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Tennant 7100, Service Manual

The Bosch 7100 Operating Instructions Manual provides essential guidance and detailed steps for optimal usage of the Bosch 7100 product. This comprehensive manual is available for free download at manualshive.com, ensuring quick and convenient access to this invaluable resource. Access your user manual today and make the most of your Bosch 7100.

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SCRUBBING

3-4

7100 330695 (10

−

00)

SOLUTION TANK

The solution tank supplies the brushes with a

water and detergent solution. The solution tank is

located to the right of the recovery tank and

behind the operators seat.

Access to the solution tank is through the opening

at the top of the tank, reached by lifting up the

tank cover.

The solution tank requires no regular

maintenance. If detergent cakes on the bottom of

the tank, remove the deposits with a strong blast

of warm water. Do not use water hotter than 130

F (54

 C) or use steam to clean the tank because

damage may occur. A tank drain hose has been

provided to allow the tank to be drained for

cleaning.

The solution tanks with  ES

 

should be drained

and cleaned after every work shift.

Summary of Contents for 7100

Page 1: ...330695 Rev 02 8 11 Service Manual 7100 ...

Page 2: ... machine maintenance chart Chassis Tire wheel replacement brake adjustment and replacement steering adjustment and replacement and machine cab information Scrubbing Scrub head repair replacement brush repair replacement skirt seal repair replacement squeegee repair replacement solution and recovery tank repair replacement and scrubbing troubleshooting Electrical Battery maintenance and replacement...

Page 3: ...CHINE DIMENSIONS 1 9 MAINTENANCE 1 10 MAINTENANCE CHART 1 11 PUSHING TOWING AND TRANSPORTING THE MACHINE 1 12 PUSHING OR TOWING THE MACHINE 1 12 TRANSPORTING THE MACHINE 1 12 MACHINE JACKING 1 14 STORAGE INFORMATION 1 15 FREEZE PROTECTION 1 15 HARDWARE INFORMATION 1 16 STANDARD BOLT TORQUE CHART 1 16 METRIC BOLT TORQUE CHART 1 16 BOLT IDENTIFICATION 1 16 THREAD SEALANT AND LOCKING COMPOUNDS 1 16 ...

Page 4: ...GENERAL INFORMATION 1 2 7100 330695 8 11 ...

Page 5: ...ns If not in proper operating condition 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 Follow safety guidelines concerning wet floors 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 machin...

Page 6: ...ailer Turn off machine Use truck or trailer that will support the weight of the machine Use winch Do not drive the machine onto off the truck or trailer unless the load height is 380 mm 15 in or less from the ground Set parking brake after machine is loaded Block machine tires Tie machine down to truck or trailer ...

Page 7: ...damaged or illegible install a new label in its place BATTERY CHARGING LABEL LOCATED ON AND UNDERNEATH THE SEAT SUPPORT FLAMMABLE SPILLS LABEL LOCATED ON THE SEAT SUPPORT FOR SAFETY LABEL LOCATED ON THE SEAT SUPPORT FLAMMABLE MATERIALS LABEL LOCATED ON THE UNDERSIDE OF THE TANK COVER AND ON THE LEFT SIDE OF THE OPERATOR COMPARTMENT 353450 ...

Page 8: ...d 850 mm Squeegee width for 800 mm 32 in scrub head 1015 mm Scrubbing path width for 700 mm 28 in scrub head 700 mm Scrubbing path width for 800 mm 32 in scrub head 800 mm Solution tank capacity 130 L Recovery tank capacity 130 L Sound level at operator ear 75 dBA Vibration level at steering wheel does not exceed 2 5 m s2 Vibration level at operator seat does not exceed 0 5 m s2 Weight net less ba...

Page 9: ...ric Motors Scrub brush disk 36 0 60 0 80 Scrub brush cylindrical 36 0 56 0 75 Vacuum fan 36 0 6 0 8 Propelling 36 1 2 1 6 Type VDC amp Hz Phase VAC Chargers Smart 36 30 60 1 120 36 25 50 1 230 36 25 50 1 245 TIRES Location Type Size Front 1 Solid 90 mm wide x 300 mm OD 3 5 in wide x 11 8 in OD Rear 2 Solid 90 mm wide x 310 mm OD 3 5 in wide x 12 3 in OD ...

Page 10: ...GENERAL INFORMATION 1 8 7100 330695 8 11 820 mm 32 25 in 820 mm 32 25 in 28 in scrub 850 mm 33 5 in 1370 mm 54 in 32 in scrub 1015 mm 40 in 1690 mm 66 5 in 353475 MACHINE DIMENSIONS ...

Page 11: ...GENERAL INFORMATION 1 9 7100 330695 10 00 MAINTENANCE 1 1 2 8 7 9 11 5 10 4 3 6 12 12 13 14 14 353450 ...

Page 12: ...electrolyte level DW 3 12 Disk scrub head floor skirts Check for damage and wear 2 100 Hours 5 Cylindrical scrub brush drive belts Check tension 2 3 Steering caster pivot bear ing Lubricate SPL 1 5 Scrub head lift bearings option Lubricate SPL 2 9 Vacuum Fan and tank seals Check for damage and wear 3 14 Tires Check for damage and wear 3 200 Hours 4 Battery terminals and cables Check and clean 12 1...

Page 13: ...R SAFETY Use a truck or trailer that will support the weight of the machine NOTE Empty the recovery and solution tanks before transporting the machine 2 If the loading surface is not horizontal or is higher than 380 mm from the ground use a winch to load machine If the loading surface is horizontal AND is 380 mm or less from the ground the machine may be driven onto the truck or trailer 3 To winch...

Page 14: ...ansporting The front tie down locations are on the front jack supports The rear tie down locations are on the rear corners of the machine 6 If the loading surface is not horizontal or is higher than 380 mm from the ground use a winch to unload machine If the loading surface is horizontal AND is 380 mm or less from the ground the machine may be driven off the truck or trailer FOR SAFETY When unload...

Page 15: ...n 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 jack stands Jack up the rear of the machine from underneath the rear corners Use a piece of wood between the jack and the frame to distribute the machine weight load FOR SAFETY When servicing machine block machine tires before jackin...

Page 16: ...p 2 Park the machine in a cool dry area 3 Remove the batteries or charge them every three months FREEZE PROTECTION 1 Be sure the solution tank is empty 2 Pour 3 8 L 1 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 and ES system to circulate the washer solution through the ...

Page 17: ... 291 380 313 407 424 552 1 00 in 500 650 678 881 757 984 1026 1334 NOTE Decrease torque by 20 when using a thread lubricant METRIC BOLT TORQUE CHART Thread Size Class 8 8 Torque ft lb Nm Class 10 9 Torque ft lb Nm M4 2 3 3 4 M5 4 5 6 8 M6 7 9 10 14 M8 18 24 25 34 M10 32 43 47 64 M12 58 79 83 112 M14 94 127 133 180 M16 144 195 196 265 M20 260 352 336 455 M24 470 637 664 900 NOTE Decrease torque by ...

Page 18: ...GENERAL INFORMATION 1 16 7100 330695 10 00 ...

Page 19: ... REAR WHEEL HUB BEARINGS 2 7 FRONT DRIVE WHEEL AND WHEEL HOUSING SUPPORT 2 10 TO REMOVE FRONT DRIVE ASSEMBLY2 10 TO INSTALL FRONT DRIVE ASSEMBLY 2 14 TO REPLACE FRONT TIRE 2 18 TO ADJUST STEERING CHAIN 2 24 TO REPLACE STEERING CHAIN 2 26 TO REPLACE STEERING HOUSING BEARINGS 2 29 TO REPLACE STEERING U JOINT 2 35 TO REPLACE SMALL STEERING SPROCKET 2 37 TO REPLACE LARGE STEERING SPROCKET 2 40 TO REPL...

Page 20: ...CHASSIS 2 2 7100 330695 8 11 ...

Page 21: ...CHASSIS 2 3 7100 330695 8 11 INTRODUCTION This section includes information on the main chassis related components for example the front drive steering brakes and tires ...

Page 22: ...ed with a foot pedal TO ADJUST SERVICE PARKING BRAKE Serial Numbers 00000000 10160409 FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface place blocks in front and back of back wheels 1 If the service brake pedal has excessive movement before the brake is activated the service brake needs to be adjusted 2 Go under the front of the machine on the right side and locate the disc brak...

Page 23: ...e brake arm from the caliper arm 3 Remove the two hex screws holding the brake caliper assembly to the drive assembly 4 Remove the existing brake pads from the caliper assembly Position the new brake pads onto the caliper assembly Make sure to reinstall the compression springs 5 Reinstall the brake caliper assembly onto the drive assembly Reinstall the two hex screws and tighten to 18 24 Nm 15 20 ...

Page 24: ...reference point is in the right position 4 Check that the brake is correctly working internally to the gearbox disk shoulder NOTE Clean carefully all the removed components and clean the gearbox disk where the break acts NOTE Execute the operation in reverse for the new brake assembly eventually using a plastic hammer to help the right insertion in the gearbox ball bearing seat NOTE Check periodic...

Page 25: ...RINGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Jack up the rear corner of the machine where the tire needs to be removed Place a jack stand under the machine frame NOTE Do not raise both rear wheels off the floor at the same time The machine will become unstable because of the single front tire 2 Remove the rubber boot covering the wheel bearing ...

Page 26: ...ring to the axle shaft Pull the tire and hub assembly off the axle shaft 4 Remove the three nuts holding the tire and wheel to the hub Remove the tire and wheel from the hub 5 Use a hammer and punch to remove the existing hub bearings 6 Use an arbor press to install the new hub bearings ...

Page 27: ...nuts must face the outside of the machine 8 Reinstall the wheel and hub assembly onto the axle shaft Make sure the axle shaft has a coating of grease applied before installing hub Reinstall the retaining ring onto the axle shaft 9 Reinstall the rubber boot onto the wheel hub 10 Remove the jack stand and lower the machine Check the new wheel bearings for proper operation ...

Page 28: ...d by a steering wheel which turns a chain that is connected to the front wheel housing The front wheel housing turns on a large bearing and rubber seal TO REMOVE FRONT DRIVE ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface place blocks in front and back of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 ...

Page 29: ...he steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain 5 Locate the master link on the steering chain Remove the master link from the steering chain Remove the steering chain from the machine 6 Remove the power wire cover from the side of the drive assembly ...

Page 30: ... plastic sleeve Remove the wire from the drive assembly 9 Go to the operators compartment and locate the clevis pin holding the brake pedal assembly to the floor plate Remove the clevis pin and tension spring from the brake pedal 10 Pull the brake pedal up and disconnect the clevis end of the short brake rod where it attaches to the brake pedal assembly ...

Page 31: ... 7100 330695 8 11 11 Support the front drive assembly with a jack or blocks Remove the four button head screws holding the front drive assembly in the machine 12 Lower the drive assembly down and out of the machine ...

Page 32: ... floor jack to position the drive assembly into the machine 2 Line up the four threaded holes in the swivel plate weldment with the mount holes in the machine frame Reinstall the four button head screws and tighten to 64 83 Nm 47 61 ft lb Make sure the brake assembly is on the right side of the machine 3 Reinstall the steering chain onto both steering sprockets Reinstall the master link ...

Page 33: ...eering housing forward in the slots This will remove any slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 5 Reconnect the short brake rod to the brake pedal 6 Reinstall the brake pedal and clevis pin 7 Route the drive motor wire onto the drive assembly ...

Page 34: ...0 330695 8 11 8 Reconnect the wires to the drive motor 9 Reinstall the wire clamp and position the wires into the plastic sleeve 10 Reinstall the drive motor wire cover 11 Reconnect the battery connector to the machine ...

Page 35: ...CHASSIS 2 17 7100 330695 8 11 12 Close the seat support 13 Lower the machine to the floor 14 Operate the machine Check the front drive for proper operation ...

Page 36: ...back of the rear tires 1 Remove the front drive assembly See TO REMOVE FRONT DRIVE ASSEMBLY instructions in this section 2 Remove the eight hex screws holding the steering weldment to the top of the drive assembly Remove the steering weldment from the top of the drive assembly 3 Position the drive assembly gearbox end facing down onto a work bench ...

Page 37: ...ap onto the drive assembly 5 Mark a line on the side of the motor armature cap and the drive assembly This will allow proper re assembly 6 Remove the motor armature cap from the drive assembly You may have to pry the cap off with a screw driver 7 Set the motor armature cap to the side for now ...

Page 38: ...0695 8 11 8 Make sure the wavy washer is in position inside the motor brush housing 9 Remove the eight M6 cap screws holding the wheel to the gear box assembly 10 Lift up on the wheel 11 Remove the wheel from the gear box ...

Page 39: ...ide the wheel rim pointing up 13 Place the new front tire onto the gear box 14 Reinstall the eight M6 cap screws Tighten to 8 10 Nm 6 8 ft lb 15 Before the motor end cap can be reinstalled the four motor brushes must be removed First remove the black plastic cap by turning and pulling out ...

Page 40: ...ve the two screws holding the motor brush to the housing Remove the motor brush from the housing 18 Position the motor cap housing onto the wheel armature assembly Make sure to line up the line marked on the housing 19 Reinstall the eight M5 cap screws Tighten to 443 575Ncm 40 50 inch lbs ...

Page 41: ...es and caps 21 Reinstall the eight hex screws holding the steering weldment to the top of the drive assembly Tighten to 18 24 Nm 15 20 ft lb 22 Reinstall the front drive assembly into the machine See TO INSTALL FRONT DRIVE ASSEMBLY instructions in this section ...

Page 42: ...f the machine at the jack point Install jack stands under the machine frame 2 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws 3 Turn the steering wheel all the way to the left and then to the right Find the point in the rotation where the steering chain is the most tight ...

Page 43: ... forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 5 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering chain for proper operation ...

Page 44: ... of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots ...

Page 45: ...ering chain Remove the master link and steering chain 6 Position the new steering chain around both the large steering sprocket and small sprocket Install a new master link in the new chain 7 Turn the steering wheel all the way to the left and then to the right Find the point in the rotation where the steering chain is the most tight ...

Page 46: ... forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 9 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering chain for proper operation ...

Page 47: ... Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the steering U joint Loosen the two set screws on the top of the steering U joint ...

Page 48: ...oint 5 Remove the two hex screws holding the steering bearing housing to the machine frame Push the bearing housing back in the slots 6 Go under the machine and locate the small steering chain sprocket 7 Locate the master link on the steering chain Remove the master link and steering chain from the small steering sprocket ...

Page 49: ...nd retain the U joint and square key 10 Loosen the set screw holding the small steering sprocket to the bottom of the short steering shaft Remove and retain small sprocket and woodruff key 11 Use an arbor press to press the short steering shaft and two bearings out of the housing Discard the bearings Retain the short shaft Note the orientation of the shaft in the housing ...

Page 50: ...13 Use the arbor press to install the short steering shaft into the new bearings 14 Reinstall the small steering sprocket and woodruff key on the bottom of the steering housing Tighten the set screws tight 15 Reinstall the U joint and square key on the top of the steering housing Tighten the set screws tight ...

Page 51: ...g shaft and steering wheel into the top of the steering U joint Tighten the set screws tight 18 Go under the machine and reinstall the steering chain around the small steering sprocket Reinstall the master link 19 Turn the steering wheel all the way to the left and then to the right Find the point in the rotation where the steering chain is the most tight ...

Page 52: ... forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 21 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering chain for proper operation ...

Page 53: ...Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Go to the operators compartment and locate the steering U joint Loosen the two set screws on the top of the steering U joint 3 Pull the steering wheel and long steering shaft up and out of the top of the steering U joint ...

Page 54: ...scard the U joint and square key 5 Install the new U joint and square key on the top of the steering housing Tighten the set screws tight 6 Position the long steering shaft and steering wheel into the top of the steering U joint Tighten the set screws tight 7 Operate the machine and check the steering U joint for proper operation ...

Page 55: ...the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain ...

Page 56: ...eering chain 6 Loosen the set screw holding the small steering sprocket to the bottom of the short steering shaft Remove and discard the small sprocket Retain the woodruff key 7 Install the new small sprocket and woodruff key onto the steering shaft The teeth of the new sprocket face down Position the sprocket in the same location as the old one Tighten the two set screws tight ...

Page 57: ...to the right Find the point in the rotation where the steering chain is the most tight 10 Push the bearing housing forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 11 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering for proper operation ...

Page 58: ...tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain ...

Page 59: ... the steering chain from the machine 5 Remove the front drive assembly See TO REMOVE FRONT DRIVE ASSEMBLY instructions in this section 6 Remove the four hex screws holding the front drive pivot assembly to the upper drive casting Note the location of the spacers 7 Remove the pivot assembly and large sprocket from the upper casting ...

Page 60: ...embly onto the new large sprocket Install the four hex screws and one spacer Use blue loctite 242 on the threads Tighten to 37 48 Nm 26 34 ft lb 10 Reinstall the front drive assembly See TO INSTALL FRONT DRIVE ASSEMBLY instructions in this section 11 Reinstall the steering chain onto both steering sprockets Reinstall the master link ...

Page 61: ...ation where the steering chain is the most tight 13 Push the bearing housing forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 14 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering for proper operation ...

Page 62: ...of the rear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain ...

Page 63: ...the machine 5 Remove the front drive assembly See TO REMOVE FRONT DRIVE ASSEMBLY instructions in this section 6 Remove the four hex screws holding the front drive pivot assembly to the upper drive casting Note the location of the spacers 7 Remove the small thread roller screw holding the castle nut to the pivot shaft Remove the castle nut and flat washer ...

Page 64: ...washer Remove and discard the needle bearing and lower thrust washer 11 Install the new thrust washer onto the swivel plate weldment 12 Grease the new needle bearing and position on top of the new thrust washer Install the second thrust washer on top of the needle bearing 13 Reinstall the swivel plate onto the swivel plate weldment Make sure the rubber seal ring is in place on the swivel plate bef...

Page 65: ...b Reinstall the small thread roller into the cross hole Back off the castle nut if needed to align cross hole 16 Position the front drive pivot assembly onto the large sprocket Install the four hex screws and one spacer Use blue loctite 242 on the threads Tighten to 37 48 Nm 26 34 ft lb 17 Reinstall the front drive assembly See TO INSTALL FRONT DRIVE ASSEMBLY instructions in this section ...

Page 66: ... then to the right Find the point in the rotation where the steering chain is the most tight 20 Push the bearing housing forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 21 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering for proper operation ...

Page 67: ...ear tires 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the two hex screws holding the steering bearing housing to the machine frame Loosen the two screws and push the bearing housing back in the slots This will loosen the steering chain ...

Page 68: ...the machine 5 Remove the front drive assembly See TO REMOVE FRONT DRIVE ASSEMBLY instructions in this section 6 Remove the four hex screws holding the front drive pivot assembly to the upper drive casting Note the location of the spacers 7 Remove the small thread roller screw holding the castle nut to the pivot shaft Remove the castle nut and flat washer ...

Page 69: ...plate off the swivel plate weldment Make sure to retain the rubber seal ring 10 Reinstall the swivel plate onto the swivel plate weldment Make sure the rubber seal ring is in place on the swivel plate before installing 11 Reinstall the cone bearing in the swivel plate Grease the bearing if needed ...

Page 70: ...needed to align cross hole 13 Position the front drive pivot assembly onto the large sprocket Install the four hex screws and one spacer Use blue loctite 242 on the threads Tighten to 37 48 Nm 26 34 ft lb 14 Reinstall the front drive assembly See TO INSTALL FRONT DRIVE ASSEMBLY instructions in this section 15 Reinstall the steering chain onto both steering sprockets Reinstall the master link ...

Page 71: ...ation where the steering chain is the most tight 17 Push the bearing housing forward in the slots This will remove any excess slack in the steering chain Tighten the two hex screws to 37 48 Nm 26 34 ft lb 18 Remove the jack stands and lower the machine to the floor Operate the machine and check the steering for proper operation ...

Page 72: ...CHASSIS 2 54 7100 330695 8 11 ...

Page 73: ...HES 3 49 CYLINDRICAL SCRUB BRUSHES 3 51 TO REPLACE CYLINDRICAL SCRUB BRUSHES 3 51 TO CHECK AND ADJUST CYLINDRICAL BRUSH PATTERN 3 54 CYLINDRICAL BRUSH DRIVE BELT 3 57 TO REPLACE BRUSH DRIVE BELT 3 57 TO REPLACE BRUSH DRIVE PLUG BEARINGS 3 62 TO REPLACE BRUSH IDLER PLUG 3 64 TO REPLACE SCRUB HEAD LIFT ARM BEARINGS ROLL OUT BATTERY OPTION MACHINES ONLY 3 67 MANUAL SOLUTION VALVE 3 70 TO REPLACE SOLU...

Page 74: ...SCRUBBING 3 2 7100 330695 7 01 ...

Page 75: ...lows from the solution tank through the solution valve and down to the scrub brushes The brushes scrub the floor As the machine moves forward the rear squeegee wipes the dirty solution off the floor which is then picked up and drawn into the recovery tank by the vacuum fan ...

Page 76: ... at the top of the tank reached by lifting up the tank cover The solution tank requires no regular maintenance If detergent cakes on the bottom of the tank remove the deposits with a strong blast of warm water Do not use water hotter than 130 F 54 C or use steam to clean the tank because damage may occur A tank drain hose has been provided to allow the tank to be drained for cleaning The solution ...

Page 77: ...K WITH ES 1 Close the solution tank water valve 2 Raise the scrub head and rear squeegee 3 Stop the machine next to a floor drain 4 Shut off the machine and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake ...

Page 78: ...and place them over the floor drain Remove the drain cap from the end of the hose Drain the tanks 7 Open the tank cover 8 Spray the inside of the solution and recovery tanks with a strong blast of warm water Do not use water hotter than 130 F 54 C or use steam to clean the tank because damage may occur Remove the ES outlet filter clean reinstall ...

Page 79: ...SCRUBBING 3 7 7100 330695 10 00 9 Check the vacuum fan filter on top of the recovery tank Clean or replace if necessary 10 Close the tank cover 11 Replace the drain hose in the tank ...

Page 80: ...vel Surface Set Parking Brake 1 Make sure the solution tank has been drained 2 Raise the seat support and engage the prop rod 3 Disconnect the battery connector from the machine 4 Remove the battery cables leading to the middle battery on the left side of the machine Remove the middle left battery from the machine ...

Page 81: ...to access the solution tank hardware See TO REMOVE ROLL OUT BATTERY instructions in the ELECTRICAL section 6 Remove the three hex screws holding the solution tank to the frame 7 Open the tank cover 8 Remove the three hex screws holding the vacuum fan assembly to the solution and recovery tanks Lift the vacuum fan up and disconnect the electrical plug from the main harness remove the vacuum fan fro...

Page 82: ... check valve and hose from the top of the solution tank 10 Remove the clamp holding the wire harness to the side of the solution tank 11 If the machine is equipped with the ES option disconnect the float switch 12 Remove the hex screws holding the L bracket to the solution and recovery tanks ...

Page 83: ...ay to the back of the tanks Remove the drip tray from the machine 15 Lift the solution tank up far enough to access the clamp on the hose running from the bottom of the solution tank to the water valve Loosen this clamp and remove the hose from the solution tank 16 The solution tank can now be removed from the machine ...

Page 84: ... the machine frame 2 Drop the solution tank down in place Be careful to route the electrical harness properly Route the tank hose through the cut out in the frame Reinstall the three hex screws holding the solution tank to the machine frame Tighten the screws to 18 24 Nm 15 20 ft lb 3 Connect the hose coming from the solution tank to the hose leading to the water valve Tighten the worm drive clamp...

Page 85: ... and recovery tanks Tighten the screws to 18 24 Nm 15 20 ft lb 5 Reinstall the check valve and hose in the solution tank 6 If the machine is equipped with the ES option reconnect the float switch 7 Reinstall the clamp holding the wire harness to the side of the solution tank ...

Page 86: ...harness before installing the hardware Tighten the three hex screws to 18 24 Nm 15 20 ft lb 9 Close the tank cover and engage the cover latches 10 Push the front left battery forward in the battery tray 11 Reinstall the battery in the left middle space in the battery tray Reconnect the two battery cables ...

Page 87: ...BING 3 15 7100 330695 10 00 12 Reconnect the battery connector 13 Close the seat support 14 Reinstall the drip tray Tighten the two hex screws to 18 24 Nm 15 20 ft lb 15 Replace both drain hoses in the tanks ...

Page 88: ...SCRUBBING 3 16 7100 330695 10 00 16 Start the machine Fill the solution tank with water and check the hose connections for leaks ...

Page 89: ... by the squeegees and vacuum fan The recovery tank is located at the left rear corner of the machine on the left of the solution tank The recovery tank should be drained and cleaned after the solution tank is empty and whenever the float switch stops the vacuum fan or the recovery full light comes on ...

Page 90: ...ve 2 Raise the scrub head and rear squeegee 3 Stop the machine next to a floor drain 4 Shut off the machine and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 5 Remove the drain hose cap from the access caps at the rear of the solution tank ...

Page 91: ...ain the tanks 7 Open the tank cover 8 Spray the inside of the solution and recovery tanks with a strong blast of warm water Do not use water hotter than 130 F 54 C or use steam to clean the tank because damage may occur Remove the ES outlet filter clean reinstall 9 Check the vacuum fan filter on top of the recovery tank Clean or replace if necessary ...

Page 92: ...SCRUBBING 3 20 7100 330695 10 00 10 Close the tank cover 11 Reinstall the drain hose in the tank ...

Page 93: ...el Surface Set Parking Brake 1 Make sure the recovery tank has been drained 2 Raise the seat support and engage the prop rod 3 Disconnect the battery connector from the machine 4 Remove the battery cables leading to the middle battery on the right side of the machine Remove the middle right battery from the machine ...

Page 94: ...ut battery option roll the battery tray out far enough to access the solution tank hardware See TO REMOVE ROLL OUT BATTERY instructions in the ELECTRICAL section 6 Remove the three hex screws holding the recovery tank to the machine frame 7 Open the tank cover 8 Remove the hex screw from the end of the cover cable where it attaches at the vacuum fan mount plate ...

Page 95: ...chine 10 Remove the three hex screws holding the vacuum fan assembly to the solution and recovery tanks Lift the vacuum fan up and disconnect the electrical plug from the main harness remove the vacuum fan from the machine 11 Remove the squeegee vacuum hose from the recovery tank 12 Disconnect the recovery tank level switch from the main harness ...

Page 96: ...the check valve and hose from the top of the solution tank 14 Remove the hex screws holding the L bracket to the solution and recovery tanks 15 Remove both drain hoses from the tanks 16 Remove the hardware holding the drip tray to the back of the tanks Remove the drip tray from the machine ...

Page 97: ...SCRUBBING 3 25 7100 330695 10 00 17 Pull the recovery tank up and out of the machine frame ...

Page 98: ...ry tank on the right side edge of the machine frame 2 Drop the recovery tank down in place Be careful to route the electrical harness properly Reinstall the three hex screws holding the recovery tank to the machine frame Tighten the screws to 18 24 Nm 15 20 ft lb 3 Reinstall the L bracket to the solution and recovery tanks Tighten the screws to 18 24 Nm 15 20 ft lb ...

Page 99: ...ank 5 Reconnect the recovery tank level switch to the main harness 6 Reinstall the squeegee vacuum hose into the recovery tank 7 Reinstall the vacuum fan assembly Connect the vacuum fan to the main harness before installing the hardware Tighten the three hex screws to 18 24 Nm 15 20 ft lb ...

Page 100: ... three hex screws and tighten to 18 24 Nm 15 20 ft lb 9 Reinstall the cover cable where it attaches to the vacuum fan mount plate Reinstall the hex screw and tighten to 18 24 Nm 15 20 ft lb 10 Close the tank cover and engage the cover latches 11 Push the right rear battery backward in the battery tray ...

Page 101: ...einstall the battery in the right middle space in the battery tray Reconnect the two battery cables 13 Reconnect the battery connector 14 Close the seat support 15 Reinstall the drip tray Tighten the two hex screws to 18 24 Nm 15 20 ft lb ...

Page 102: ...SCRUBBING 3 30 7100 330695 10 00 16 Replace both drain hoses in the tanks 17 Start the machine Fill the recovery tank with water and check the hose connections for leaks ...

Page 103: ...head The scrub head houses the scrub brushes and their drive mechanisms The scrub head adjustments are factory set and should not be changed unless scrub head parts are damaged or replaced The scrub head also includes floor skirts to control water spray These skirts can be adjusted and need to be replaced if worn or damaged ...

Page 104: ...HEAD LINKS The scrub head links attach the scrub head frame to the machine frame The two scrub head links allow the scrub head to follow the contour of the floor The links have a pivot point on each end The links need no regular lubrication ...

Page 105: ... frame Remove the scrub head links from the machine 3 The measurement for the new scrub head links should be 11 25 inches from the center of the front ball joint to the center of the rear balljoint 4 Install the new scrub head links on the machine with the ball joints facing the inside of the machine frame Firmly tighten the four nyloc nuts NOTE Use the front frame hole for the cylindrical scrub h...

Page 106: ...the floor Shut off the key FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Disconnect the water line leading from the shut off valve to the scrub head 3 Disconnect the scrub brush motors shunt from the main electrical harness Mark the connectors for proper re assembly ...

Page 107: ...e frame and actuator 5 Remove the nyloc nut holding the ball joint to the mount bracket on the scrub head Do this on both sides of the scrub head 6 Jack up the front of the machine far enough to slide the scrub head out Install jack stands under the machine frame 7 The scrub head can now be pulled out from under the machine frame ...

Page 108: ...unt hole on the scrub head The ball joint should be positioned so it is facing the inside of the machine frame Do this on both sides of the machine NOTE The measurement for the scrub head links should be 11 25 inches from the center of the front ball joint to the center of the rear balljoint 3 Position the scrub head as close as possible to the center Remove the jack stands and lower the machine u...

Page 109: ... 5 Reconnect the brush drive motors to the main electrical harness 6 Reconnect the water line to the scrub head 7 Start the machine and raise the scrub head Operate the machine and check the scrub head for proper operation Check the scrub brushes for proper rotation the brushes should rotate toward each other at the front of the scrub head ...

Page 110: ... to the floor Shut off the key FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Disconnect the water line leading from the shut off valve to the scrub head 3 Disconnect the two scrub brush motors from the main electrical harness Mark the connectors for proper re assembly ...

Page 111: ... to the scrub head 5 Remove the nyloc nut holding the ball joint to the mount bracket on the scrub head Do this on both sides of the machine 6 Jack up the front of the machine far enough to slide the scrub head out Install jack stands under the machine frame 7 The scrub head can now be pulled out from under the machine frame ...

Page 112: ...scrub head The ball joint should be positioned so it is facing the inside of the machine frame Do this on both sides of the machine NOTE The measurement for the scrub head links should be 11 25 inches from the center of the front ball joint to the center of the rear balljoint 3 Position the scrub head as close as possible to the center Remove the jack stands and lower the machine until the clevis ...

Page 113: ...e to the scrub head 6 Start the machine and raise the scrub head Operate the machine and check the scrub head for proper operation Check the scrub brushes for pattern and proper rotation the brushes should rotate away from each other at the top of the scrub head See TO CHECK AND ADJUST CYLINDRICAL BRUSH PATTERN instructions ...

Page 114: ...every 50 hours of operation The skirts should clear the floor by 0 to 0 25 in 0 to 6mm when the scrub head is down Check the floor skirt adjustment after every 50 hours of operation TO ADJUST DISC SCRUB HEAD SKIRTS 1 Start the machine and lower the scrub head to the floor Shut off the key FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Loosen the screws hol...

Page 115: ...0 3 Position the up or down as needed to achieve 1 8 to 1 4 inch clearance from the bottom of the skirt to the floor 4 Re tighten the retainer screws Operate the machine and check the scrub head skirts for proper water spray control ...

Page 116: ...top On Level Surface Set Parking Brake 2 Remove the screws holding the retainer and skirt to the scrub head frame Remove and discard the skirt 3 Position the new skirt and existing retainer on the scrub head Adjust the skirt and tighten the retainer screws See TO ADJUST DISC SCRUB HEAD SKIRTS instructions 4 Operate the machine and check the scrub head skirts for proper water spray control ...

Page 117: ...ed behind the rear scrub brush The debris tray can be easily removed and emptied TO REMOVE DEBRIS TRAY 1 Start the machine and touch the scrub button Shut off the key when the scrub head is near the floor Do not touch the directional pedal FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Go to the right side of the machine Locate the scrub head side squeegee...

Page 118: ...d 4 Grasp the plastic debris tray and pivot the bottom up away from the back of the scrub head Pivot the debris tray far enough to allow the rubber skirt to clear the scrub head 5 Pull the debris tray straight out to the right until it is free of the scrub head lip Empty the debris tray ...

Page 119: ...l Surface Set Parking Brake 2 Position the debris tray opening facing forward on the lip on the back of the scrub head Push the debris tray in until is stops 3 Swing the right hand side squeegee back to the side of the scrub head Make sure the lock pin is positioned in the mount hole Reinstall the hair pin 4 Start the machine and raise the scrub head ...

Page 120: ... Set Parking Brake 2 Remove the six screws washers and nuts holding the debris tray skirt and retainer to the top lip of the tray Remove the retainer and skirt Discard the skirt 3 Position the new debris tray skirt and existing retainer on the top lip of the tray 4 Reinstall the hardware and hand tighten lightly 5 Reinstall the debris tray in the machine See TO INSTALL DEBRIS TRAY instructions ...

Page 121: ... brushes should be replaced if a large number of bristles are missing or if bristle length is less than 10 mm 0 38 in NOTE Replace worn brushes in pairs Scrubbing with brushes of unequal bristle length will result in diminished scrubbing performance TO REPLACE DISC SCRUB BRUSHES 1 Make sure the scrub head is in the raised position FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surfac...

Page 122: ...rub head 4 Place the new scrub brush on the floor in front of the scrub head Push the brush under the scrub head 5 Line up the brush drive socket with the drive plug 6 While pressing the brush spring clip together with your thumb and index finger lift the scrub brush onto the drive plug 7 Check to make sure the brush is securely mounted on the brush drive hub 8 Repeat for the other brush ...

Page 123: ...in NOTE Replace worn brushes in pairs Scrubbing with brushes of unequal bristle length will result in diminished scrubbing performance NOTE Fill the solution tank before checking or adjusting the brush pattern TO REPLACE CYLINDRICAL SCRUB BRUSHES 1 Press the scrubbing switch When the scrub head is approximately 25 mm 1 in from the floor turn the machine power off FOR SAFETY Before Leaving Or Servi...

Page 124: ... from the scrub head Pull the bottom of the door outward then pull the idler door and idler plug off of the brush 4 Pull the old brush out of the scrub head 5 Position the brush with the double row end towards you Guide the new brush onto the drive hub 6 Insert the Idler plug on the inside of the idler door into the brush ...

Page 125: ...Make sure the lock pin is positioned in the mount hole Reinstall the hair pin 9 Start the machine and raise the scrub head 10 Repeat for the other brush on the other side of the scrub head NOTE Each side of the scrub head is stamped with a letter The idler door of that side of the scrub head is stamped with the same letter Make sure the letter on the door matches the letter on the scrub head when ...

Page 126: ...floor 2 Set the parking brake 3 Lower the scrub head in the chalked area Allow the machine to scrub in the same place for 15 to 20 seconds NOTE If chalk or other material is not available allow the brushes to spin on the floor for two minutes A polish mark will remain on the floor 4 Raise the scrub head and move the machine away from the chalked area Turn the machine power off ...

Page 127: ...shes need adjustment to straighten the brush pattern 1 To adjust brush taper push downward on the mounting spring and idler door until the top of the door releases from the scrub head Pull the bottom of the door outward then pull the idler door and idler plug off of the brush 2 While holding the flat end of the idler shaft with a wrench loosen the mounting screw on the outside of the idler door 10...

Page 128: ...4 Check the brush patterns again and readjust as necessary until both patterns are the same 6 If one brush pattern is wider than the other the scrub head needs to be leveled Level the scrub head by turning the scrub head links Both scrub head links should be adjusted equally Check the brush patterns again and readjust as necessary until both patterns are the same ...

Page 129: ...n deflection from a force of 1 1 to 1 2 kg 2 5 to 2 7 lb at the belt midpoint Check and adjust the belt tension every 100 hours of operation TO REPLACE BRUSH DRIVE BELT 1 Start the machine and lower the scrub head near the floor Shut off the key FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Remove the scrub brushes See TO REPLACE CYLINDRICAL SCRUB BRUSHES...

Page 130: ...n the belt tension bolt under the brush motor Turn the bolt down far enough to allow the belt to be slipped off the motor pulley Push the drive belt down toward the lower brush drive plug 6 Remove the drive plug from the scrub head Use a wrench on the flats of the hub shaft Turn the shaft counter clockwise NOTE Make sure the scrub head is slightly off the floor before attempting to remove the driv...

Page 131: ...achine NOTE It is a tight fit for the belt in the area of the lower belt cover and bottom drive plug Carefully work the belt past the lower cover DO NOT remove the lower cover 9 Slip the new drive belt into position Push the rest of the drive belt up toward the motor belt pulley Slip the drive belt over the motor belt pulley 10 Position the brush drive plug and shaft into the belt area Install the...

Page 132: ... under the drive motor to tighten the drive belt Apply 3 0 5 0 lbs of force to the drive belt in the middle of the span The belt should deflect 0 10 inch 13 Tighten the drive motor pivot bolts to 18 24 Nm 15 20 ft lb Re check the belt tension Tighten the two motor pivot screws to 18 24 Nm 15 20 ft lb Re check the belt tension 14 Reinstall the belt cover Tighten the screws to 11 14 Nm 7 10 ft lb ...

Page 133: ...SCRUBBING 3 61 7100 330695 10 00 15 Reinstall the scrub brushes See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions 16 Operate the machine and check the scrub brushes for proper operation ...

Page 134: ...fore Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Remove the scrub brush drive plug See TO REPLACE BRUSH DRIVE BELT instructions in this section 2 Remove the retainer ring from the drive plug shaft 3 Use an arbor press to remove the shaft from the drive plug ...

Page 135: ...arbor press to install new bearings into each end of the drive plug 6 Use an arbor press to install the shaft into the new bearings and drive plug 7 Reinstall the retainer ring onto the end of the drive plug shaft 8 Reinstall the scrub brush drive plug See TO REPLACE BRUSH DRIVE BELT instructions in this section ...

Page 136: ...icing Machine Stop On Level Surface Set Parking Brake 1 Remove the scrub brushes See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions in this section 2 Remove the idler plate from the scrub head 3 Remove the flat screw from the back of the brush idler plate Remove the idler plug from the plate ...

Page 137: ...taining ring from the idler shaft 5 Use an arbor press to remove the shaft from the idler plug Discard the existing idler plug 6 Use an arbor press to install the idler shaft into the new idler plug 7 Reinstall the retaining ring onto the idler shaft ...

Page 138: ...aft lines up with the slot in the door plate Reinstall the flat screw Position the edge of the idler 06 inch to 09 inch from the bottom edge of the door plate Tighten the flat screw to 37 48 Nm 26 34 ft lb 9 Reinstall the scrub brush and idler plate See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions in this section ...

Page 139: ...ce Set Parking Brake 1 Remove the scrub head See TO REMOVE CYLINDRICAL DISC SCRUB HEAD instructions in this section 2 Remove the cotter pin and clevis pin from the bottom of the scrub head lift actuator where it attaches to the scrub head lift arm 3 Remove the four hex screws holding the two left arm bearings to the machine frame Remove the scrub head lift arm from the machine ...

Page 140: ...he lever to the arm 5 Slip the bearing off the end of the lift arm Discard the existing bearing Install the new bearing in the same orientation 6 Position the actuator lever onto the end of the lift arm in the same orientation it was removed Use a hammer to reinstall the roll pin 7 Go to the other end of the lift arm Remove the outside retainer ring from the end of the lift arm ...

Page 141: ... positioned on the outside of the machine frame rails NOTE Make sure to position the grease zerk pointing down Pump 6 pumps of grease into each new bearing 10 Reinstall the four hex screws and nuts Tighten to 37 48 Nm 26 34 ft lb 11 Reconnect the scrub head lift actuator to the lift arm Reinstall the clevis pin and cotter pin 12 Reinstall the scrub head See TO INSTALL CYLINDRICAL DISC SCRUB HEAD i...

Page 142: ...chine This valve controls the amount of water being sent to the scrub brushes The control lever is located in the operators compartment next to the operators left leg TO REPLACE SOLUTION VALVE 1 Drain the solution tank 2 Lower the scrub head to the floor FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake ...

Page 143: ...te the manual solution valve above the scrub head 5 Remove the cotter pin from the control lever rod where it attaches to the valve Pop the rod out of the mount hole 6 Loosen the worm drive clamps holding the two solution hoses to the valve fittings Pull the hoses off the fittings ...

Page 144: ...me Remove the manual valve from the machine 8 Remove the fittings from the old valve and install in the new valve in the same orientation 9 Remove the lever from the old valve and install it on the new valve in the same orientation 10 Install the new valve on the machine Hand tighten the screws ...

Page 145: ...95 10 00 11 Reconnect the two solution hoses Hand tighten the worm drive clamps 12 Place the control lever rod in the mount hole and install the cotter pin 13 Operator the machine and check the water valve for proper operation ...

Page 146: ...ring transport of the machine SQUEEGEE WHEEL CAMS The squeegee wheel cams adjust the rear squeegee deflection along the entire length of the rear squeegee There are wheel cams at either end of the squeegee Increase deflection Turn the cams counterclockwise Decrease deflection Turn the cams clockwise SQUEEGEE LEVELING KNOB The squeegee leveling knob adjusts the deflection at the ends of the rear sq...

Page 147: ...MBLY 1 Lower the squeegee to approximately 25 mm 1 in from the floor 2 Turn the machine power off and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 Remove the squeegee suction hose from the squeegee ...

Page 148: ...SCRUBBING 3 76 7100 330695 10 00 4 Remove both squeegee mounting knobs 5 Pull the squeegee assembly off the machine ...

Page 149: ...EAR SQUEEGEE ASSEMBLY 1 Make sure the squeegee pivot is lowered FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Place the squeegee under the squeegee pivot 3 Push the squeegee frame onto the squeegee pivot ...

Page 150: ...e suction hose onto the squeegee fitting 6 Operate the machine Check the rear squeegee for proper roll out and levelness NOTE Make sure the rear squeegee upper and lower links are adjusted to the proper length 10 5 inches from the center lines of the rod ends UPPER LINK LOWER LINK ...

Page 151: ...squeegee blade with the surface being scrubbed Make sure this adjustment is done on an even level floor 1 Turn the machine power on 2 Lower the squeegee 3 Drive the machine forward a few feet then set the parking brake Shut off the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake ...

Page 152: ... directly behind the squeegee suction hose DO NOT disconnect the suction hose from the squeegee frame when leveling squeegee Turn the squeegee leveling knob counter clockwise to increase the deflection at the ends of the squeegee Turn the squeegee leveling knob clockwise to decrease the deflection at the ends of the squeegee blade 6 Drive the machine forward with the squeegee down to check the squ...

Page 153: ...eflection is the amount of curl the squeegee blade has when the machine moves forward while the squeegee lowered to the floor The best deflection is when the squeegee wipes the floor just dry with a minimum amount of deflection 1 Turn the machine power on 2 Lower the squeegee ...

Page 154: ... 15 mm 0 62 in for rough floors 4 To adjust the amount of deflection turn the squeegee deflection cams clockwise to decrease the blade deflection Turn the squeegee deflection cams counter clockwise to increase blade deflection 5 Drive the machine forward again to check the squeegee blade deflection 6 Readjust the squeegee blade deflection if necessary 03719 12 mm 0 50 in 03719 12 mm 0 50 in ...

Page 155: ...R On the left end of the squeegee is a guide roller that guides the squeegee blade end along a wall 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 is to the wall The squeegee blade end should be further away from the wall when the floor curves up into the wall REAR SQUEEGEE SPRINGS The rear squeegee springs are used to ...

Page 156: ... wiping edge rotate the top edges down bottom edges up To use the last edge rotate the blade end for end Rotate squeegee blades when they become worn half way through the thickness of the blade Replace damaged squeegee blades TO REPLACE OR ROTATE REAR SQUEEGEE REAR BLADE 1 Make sure the squeegee is in the raised position 2 Turn the machine power off and set the parking brake FOR SAFETY Before Leav...

Page 157: ...end of 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 7 Tighten the two retainer knobs until the ends of the front and rear squeegee blades touch Do not over tighten ...

Page 158: ...DE 1 Make sure the squeegee is in the raised position 2 Turn the machine power off and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 Remove the squeegee from the machine See TO REMOVE SQUEEGEE ASSEMBLY instructions ...

Page 159: ... SQUEEGEE REAR BLADE 5 Loosen the two remaining knobs on top of the squeