN PRESSURE 46A BLU 13J BLK 13CC BLK BLK RED WHT 88 BLK 87 CLR 18G YEL 51 GRY 13D BLK 13P BLK 41 BLU 13J BLK 13D BLK 9C GRN 9D GRN 13H BLK 13L BLK 13K BLK 58 BLU 18H YEL 3 ORG 18H YEL 18A YEL 60B YEL 64A GRY 60A YEL 62A BLU 13C BLK 13B BLK ...

Page 251: ... BLK 1A RED CONTACTOR M1 VIEW C C 47B GRY CONTACTOR M2 VIEW B B 60 YEL 47A GRY 3C ORA 13E BLK 13N BLK M1 CONTACTOR VIEW C C C C B BCONTACTOR VIEW B B M2 51B GRY 52 GRN 13Q BLK 13C BLK 1B RED 2 RED 3D ORA 70 BLU 43 GRN 13HH BLK 13N BLK TIMER M3 53 M6 M4 M5 56 47C 47D 26 27 46A 46 41 42 40 18D M6 M5 M4 M5 M4 A A NUMBERS CAST INTO PLUG SHOWN FOR REF ONLY RELAY TERMINAL HOUSING RELAYS SECTION A A 51B ...

Page 252: ...ELECTRICAL 5680 5700 MM406 6 03 4 132 Wire Harness Group 5700 022000 1 of 3 ...

Page 253: ...ELECTRICAL 4 133 5680 5700 MM496 6 03 Wire Harness Group 5700 022000 2 of 3 ...

Page 254: ...ELECTRICAL 5680 5700 MM406 6 03 4 134 Wire Harness Group 5700 022000 3 of 3 ...

Page 255: ...2B BLU 87A CLR 13S BLK 56 PUR ES PUMP 13M BLK 47A GRY 30 PUR 31 BRN 64A GRY 13EE BLK 13DD BLK 13U BLK 13V BLK 88A BLK 66A GRN UPPER TANK LEVEL SWITCH LOWER TANK ES LEVEL SWITCH 13R BLK 54 BRN 53 GRN 13G BLK 40 GRN 18C YEL 66B GRN 64B BLU LEFT BRUSH MOTOR RIGHT BRUSH MOTOR SOLUTION SOLENOID VALVE 44 PUR 45 GRY 46 GRY 13T BLK 58 BLU GRN BLU BLK RED POWER WAND PUMP HEADLIFT ACTUATOR PROPEL MOTOR VAC ...

Page 256: ...TCH POWER ON LIGHT HOURMETER SCRUB LIGHT BRUSH HEADLIFT SWITCH TANK FULL LIGHT LIGHTED ES SWITCH STOP 9C GRN 9 GRN 5 ORG 6 BLU SHIELDED CABLE DOWN PRESSURE 46A BLU 13J BLK 13CC BLK BLK RED WHT 88 BLK 87 CLR 18G YEL 51 GRY 13D BLK 13P BLK 41 BLU 13J BLK 13D BLK 9C GRN 9D GRN 13H BLK 13L BLK 13K BLK 58 BLU 18H YEL 3 ORG 18H YEL 18A YEL 60B YEL 64A GRY 60A YEL 62A BLU 13C BLK 13B BLK 9B GRN 13B BLK 2...

Page 257: ...7B GRY CONTACTOR M2 VIEW B B 60 YEL 47A GRY 3C ORA 13E BLK 13N BLK M1 CONTACTOR VIEW C C C C B BCONTACTOR VIEW B B M2 51B GRY 52 GRN 13Q BLK 13C BLK 1B RED 2 RED TIMER 53 M6 M4 M5 56 47C 47D 26 27 46A 46 41 42 40 18D M6 M5 M4 M5 M4 A A NUMBERS CAST INTO PLUG SHOWN FOR REF ONLY RELAY TERMINAL HOUSING RELAYS SECTION A A 51B 51A 52 51A 51 87A 30 85 87 86 M6 9F GRN 3A ORG 3 ORG 3C ORG 3D ORG 13E BLK 1...

Page 258: ...RN 71B BRN OPTIONAL VAC FAN C 2 1 SHUNT 66A GRN 62B BLU 30 PUR 31 BRN 64A PUR 13EE BLK 13DD BLK 13U BLK 13V BLK 88A BLK UPPER TANK LEVEL SWITCH LOWER TANK ES LEVEL SWITCH 13R BLK 13G BLK 40 GRN 18C YEL 66B GRN 64B BLU LEFT BRUSH MOTOR RIGHT BRUSH MOTOR SOLUTION SOLENOID VALVE 44 PUR 45 GRY 13T BLK 58 BLU BLK RED POWER WAND PUMP HEADLIFT ACTUATOR PROPEL MOTOR VAC FAN BATTERIES 51 GRN 50 BLU SQUEEGE...

Page 259: ...L 13D BLK 18R YEL BDI 4 2 1 3 1 2 3 13GG BLK CB 1 2 5 AMP CB 4 10 AMP CONTROL POWER LIGHTED POWER WAND SWITCH 25 AMP 20 OR 40 AMP 20 OR 35 AMP 20 OR 35 AMP CB 5 BRUSH MOTOR BRUSH MOTOR CB 6 DIODE BRIDGE D1 PROPEL VAC FAN POWER UP CB 3 CB 2 KEY SWITCH HOURMETER STOP 9 GRN 5 ORG 6 BLU 58 BLU 3 ORG 18A YEL 60B YEL 60A YEL 62A BLU 9 GRN 13B BLK 5 ORG 4 YEL 1C RED 1B RED 71A BRN 70 BLU 12B BLU 12A BLU ...

Page 260: ... 47 GRY 50 BLU 10 ORG 13L BLK 18E YEL 45 GRY 44 PUR 13Q BLK 18D YEL 15 14 13 12 10 9 8 7 11 6 12 11 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 3 2 1 15 14 13 12 11 10 9 8 7 6 12 11 10 9 8 7 6 5 3 2 1 WIRE NO SOCKET NO SOCKET NO WIRE NO 1 2 3 4 5 4 3 2 1 WIRE NO SOCKET NO SHIELDED CABLE 47 GRY 60 YEL 18K YEL 18J YEL 18J YEL 12C BLU 12D BLU 13C BLK 32 PUR 33 BRN SEE VIEW B B CURTIS PROPEL CONTROLLER 1203 B B M1...

Page 261: ...ELECTRICAL 4 141 5680 5700 MM496 6 03 Wire Harness Group 5700XP 022000 1 of 3 ...

Page 262: ...ELECTRICAL 5680 5700 MM406 6 03 4 142 Wire Harness Group 5700XP 022000 2 of 3 ...

Page 263: ...ELECTRICAL 4 143 5680 5700 MM496 6 03 Wire Harness Group 5700XP 022000 3 of 3 ...

Page 264: ...ELECTRICAL 5680 5700 MM406 6 03 4 144 Wire Harness Group FaSTt t t t 5700 and 5700XP ...

Page 265: ...S 13FF 13W 13Z 88 BLK 71B BRN 71C BRN OPTIONAL VAC FAN C 2 1 SHUNT 62A BLU 66A GRN 62B BLU 30 PUR 31 BRN 64A PUR 13EE BLK 13DD BLK 13U BLK 13V BLK 48 GRY 18N YEL 40 GRN 13R BLK 18G ORG 13G BLK 18C YEL 88A BLK 66B GRN 64B BLU SOLUTION SOLENOID VALVE LEFT BRUSH MOTOR RED BLK 13T BLK 58 BLU POWER WAND PUMP RIGHT BRUSH MOTOR HEADLIFT ACTUATOR PROPEL MOTOR VAC FAN BATTERIES 44 PUR 45 GRY 51 GRN 50 BLU ...

Page 266: ... POWER WAND SWITCH 20 OR 35 AMP BRUSH MOTOR CB 5 20 OR 35 AMP BRUSH MOTOR CB 6 D1 DIODE BRIDGE 20 OR 40 AMP 25 AMP PROPEL VAC FAN CB 2 CB 1 2 5 AMP CB 3 POWER UP KEY SWITCH STOP 9 GRN 5 ORG 6 BLU 13D BLK 13GG BLK 18B YEL 58 BLU 3 ORG 18R YEL 18A YEL 60B YEL 64A PUR 60A YEL 62A BLU 10 ORG 13B BLK 9 GRN 9D GRN 4 YEL 5 ORG 4 YEL 1B RED 1C RED 71A BRN 70 BLU 12B BLU 12A BLU 3A ORG 1C RED 12A BLU HOURM...

Page 267: ...12 11 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 3 2 1 47 GRY 13L BLK 51 GRN 46 PUR 48 GRY 43 GRN 50 BLU 10 ORG 18E YEL 45 GRY 44 PUR 13Q BLK 18D YEL 15 14 13 12 11 10 9 8 7 6 18H YEL 42 BRN 40 GRN 54 BLU 13P BLK 12 11 10 9 8 7 6 5 88 RED 87 WHT 13CC SHLD 3 2 1 WIRE NO SOCKET NO SOCKET NO WIRE NO 1 2 3 4 5 4 3 2 1 WIRE NO SOCKET NO SHIELDED CABLE SEE VIEW B B SEE VIEW B B 1A RED CONTACTOR M1 VIEW B B 60 YEL C...

Page 268: ...ELECTRICAL 5680 5700 MM406 NIL 4 148 ...

Page 269: ...680 5700 MM406 6 03 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 270: ... CB 1 M1 2 RED 13 BLK 1 RED 2 5A 1B RED 4 YEL 5 ORA 6 BLU 9 GRN 9B GRN 9C GRN 9D GRN 13C BLK 13H BLK 13K BLK LT 1 V KEY SWITCH BATTERY CHARGER CONNECTOR 1A RED M1 PROPEL POT 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC OPT STOP SW POWER ON VOLT 9 GRN 13B BLK HR 2 1 OPT ...

Page 271: ... REPLACE CB 1 REPAIR OR REPLACE REPAIR OR REPLACE 4 YEL CHECK VOLTAGE AT KEY SWITCH 4 YEL TO BATT NEG RESET OR CHECK VOLTAGE AT KEY SWITCH 5 ORA TO BATT NEG REPLACE KEY SWITCH NO YES CHECK VOLTAGE AT M1 9D GRN TO BATT NEG NO YES REPAIR OR REPLACE 9D GRN NOTE OPT STOP SWITCH CHECK VOLTAGE AT M1 13K BLK TO 1 RED AT BATT POS YES REPLACE M1 NO REPAIR OR REPLACE 13K BLK CONNECTIONS TO BATTERY ...

Page 272: ...52 5700 PROPEL CIRCUIT MTR CB 3 25A P1 6 B B M1 M2 P1 3 P1 2 P1 1 B PROPEL MOTOR CONTROLLER PUR 31 BRN GRN 12B BLU 13F BLK 1 RED M1 3A ORA PROPEL MOTOR BLK RED WHT PROPEL POT 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC PROPEL CONTROL SUB HARNESS ...

Page 273: ...IR OR 3A ORA REPLACE REPAIR OR REPLACE 12B BLU CHECK VOLTAGE AT PROPEL CONTROLLER TO BATT NEG RESET OR CHECK VOLTAGE AT NO YES 30 PUR TO 31 BRN CHECK VOLTAGE YES REPLACE NO REPAIR OR REPLACE PROPEL CONTROLLER 13F BLK TO 1 RED BATT POS 12B BLU REPAIR OR REPLACE 13F BLK THROTTLE HANDLE IN FORWARD CHECK VOLTAGE PROPEL CONTROLLER ACROSS ACROSS PROPEL MOTOR 30 PUR TO 31 BRN 30 PUR 31 BRN PROPEL MOTOR C...

Page 274: ... MOTOR CONTROLLER SAFETY NOTE CAN NOT PROPEL WITH THIS WIRE DISCONNECTED DISCONNECT POT FROM PROPEL MOTOR CONTROLLER CHECK VOLTAGES P1 3 0 V AT CONTROL BOARD P1 1 5 V ACROSS WHT RED TURN THROTTLE BACK AND FORTH 0 OHM 5K OHM 300 OHM BAD REPLACE POT REPLACE PROPEL MOTOR CONTROLLER CONTROLLER GOOD REPLACE PROPEL MOTOR CONTROLLER TO MACHINE GROUND ...

Page 275: ...700 HEAD LIFT CIRCUIT MTR 1 RED M1 3 ORA CB 4 10A 18A YEL 18E YEL 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 13L BLK BRUSH HEAD LIFT SWITCH 44 PUR 45 GRY BLU BLK RED DN LIMIT UP LIMIT BR HD LIFT ACTUATOR BR MTR SW 18F YEL SW3 UP DN 44A PUR 45A GRY ...

Page 276: ...EL 3 ORA 18A YEL REPLACE CB 4 REPAIR OR 3 ORA REPLACE REPAIR OR REPLACE 18E YEL CHECK VOLTAGE AT HEAD LIFT SWITCH 18E YEL TO BATT NEG RESET OR CHECK VOLTAGE 44 PUR TO 45 GRY REPLACE HEAD LIFT SWITCH NO YES CHECK VOLTAGE AT NO YES REPAIR OR REPLACE KEY ON SW3 HELD IN DOWN POSITION AT HEAD LIFT SWITCH 44 PUR TO 45 GRY HEAD LIFT ACTUATOR 44 PUR OR REPLACE HEAD LIFT ACTUATOR 45 GRY ...

Page 277: ...LK 13J BLK 47A GRY 47B GRY 46A BLU M4 LT 3 87 30 SOL 1 SCRUB 46 BLU BLU DN LIMIT UP LIMIT BR HD LIFT ACTUATOR BR MTR SW 18F YEL RIGHT BRUSH LEFT BRUSH CB 5 CB 6 M 2 3C ORA 60 YEL 62B BLU 64B PUR 62A BLU 64A PUR 60A YEL 60B YEL 66A GRN 66B GRN CURRENT SHUNT HARNESS MULTI TAP BR MTR CURRENT SHUNT 88A RED 87 WHT 88 RED BR DN PRESSURE 13CC BLK 13U BLK 13V BLK 13DD BLK 13EE BLK SHIELD SCRUB MODE 20A 35...

Page 278: ...D LIFT ACTUATOR DOES SCRUB MODE LIGHT COME ON ACTUATOR 18F YEL TO BATT NEG YES NO ENGAGE FWD 26 GRY TO 27 BRN REPLACE PROPEL MOTOR CONTROLLER CHECK VOLTAGE AT M4 46 BLU TO BATT NEG YES NO REPAIR OR REPLACE 46 BLU CHECK VOLTAGE AT M4 47B GRY TO BATT NEG NO YES REPLACE M4 CHECK VOLTAGE AT M2 47B GRY TO BATT NEG NO YES CONT NEXT PAGE REPAIR OR REPLACE 47B GRY IF ONE MOTOR WORKS CHECK INDIVIDUAL CIRCU...

Page 279: ...AGE AT M2 13E BLK TO BATT POS YES CHECK VOLTAGE AT M2 3C ORA TO BATT NEG CHECK VOLTAGE AT M2 60 YEL TO BATT NEG REPLACE M2 CHECK VOLTAGE AT BRUSH MOTOR CB S 60A 60B YEL TO BATT NEG REPAIR OR REPLACE 60 YELLOWS CHECK VOLTAGE AT SHUNT HARNESS 13U 13V BLK TO BATT POS NO REPAIR OR REPLACE 13U 13V BLK REPLACE SHUNT HARNESS ASSEMBLY ...

Page 280: ...6 VDC 6 VDC 6 VDC 6 VDC M5 M3 LT 2 13N BLK 13D BLK 13HH BLK 13G BLK 43A GRN 40 GRN 87 30 41 BLU 42 GRY 43 GRN SQUEEGEE LIMIT TANK FULL M5 C N O B LEVEL SW BLK BRN CB 2 M 3 70 BLU 71A BRN 3D ORA 20 40A 71B BRN 71C BRN 13Z BLK 13X BLK 13Y BLK VAC FAN OPT VAC FAN VAC FAN TANK FULL C A SQUEEGEE CIRCUIT NORMALLY CLOSED HELD OPEN ...

Page 281: ...PLACE 42 GRY CHECK VOLTAGE AT M5 40 GRN TO BATT NEG NO YES CONT NEXT PAGE NOTE THIS MACHINE USES SOLID STATE LIQUID LEVEL SWITCHES MAKE SURE THAT THEY ARE CLEAN THIS TEST ASSUMES THAT THE LIQUID LEVEL IN RECOVERY TANK IS LOWER THAN THE UPPER LEVEL SWITCH IS RED LIGHT ON THE UPPER LEVEL SWITCH ON CHECK VOLTAGE 18 YEL TO BATT NEG NO YES IS THE RECOVERY TANK FULL YES EMPTY TANK NO CLEAN OR REPLACE TH...

Page 282: ...R 3D ORA REPLACE CHECK VOLTAGE AT M3 70 BLU TO BATT NEG NO REPLACE M3 YES VAC FAN 71B BRN TO BATT NEG REPAIR OR 71A 71B BRN REPLACE CHECK VOLTAGE AT VAC FAN 13X BLK 13Z BLK NO YES REPAIR OR REPLACE 13X 13Z BLK REPLACE VAC FAN MOTOR TO BATT POS CHECK VOLTAGE YES NO 13N BLK TO BATT POS AT M3 43A GRN TO BATT NEG REPAIR OR REPLACE 43 43A GRN CHECK VOLTAGE AT M3 YES NO REPAIR OR REPLACE 13N BLK CHECK V...

Page 283: ...OL BOARD TRY SPEED AND DOWN PRESSURE PUSH BUTTONS ARE LIGHTS LIT ON THE TOUCH PANEL YES IS PROPEL WORKING NO DEFINE PROBLEM NO YES IS PROBLEM WITH BRUSH MOTORS OR HEAD LIFT OPERATION NO SEE BRUSH AND HEAD LIFT TROUBLESHOOTING IS PROBLEM WITH SQUEEGEE AND OR VAC FAN OPERATION SEE VAC FAN SQUEEGEE TROUBLESHOOTING IS PROBLEM WITH SOLUTION FLOW SOLENOID ES PUMP OR HOURMETER YES SEE SOLUTION ES PUMP AN...

Page 284: ... M1 2 RED 13 BLK 1 RED 2 5A 1B 4 YEL 5 ORA 6 BLU 9 GRN 13E BLK KEY SWITCH BATTERY CHARGER CONNECTOR 1A RED M1 3 ORA 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC OPT STOP SW RED P4 1 P4 5 36 VDC CONTROL GROUND 18H YEL 18J YEL 13P BLK 13BB BLK 9E GRN 9D GRN TOUCH PANEL MACHINE CONTROLLER ...

Page 285: ...OR 1B RED REPLACE REPAIR OR REPLACE 4 YEL CHECK VOLTAGE AT KEY SWITCH 4 YEL TO BATT NEG RESET OR CHECK VOLTAGE AT KEY SWITCH 5 ORA TO BATT NEG REPLACE KEY SWITCH NO YES CHECK VOLTAGE AT M1 9 GRN TO BATT NEG NO YES REPAIR OR REPLACE 9 GRN NOTE OPT STOP SWITCH CHECK VOLTAGE AT M1 13E BLK TO 1 RED AT BATT POS YES REPLACE M1 NO REPAIR OR REPLACE 13E BLK CHECK VOLTAGE AT M1 3 ORA TO BATT NEG NO YES CON...

Page 286: ...A ONLY BATTERY VOLTAGE TO BATT NEG 3 ORA OR 18J YEL 3 ORA 18J YEL REPLACE CB 4 REPAIR OR 3 ORA REPLACE REPAIR OR REPLACE 18J 18H YEL CHECK VOLTAGE AT MAIN CONTROLLER 18H YEL TO BATT NEG RESET OR CHECK VOLTAGE AT MAIN CONTROLLER 13P BLK TO 1 RED NO YES REPAIR OR REPLACE 13P BLK BATT POS REPLACE MAIN CONTROLLER ...

Page 287: ...2 RED 13 BLK 1 RED 1C RED 12A BLU D1 1B BATTERY CHARGER CONNECTOR 1A RED M1 3A ORA CB 3 25A 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC RED BLK RED WHT P7 1 2 3 P6 1 2 3 4 5 6 LO REF HI 30 PUR 31 BRN 13H BLK 13F BLK 13C BLK 12C BLU 12D BLU SPEED CONTROL TOUCH PANEL MACHINE CONTROLLER B B REV FWD M1 M2 ...

Page 288: ...IR OR REPLACE 12B 12C BLU CHECK VOLTAGE AT PROPEL CONTROLLER TO BATT NEG RESET OR CHECK VOLTAGE AT NO YES 30 PUR TO 31 BRN CHECK VOLTAGE YES REPLACE NO REPAIR OR REPLACE LED S ON TOUCH PANEL LIGHT PROPEL CONTROLLER 13C 13F BLK TO 1 RED BATT POS 12C 12D BLU REPAIR OR REPLACE 13C 13F BLK THROTTLE HANDLE IN FORWARD CHECK VOLTAGE PROPEL CONTROLLER ACROSS 1 VOLT 1 VOLT ACROSS PROPEL MOTOR 30 PUR TO 31 ...

Page 289: ...CHECK VOLTAGE AT CONTROL BOARD P7 3 5 V ACROSS WHT RED TURN THROTTLE BACK AND FORTH 0 OHM 5K OHM 300 OHM GOOD BAD REPLACE POT RECONNECT POT AT MAIN CONTROLLER P6 2 TO BATT NEG NEUTRAL 2 5 V FWD 2 5 V REV 2 5 V REPLACE MAIN CONTROL BOARD CHECK VOLTAGE AT PROPEL MOTOR CONTROLLER P1 2 TO BATT NEG NEUTRAL 2 5 V FWD 2 5 V REV 2 5 V YES NO REPLACE REPAIR OR REPLACE HARNESS BETWEEN MAIN CONTROLLER AND PR...

Page 290: ... V YES HARNESS BETWEEN MAIN CONTROLLER AND PROPEL CONTROLLER REPAIR OR REPLACE NO AT PROPEL MOTOR CONTROLLER P1 3 TO BATT NEG CHECK VOLTAGE AT PROPEL MOTOR CONTROLLER P1 6 TO BATT NEG CHECK VOLTAGE 36 V HARNESS BETWEEN MAIN CONTROLLER AND PROPEL CONTROLLER REPAIR OR REPLACE NO YES YES REPLACE PROPEL MOTOR CONTROLLER REPLACE MAIN CONTROLLER NO HARNESS BETWEEN MAIN CONTROLLER AND PROPEL CONTROLLER R...

Page 291: ...3 LED DN PRESS 2 LED DN PRESS 1 LED DN PRESS 0 LED RIGHT BRUSH LEFT BRUSH CB 5 CB 6 M2 3C ORA 60 YEL 62B BLU 64B PUR 62A BLU 64A PUR 60A YEL 60B YEL 66A GRN 66B CURRENT SHUNT HARNESS MULTI TAP BR MTR CURRENT SHUNT 13U BLK 13V BLK 13DD BLK 13EE BLK 13AA BLK 13CC SHIELD 88A RED 87A WHT 87 CLR 88 BLK LED 5 LED 6 LED 7 LED 8 LED 9 LED 10 MEMBRANEPANEL PB 3 PB 4 MEMBRANE PANEL 18H YEL 18D YEL 18E YEL 4...

Page 292: ... YES NO IS BATTERY DISCHARGE INDICATOR FLASHING NO YES RECHARGE BATTERY THEN RETEST IS RECOVERY TANK OVERFLOW INDICATOR ACTIVE DRAIN RECOVERY TANK THEN RETEST RESET CB 5 AND CB 6 DOES PROBLEM STILL EXIST RUN DIAGNOSTICS OBSERVE WHETHER BRUSH HEAD LOWERS AND RAISES AND VAC FAN TURNS ON OFF DECIPHER AND RECORD EACH ERROR CODE 1 THRU 15 CONT NEXT PAGE SHUT OFF ...

Page 293: ...EPLACE ACTUATOR CONT NEXT PAGE IS ERROR CODE 9 ACTIVE SHORTED OUTPUT TO ACTUATOR IS ERROR CODE 8 ACTIVE CIRCUIT BOARD OUTPUT BAD DISCONNECT BRUSH ACTUATOR MOTOR AND RUN DIAGNOSTICS AGAIN IS ERROR CODE 9 ACTIVE AGAIN YES DISCONNECT CIRCUIT BOARD AND CHECK FOR CONTINUITY BETWEEN 44 PUR AND 45 GRY BAD REPAIR OR REPLACE 44 PUR 45 GRY GOOD REPLACE BOARD CHECK FOR MECHANICAL BINDING OF MOTOR RUN DIAGNOS...

Page 294: ...TIVE REPLACE M2 POWER OFF DISCONNECT CONTROL BOARD CHECK CONTINUITY 47 GRY TO GROUND YES NO REPLACE CONTROL BOARD REPAIR OR REPLACE 47 GRY RESET CB 5 AND CB 6 RE RUN DIAGNOSTICS DO BOTH BRUSHES TURN ON DURING DIAGNOSTICS CONT PAGE 4 176 CONT PAGE 4 177 NO YES NO YES NO NO CHECK VOLTAGE ACROSS NON RUNNING BRUSH MOTOR RE RUN DIAGNOSTICS IS 36V APPLIED MOMENTARILY WHEN OTHER BRUSH MOTOR TURNS ON REPL...

Page 295: ...NTINUITY OF WIRES 88 BLK 87 CLR FROM CONTROL BOARD PS TO SHUNT REPLACE CONTROL BOARD REPAIR OR REPLACE WIRES IS ERROR CODE 14 ACTIVE BRUSH RELAY OUTPUT BAD RETEST THEN REPLACE BOARD CHECK VOLTAGE ACROSS M2 RELAY 18K YEL AND 47 GRY RELAY ON REPLACE M2 RELAY POWER OFF DISCONNECT CONTROL BOARD CHECK CONTINUITY 47 GRY TO GROUND REPLACE CONTROL BOARD REPAIR OR REPLACE 47 GRY IS ERROR CODE 1 ACTIVE SHUN...

Page 296: ...HECK CONTINUITY 47 GRY FROM M2 TO CONTROL BOARD REPLACE M2 REPAIR OR REPLACE 47 GRY RE RUN DIAGNOSTICS CHECK VOLTAGE ON 62B BLU AND 64B PUR AT THE BRUSH MOTORS DID THE 36V PULSE OCCUR REPLACE OPEN MOTOR CHECK CONTINUITY REPAIR OR REPLACE WIRES 60 YEL AT M2 TO 60A YEL AT CB 5 60 YEL AT M2 TO 60B YEL AT CB 6 ACROSS CB 5 AND CB 6 62A BLU AT CB 5 TO 62B BLU AT L MTR 64A PUR AT CB 6 TO 64B PUR AT R MTR...

Page 297: ... 3 ACTIVE HIGH BRUSH CURRENT IS ERROR CODE 2 ACTIVE LOW BRUSH CURRENT DISCONNECT BRUSH ACTUATOR SELECT SCRUB AND SLIGHT FORWARD UNTIL BRUSHES TURN ON CHECK AMP DRAW OF EACH BRUSH MOTOR REPLACE MOTOR NO SYSTEM CHECKS OUT OK GOOD SYSTEM CHECKS OUT OK BRUSHES SHOWING SIGNS OF WEAR OR BREAK IN ...

Page 298: ...GROUND VAC FAN SQUEEGEE GROUND GROUND GROUND LOW BATT REC TANK LOW REC TANK FULL 5 VDC TANK FULL LED CB 2 M3 70 BLU 71A BRN 3D ORA 20 40A 71B BRN 71C BRN 13Z BLK 13X BLK 13Y BLK VAC FAN OPT VAC FAN 13AA BLK VAC FAN SQUEEGEE LED LED 5 LED 11 MEMBRANEPANEL PB 5 MEMBRANE PANEL 18H YEL 18B YEL 18D YEL 18E YEL 43 GRN 50 BLU 51 GRN M3 18K YEL 13L BLK 13Q BLK 13S BLK 13P BLK 42 BRN 13N BLK 13G BLK 18C YE...

Page 299: ...HECK CONTINUITY 50B BLU AND 51 GRN GOOD BAD REPLACE OPEN ACTUATOR MOTOR REPAIR OR REPLACE 50B BLU AND 51 GRN IS ERROR CODE 5 ACTIVE NO YES BAD OUTPUT YES RE RUN DIAGNOSTICS THEN REPLACE CONTROL BOARD CHECK CONTINUITY 50B BLU AND 51 GRN BAD GOOD REPAIR OR REPLACE 50B BLU AND 51 GRN MOTOR IS STALLED OR SHORTED LOOK FOR MECHANICAL BINDING BAD GOOD FIX MECHANICAL BINDING REPLACE MOTOR NOTE THIS TEST A...

Page 300: ... AND 18J YEL AT M3 RELAY REMOVE 43 BRN FROM M3 AND RE RUN DIAGNOSTICS NO YES SEE FLOAT TESTING IS ERROR CODE 13 ACTIVE 0V REPAIR OR REPLACE 30 ORA AND 18J YEL YES 36V NO CHECK VOLTAGE ACROSS M3 43 GRN AND 18J YEL 36V REPAIR OR REPLACE 43 GRN 0V REPLACE M3 CHECK CONTINUITY 43 GRN TO GROUND ERROR CODE 12 STILL ACTIVE YES POWER OFF REMOVE CONTROL BOARD FROM HARNESS BAD REPLACE VAC FAN MOTOR REPLACE C...

Page 301: ...K VOLTAGE ACROSS VAC FAN ON 71B BRN AND 13X BLK DID 36V PULSE OCCUR REPLACE VAC FAN MOTOR NO CHECK CONTINUITY 13X BLK TO GROUND 70 BLU AT M3 TO 70 BLU AT CB 2 ACROSS CB 2 71A BRN AT CB 2 TO 71B BRN AT VAC MTR BAD REPAIR OR REPLACE BAD WIRES OR CB CHECK CONTINUITY 43 GRN FROM M3 TO CONTROL BOARD GOOD BAD REPAIR OR REPLACE 43 GRN REPLACE M3 ...

Page 302: ... P3 2 P3 7 P3 14 P1 1 P1 3 P2 1 P2 5 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER ES PUMP OPT GROUND ES ENABLE GROUND GROUND GROUND 5 VDC ES LED 13AA BLK LED 4 MEMBRANEPANEL PB 2 MEMBRANE PANEL 18H YEL 18D YEL 18E YEL 46 PUR 18M YEL 18P YEL 13L BLK 13Q BLK 13S BLK 13P BLK TOUCH PANEL MACHINE CONTROLLER MTR ...

Page 303: ... 12 STILL ACTIVE NO REPLACE MOTOR POWER OFF DISCONNECT PC BOARD IS 46 PUR GROUND NO YES REPLACE CONTROL BOARD 46 PUR CHECK VOLTAGE 18P YEL AT ES PUMP 36V RE RUN DIAGNOSTICS CHECK VOLTAGE 46 PUR MOMENTARILY DURING DIAGNOSTICS DID LOW PULSE OCCUR REPLACE ESt PUMP REPAIR OR REPLACE 18P YEL REPAIR OR REPLACE 46 PUR IS PUMP ALWAYS ON DURING TEST YES NO SEE FLOAT TESTING IS ERROR CODE 12 ACTIVE YES NO R...

Page 304: ...B 4 10A 3 ORA 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC P4 1 P3 2 P3 7 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER GROUND GROUND GROUND 18H YEL 18D YEL 18E YEL 13L BLK 13Q BLK 13S BLK 13P BLK TOUCH PANEL MACHINE CONTROLLER P3 13 SOLUTION SOLENOID 48 GRY 18N YEL ...

Page 305: ...S NO REPAIR OR REPLACE 48 GRY RE RUN DIAGNOSTICS REPLACE CONTROL BOARD DISCONNECT SOLUTION FLOW SOLENOID IS ERROR CODE 11 STILL ACTIVE REPLACE SOLUTION FLOW SOLENOID REPAIR OR REPLACE 18N YEL RE RUN DIAGNOSTICS CHECK VOLTAGE ACROSS 18N YEL AND 48 GRY MOMENTARILY 0V 36V REPLACE SOLUTION FLOW SOLENOID TO MACHINE GROUND NOTE VALVE HANDLE MUST BE MECHANICAL FORWARD AND MACHINE MUST BE PROPELLING FOR S...

Page 306: ... KEY SWITCH 3 ORA 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC RED P4 1 P3 2 P3 7 P3 9 P2 1 P2 7 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER GROUND GROUND GROUND HR 5 VDC SCRUB MODE LED 13AA BLK LED 6 MEMBRANEPANEL 18H YEL 18D YEL 18E YEL 13L BLK 13Q BLK 13S BLK 13P BLK 10 ORA 18A YEL 9A GRN TOUCH PANEL MACHINE CONTROLLER ...

Page 307: ... 0V DOES HOUR GLASS FLASH EVERY 5 SECONDS YES NO DISCONNECT P7 ON CONTROL BOARD VERIFY SCRUB IS OFF DOES HOUR GLASS FLASH EVERY 5 SECONDS HOURMETER IS OK REPLACE CONTROL BOARD YES NO RECONNECT P7 HOURMETER IS OK ADJUST FWD REV POT BOARD IS SENSING FWD OR REV CHECK VOLTAGE 10 ORA AT HOURMETER 36V REPLACE HOURMETER 0V REPAIR OR REPLACE 10 ORA 0V 36V CHECK VOLTAGE REPLACE HOURMETER DISCONNECT HOURMET...

Page 308: ...4 YEL 3 ORA 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC RED P4 1 P3 2 P3 7 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER GROUND GROUND GROUND 18H YEL 18D YEL 18E YEL 13L BLK 13Q BLK 13S BLK 13P BLK 18A YEL TOUCH PANEL MACHINE CONTROLLER P4 8 LOW BATT 42 BRN 13D BLK BD I 1 2 3 4 ...

Page 309: ...UGE IF NEW GAUGE FLASHES EARLY TEST BATTERIES RECHARGE BATTERIES COMPLETELY IS GAUGE STILL FLASHING BDI OK RECHARGE BATTERIES AGAIN DOES BATTERY VOLTAGE GET ABOVE 42 5V FOR 6 MINUTES RESETS GAUGE TEST BATTERIES AND CHARGER REPLACE GAUGE CHECK VOLTAGE 18A YEL TO 13D BLK AT GAUGE 0V 36V REPAIR OR REPLACE 18A YEL AND 13D BLK CHECK VOLTAGE 4A YEL TO 13D BLK AT GAUGE 0V REPAIR OR REPLACE 4A YEL REPLACE...

Page 310: ...P2 6 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER GROUND GROUND GROUND REC TANK LOW REC TANK FULL 5 VDC TANK FULL LED 13AA BLK LED 5 MEMBRANEPANEL 18H YEL 18D YEL 18E YEL 13L BLK 13Q BLK 13S BLK 13P BLK 13N BLK 13G BLK 18C YEL 18F YEL 18G ORA 13R BLK 40 GRN 54 BRN 18A YEL TOUCH PANEL MACHINE CONTROLLER P3 14 ES PUMP OPT 18M YEL 18P YEL MTR ...

Page 311: ...N LOWER LEVEL SW IS OK CHECK VOLTAGE 54 BRN AT CONTROL BOARD 36V REPLACE CONTROL BOARD 0V DISCONNECT LEVEL SW CHECK VOLTAGE 18G ORA TO 13R BLK 0V 36V REPLACE LOWER LEVEL SW REPAIR OR REPLACE 18C YEL AND 13G BLK RUN DIAGNOSTICS WHEN ERRORS ARE DISPLAYED DOES THE OVERFLOW LED EVER TURN ON THEN OFF TEST AND REPLACE BAD RIBBON AND OR TOUCH PANEL CONT NEXT PAGE CHECK VOLTAGE 46 PUR AT CONTROL BOARD TO ...

Page 312: ... SYSTEM IS OK CHECK VOLTAGE 40 GRN AT CONTROL BOARD REPLACE CONTROL BOARD DISCONNECT LEVEL SW CHECK VOLTAGE 18C YEL TO 13G BLK AT LEVEL SW REPLACE UPPER LEVEL SW REPAIR OR REPLACE 18C YEL AND 13G BLK SELECT SCRUB FUNCTION ON TOUCH PANEL DID LED TURN OFF YES NO CHECK VOLTAGE 40 GRN AT CONTROL BOARD 36V 0V REPLACE UPPER LEVEL SW START LEVEL TEST OVER REPLACE CONTROL BOARD TURN KEY ON THEN OFF OUT OF...

Page 313: ...L BOARD TRY SPEED AND DOWN PRESSURE PUSH BUTTONS ARE LIGHTS LIT ON THE TOUCH PANEL YES IS PROPEL WORKING NO DEFINE PROBLEM NO YES IS PROBLEM WITH BRUSH MOTORS OR HEAD LIFT OPERATION NO SEE BRUSH AND HEAD LIFT TROUBLESHOOTING IS PROBLEM WITH SQUEEGEE AND OR VAC FAN OPERATION SEE VAC FAN SQUEEGEE TROUBLESHOOTING IS PROBLEM WITH SOLUTION FLOW SOLENOID ESt PUMP OR HOURMETER YES SEE SOLUTION ESt PUMP A...

Page 314: ...2 RED 13 BLK 1 RED 2 5A 1B 4 YEL 5 ORA 6 BLU 9 GRN 13E BLK KEY SWITCH BATTERY CHARGER CONNECTOR 1A RED M1 3 ORA 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC OPT STOP SW RED P4 1 P4 5 36 VDC CONTROL GROUND 18H YEL 18J YEL 13P BLK 13BB BLK 9E GRN 9D GRN TOUCH PANEL MACHINE CONTROLLER ...

Page 315: ...OR 1B RED REPLACE REPAIR OR REPLACE 4 YEL CHECK VOLTAGE AT KEY SWITCH 4 YEL TO BATT NEG RESET OR CHECK VOLTAGE AT KEY SWITCH 5 ORA TO BATT NEG REPLACE KEY SWITCH NO YES CHECK VOLTAGE AT M1 9 GRN TO BATT NEG NO YES REPAIR OR REPLACE 9 GRN NOTE OPT STOP SWITCH CHECK VOLTAGE AT M1 13E BLK TO 1 RED AT BATT POS YES REPLACE M1 NO REPAIR OR REPLACE 13E BLK CHECK VOLTAGE AT M1 3 ORA TO BATT NEG NO YES CON...

Page 316: ...A ONLY BATTERY VOLTAGE TO BATT NEG 3 ORA OR 18J YEL 3 ORA 18J YEL REPLACE CB 4 REPAIR OR 3 ORA REPLACE REPAIR OR REPLACE 18J 18H YEL CHECK VOLTAGE AT MAIN CONTROLLER 18H YEL TO BATT NEG RESET OR CHECK VOLTAGE AT MAIN CONTROLLER 13P BLK TO 1 RED NO YES REPAIR OR REPLACE 13P BLK BATT POS REPLACE MAIN CONTROLLER ...

Page 317: ... 13P BLK LO REF HI 30 PUR 31 BRN 13H BLK 13C BLK 12C BLU 12D BLU TOUCH PANEL MACHINE CONTROLLER 32 YEL 33 GRN B B B B LEFT PROPEL RIGHT PROPEL MOTOR MOTOR LEFT PROPEL CONT RIGHT PROPEL CONT P3 3 P3 4 P3 5 P3 6 P4 3 P4 4 P4 5 P4 6 P1 1 P1 2 P1 3 P1 4 P1 6 P2 1 P2 2 P2 3 POWER STEERING CONTROL LO LVL SPD RFE HI LVL LO LVL HI LVL STA REF 36V 36V P7 1 P7 2 P7 3 5K POT 2 5K POT 1 16 BLK 14 WHT 15 RED 1...

Page 318: ...T ON STEERING P C B ARE VOLTAGES EQUAL ON P3 5 P4 5 WHEN STEERING STRAIGHT NO YES NO DISCONNECT STEERING POT FROM STEERING P C B CHECK VOLTAGES AT P C B P2 1 P2 3 BOTH 0 V P2 2 12 V NO YES CHECK RESISTANCE AT STEERING POT ACROSS BLK RED TURN STEERING BACK FORTH FROM 10 2 OHMS TO 2K 200 OHMS BAD REPLACE POT GOOD STEERING P C B CONNECTED TO MAIN CONTROLLER P C B CORRECTLY NO YES SECURE CONNECTION RE...

Page 319: ...E 13C 13F BLK CHECK VOLTAGE ACROSS PROPEL CONTROLLERS THROTTLE CONTROL FORWARD 1V 1V CHECK VOLTAGE ACROSS PROPEL MOTORS 30 PUR TO 31 BRN 32 YEL TO 33 GRN 36V 0V REPAIR OR REPLACE 30 PUR TO 31 BRN OR 32 YEL TO 33 GRN REPLACE PROPEL MOTOR S DISCONNECT 30 PUR 32 YEL AT PROPEL MOTOR CONTROLLERS DISCONNECT SPEED POT FROM MAIN CONTROL BOARD CHECK VOLTAGE AT P7 3 6 V P7 1 0 V YES CHECK RESISTANCE AT SPEE...

Page 320: ...SE AT PROPEL MOTOR SEE PREV STEP REPLACE STEERING P C B REPLACE MOTOR CONTROLLER S THAT APPEAR S BAD FULL LEFT FULL FWD RIGHT CONTR 5 9 V LEFT CONTR 3 9 V FULL LEFT NEUTRAL RIGHT CONTR 3 6 V LEFT CONTR 1 6 V FULL LEFT FULL REV RIGHT CONTR 0 7 V LEFT CONTR 1 9 V STRAIGHT FULL FWD BOTH CONTROLLERS 4 7 V STRAIGHT NEUTRAL 2 2 P1 5 V 2 8 BOTH CONTROLLERS STRAIGHT FULL REV BOTH CONTROLLERS 1 0 V FULL RI...

Page 321: ...GROUND VAC FAN SQUEEGEE GROUND GROUND GROUND LOW BATT REC TANK LOW REC TANK FULL 5 VDC TANK FULL LED CB 2 M3 70 BLU 71A BRN 3D ORA 20 40A 71B BRN 71C BRN 13Z BLK 13X BLK 13Y BLK VAC FAN OPT VAC FAN 13AA BLK VAC FAN SQUEEGEE LED LED 5 LED 11 MEMBRANEPANEL PB 5 MEMBRANE PANEL 18H YEL 18B YEL 18D YEL 18E YEL 43 GRN 50 BLU 51 GRN M3 18K YEL 13L BLK 13Q BLK 13S BLK 13P BLK 42 BRN 13N BLK 13G BLK 18C YE...

Page 322: ...HECK CONTINUITY 50B BLU AND 51 GRN GOOD BAD REPLACE OPEN ACTUATOR MOTOR REPAIR OR REPLACE 50B BLU AND 51 GRN IS ERROR CODE 5 ACTIVE NO YES BAD OUTPUT YES RE RUN DIAGNOSTICS THEN REPLACE CONTROL BOARD CHECK CONTINUITY 50B BLU AND 51 GRN BAD GOOD REPAIR OR REPLACE 50B BLU AND 51 GRN MOTOR IS STALLED OR SHORTED LOOK FOR MECHANICAL BINDING BAD GOOD FIX MECHANICAL BINDING REPLACE MOTOR NOTE THIS TEST A...

Page 323: ... AND 18J YEL AT M3 RELAY REMOVE 43 BRN FROM M3 AND RE RUN DIAGNOSTICS NO YES SEE FLOAT TESTING IS ERROR CODE 13 ACTIVE 0V REPAIR OR REPLACE 30 ORA AND 18J YEL YES 36V NO CHECK VOLTAGE ACROSS M3 43 GRN AND 18J YEL 36V REPAIR OR REPLACE 43 GRN 0V REPLACE M3 CHECK CONTINUITY 43 GRN TO GROUND ERROR CODE 12 STILL ACTIVE YES POWER OFF REMOVE CONTROL BOARD FROM HARNESS BAD REPLACE VAC FAN MOTOR REPLACE C...

Page 324: ...K VOLTAGE ACROSS VAC FAN ON 71B BRN AND 13X BLK DID 36V PULSE OCCUR REPLACE VAC FAN MOTOR NO CHECK CONTINUITY 13X BLK TO GROUND 70 BLU AT M3 TO 70 BLU AT CB 2 ACROSS CB 2 71A BRN AT CB 2 TO 71B BRN AT VAC MTR BAD REPAIR OR REPLACE BAD WIRES OR CB CHECK CONTINUITY 43 GRN FROM M3 TO CONTROL BOARD GOOD BAD REPAIR OR REPLACE 43 GRN REPLACE M3 ...

Page 325: ... P3 2 P3 7 P3 14 P1 1 P1 3 P2 1 P2 5 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER ES PUMP OPT GROUND ES ENABLE GROUND GROUND GROUND 5 VDC ES LED 13AA BLK LED 4 MEMBRANEPANEL PB 2 MEMBRANE PANEL 18H YEL 18D YEL 18E YEL 46 PUR 18M YEL 18P YEL 13L BLK 13Q BLK 13S BLK 13P BLK TOUCH PANEL MACHINE CONTROLLER MTR ...

Page 326: ... 12 STILL ACTIVE NO REPLACE MOTOR POWER OFF DISCONNECT PC BOARD IS 46 PUR GROUND NO YES REPLACE CONTROL BOARD 46 PUR CHECK VOLTAGE 18P YEL AT ES PUMP 36V RE RUN DIAGNOSTICS CHECK VOLTAGE 46 PUR MOMENTARILY DURING DIAGNOSTICS DID LOW PULSE OCCUR REPLACE ES PUMP REPAIR OR REPLACE 18P YEL REPAIR OR REPLACE 46 PUR IS PUMP ALWAYS ON DURING TEST YES NO SEE FLOAT TESTING IS ERROR CODE 12 ACTIVE YES NO RE...

Page 327: ...B 4 10A 3 ORA 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC P4 1 P3 2 P3 7 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER GROUND GROUND GROUND 18H YEL 18D YEL 18E YEL 13L BLK 13Q BLK 13S BLK 13P BLK TOUCH PANEL MACHINE CONTROLLER P3 13 SOLUTION SOLENOID 48 GRY 18N YEL ...

Page 328: ...S NO REPAIR OR REPLACE 48 GRY RE RUN DIAGNOSTICS REPLACE CONTROL BOARD DISCONNECT SOLUTION FLOW SOLENOID IS ERROR CODE 11 STILL ACTIVE REPLACE SOLUTION FLOW SOLENOID REPAIR OR REPLACE 18N YEL RE RUN DIAGNOSTICS CHECK VOLTAGE ACROSS 18N YEL AND 48 GRY MOMENTARILY 0V 36V REPLACE SOLUTION FLOW SOLENOID TO MACHINE GROUND NOTE VALVE HANDLE MUST BE MECHANICAL FORWARD AND MACHINE MUST BE PROPELLING FOR S...

Page 329: ... KEY SWITCH 3 ORA 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC RED P4 1 P3 2 P3 7 P3 9 P2 1 P2 7 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER GROUND GROUND GROUND HR 5 VDC SCRUB MODE LED 13AA BLK LED 6 MEMBRANEPANEL 18H YEL 18D YEL 18E YEL 13L BLK 13Q BLK 13S BLK 13P BLK 10 ORA 18A YEL 9A GRN TOUCH PANEL MACHINE CONTROLLER ...

Page 330: ... 0V DOES HOUR GLASS FLASH EVERY 5 SECONDS YES NO DISCONNECT P7 ON CONTROL BOARD VERIFY SCRUB IS OFF DOES HOUR GLASS FLASH EVERY 5 SECONDS HOURMETER IS OK REPLACE CONTROL BOARD YES NO RECONNECT P7 HOURMETER IS OK ADJUST FWD REV POT BOARD IS SENSING FWD OR REV CHECK VOLTAGE 10 ORA AT HOURMETER 36V REPLACE HOURMETER 0V REPAIR OR REPLACE 10 ORA 0V 36V CHECK VOLTAGE REPLACE HOURMETER DISCONNECT HOURMET...

Page 331: ...4 YEL 3 ORA 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC RED P4 1 P3 2 P3 7 P3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER GROUND GROUND GROUND 18H YEL 18D YEL 18E YEL 13L BLK 13Q BLK 13S BLK 13P BLK 18A YEL TOUCH PANEL MACHINE CONTROLLER P4 8 LOW BATT 42 BRN 13D BLK BD I 1 2 3 4 ...

Page 332: ...UGE IF NEW GAUGE FLASHES EARLY TEST BATTERIES RECHARGE BATTERIES COMPLETELY IS GAUGE STILL FLASHING BDI OK RECHARGE BATTERIES AGAIN DOES BATTERY VOLTAGE GET ABOVE 42 5V FOR 6 MINUTES RESETS GAUGE TEST BATTERIES AND CHARGER REPLACE GAUGE CHECK VOLTAGE 18A YEL TO 13D BLK AT GAUGE 0V 36V REPAIR OR REPLACE 18A YEL AND 13D BLK CHECK VOLTAGE 4A YEL TO 13D BLK AT GAUGE 0V REPAIR OR REPLACE 4A YEL REPLACE...

Page 333: ...3 3 P3 8 P4 5 36 VDC CONTROL 36 VDC POWER 36 VDC POWER GROUND GROUND GROUND REC TANK LOW REC TANK FULL 5 VDC TANK FULL LED 13AA BLK LED 5 MEMBRANEPANEL 18H YEL 18D YEL 18E YEL 13L BLK 13Q BLK 13S BLK 13P BLK 13N BLK 13G BLK 18C YEL 18F YEL 18G ORA 13R BLK 40 GRN 54 BRN 18A YEL TOUCH PANEL MACHINE CONTROLLER P3 14 ES PUMP OPT 18M YEL 18P YEL MTR ...

Page 334: ...LOWER LEVEL SW IS OK CHECK VOLTAGE 54 BRN AT CONTROL BOARD 36V REPLACE CONTROL BOARD 0V DISCONNECT LEVEL SW CHECK VOLTAGE 18G ORA TO 13R BLK 0V 36V REPLACE LOWER LEVEL SW REPAIR OR REPLACE 18C YEL AND 13G BLK RUN DIAGNOSTICS WHEN ERRORS ARE DISPLAYED DOES THE OVERFLOW LED EVER TURN ON THEN OFF TEST AND REPLACE BAD RIBBON AND OR TOUCH PANEL CONT NEXT PAGE CHECK VOLTAGE 46 PUR AT CONTROL BOARD TO MA...

Page 335: ... SYSTEM IS OK CHECK VOLTAGE 40 GRN AT CONTROL BOARD REPLACE CONTROL BOARD DISCONNECT LEVEL SW CHECK VOLTAGE 18C YEL TO 13G BLK AT LEVEL SW REPLACE UPPER LEVEL SW REPAIR OR REPLACE 18C YEL AND 13G BLK SELECT SCRUB FUNCTION ON TOUCH PANEL DID LED TURN OFF YES NO CHECK VOLTAGE 40 GRN AT CONTROL BOARD 36V 0V REPLACE UPPER LEVEL SW START LEVEL TEST OVER REPLACE CONTROL BOARD TURN KEY ON THEN OFF OUT OF...

Page 336: ...y time turn the key off then back on The diagnostics program will start and all three speed indicators will flash While the diagnostics program is running the machine outputs will be turned on in the following order 1 The brush and squeegee actuators are raised to the up position 2 The vacuum fan is turned on The squeegee runs down until the actuator stops The actuator will then run up to the top ...

Page 337: ...t this time With the machines speed handle in the neutral position the number two indicator light should be on This indicates a true neutral condition If the number one or number three speed indicator light is flashing or is on the forward reverse potentiometer needs to be adjusted to achieve true neutral 3 Record the existing error codes and turn the key switch off and back on to get out of the d...

Page 338: ... 3 Off ON Off Off No brush motor current Code 4 Squeegee Vac fan X X ON Off Squeegee actuator output reads stall Code 5 X X Off ON Early squeege actuator stall Code 6 X X ON ON No squeegee actuator stall Code 7 ON Off X X Brush actuator output reads stall Code 8 Off ON X X Early brush actuator stall Code 9 ON ON X X No brush actuator stall Code 10 Overflow ON Off Off Off Solution solenoid output b...

Page 339: ...FaSTt t t t 5 1 5680 5700 MM406 6 03 CONTENTS Page FaSTt 5 2 FaSTt PRODUCT OVERVIEW 5 6 FaSTt SCHEMATIC 5 11 FaSTt TROUBLE SHOOTING 5 12 FaSTt TEST POINTS 5 19 ...

Page 340: ...FaSTt t t t 5680 5700 MM406 6 03 5 2 Self Collapsing Foam Technology Liquid Foam Liquid What is FaSTTM Foam Scrubbing Technology _ _ _ ...

Page 341: ...FaSTt t t t 5 3 5680 5700 M406 6 03 Why FaST Works TM Increased Wetting and Surface Area using FaST Conventional FaST Conventional FaST Increased Wetting Increased Surface Area technology TM TM ...

Page 342: ...FaSTt t t t 5680 5700 MM406 6 03 5 4 How FaST Works TM TM Air Injection expands detergent water solution to over four 4 times its original volume Air ...

Page 343: ... bubblesallow FaST solution to dry quicker than conventional liquid Reduced detergent cost waste shipment cost storage Conventional FaST On board detergent metering One container lasts weeks Just drain recovery tanks and fill solution tank with water Less water used recovered solution to dispose of no chemical mixing environmentally friendly ...

Page 344: ...FaSTt t t t 5680 5700 MM406 6 03 5 6 Product Overview 3 2 4 5 1 3 Water Pump 2 Detergent Pump 4 Air Compressor 5 Mixing Chamber 6 Application to floor 1 Detergent Concentrate 6 ...

Page 345: ...d Water Tank Conventional Solution System NOTE Hose path different by model Solenoid Shut Off Valve Conventional Solution System Used with detergent mixed in water all FaST equipped machines can be used in Conventional Cleaning mode 80 Mesh Filter Usage varies by application ...

Page 346: ...internal pressure relief valve set at 45 psi Filter and Orifice Orifice is 0 036 diameter Filter prevents orifice from plugging Lowers pressure to 2 3 psi and limits water flow after orifice Assembly is filter washer orifice in water flow direction Check Valve optional component depending on application Shut Off Valve 24 vDC or 36 vDC depending on application Located in pure water line or on water...

Page 347: ...r Quick Disconnect Detergent line is sealed when connector is disconnected from Connect this connector to the storage connector on the machine if the FaST system is not used for an extended period of time FaST Pak Detergent Pump 24 vDC or 36 vDC Pump is pulsed by a blue timer at 0 5 hertz once per every 2 seconds Timer pump is on with FaST engaged Note You cannot tell if the pump is running by tou...

Page 348: ...g By the use of added air to the detergent water solution the solution expands to over four 4 times its original volume after air is injected Check Valve Prevents detergent water solution from entering the air compressor pump Mixing Chamber Ensures proper mixing of detergent water solution A media similar to a 3M Red Pad is used power resistor Air Compressor Check Valve Air Compressor Check Valve ...

Page 349: ...Mesh Filter Scrub Head Water Tank Conventional Solution System NOTE Hose path different by model Solenoid Shut Off Valve Water Pump Filter Orifice Check Valve Solenoid Shut Off Valve Compressor Air Check Valve Not used on all models Solenoid location different by model number ONE used on FaST system Item in dotted line not used on all models NOTES Solution flow direction arrow Mixing Chamber ...

Page 350: ...unning Yes No Place hand on air Pump Is it running Yes No Go to TEST 3 Go to TEST 1 Go to TEST 2 Go to TEST 1 Go to TEST 4 NOTE If it appears there is too much foam verify that only FaST detergent is being used WARNING Unplug drive motor electrical connectors for propelling system and scrub brushes before servicing START FaST Operational Requirements Ignition switch on FaST conventional switch set...

Page 351: ...too much detergent usage check pulse rate of detergent pump This rate should be approx 1 pulse every 2 seconds or 30 pulses per minute 0 5 Hz If this is not your reading go to TEST 4 Remove hose at Test Point F Does the detergent rise 1 25mm in 30 seconds Yes No Go to TEST 5 Go to TEST 4 Check for voltage at the water detergent air pumps Is there voltage at the pumps Yes No Overall System Troubles...

Page 352: ...r system as needed No Check for blockage at filter orifice 80 mesh filter tank strainer if used water hoses Is flow rate at Test Point D now about 1 quart 1 Liter in 1 minute Verify problem is repaired rerun test from START If OK reconnect propel brush motors TEST 1 Low nowater orfoam Yes No Verify problem is repaired rerun test from START If OK reconnect propel brush motors NOTE The orifice is a ...

Page 353: ... test from START If OK reconnect propel brush motors TEST 2 Too much water and low no foam Verify problem is repaired rerun test from START If OK reconnect propel brush motors NOTE The orifice is a thin round metal disc with a very small hole in the center Use ONLY brass or softer material to clean hole in orifice NOTE The correct order for assembly of filter orifice is starting from water pump si...

Page 354: ...o 30 PSI 138 to 270 kPa Inspect flow through mixing chamber Is mixing chamber clogged with debris Yes Clean or replace mixing chamber No Verify problem is repaired rerun test from START If OK reconnect propel brush motors DONE NOTE Arrow on check valve should point away from air pump WARNING Unplug drive motor electrical connectors for propelling system and scrub brushes before servicing FaST Oper...

Page 355: ...oltages at FaST compone nts 24 vDC systems 36 vDC systems Water pump Ai r pump Battery voltage 26 to 28 vDC Solenoid valve Ti mer mod ule 22 ohm resistor Not us e d 8 to 12 vDC Voltage drop across resistor Battery voltage at posts 1 3 Battery voltage D etergent pump Battery voltage Pul sed once every 2 seconds If pulses are more or less than this re place timer Battery voltage FaST Operational Req...

Page 356: ...ent draw of FaST components Do components test OK Yes FaST Operational Requirements Ignition switch on FaST conventional switch set to FaST Water tank sufficiently full FaST Pak sufficiently full connected Forward propel engaged be sure to read warning at START Adequate battery charge Scrub head lowered brushes engaged Does conventional system work properly Yes No Repair or replace components as n...

Page 357: ...entional Solution System NOTE Hose path different by model Solenoid Shut Off Valve Water Pump Filter Orifice Check Valve Solenoid Shut Off Valve Compressor Air Check Valve Not used on all models Solenoid location different by model number ONE used on FaST system Item in dotted line not used on all models NOTES Solution flow direction arrow Mixing Chamber A B C D E G F J H I K L FaSTTest Points CHA...

Page 358: ...FaSTt t t t 5680 5700 MM406 6 03 5 20 ...

Page 359: ...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 360: ...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 361: ...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 362: ...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 ...

Search results

Summary of Contents for 5700XPS

Reviews:

Tennant 5700XPS, Service Manual, Page: 1 / 362

Search results

Summary of Contents for 5700XPS

Reviews: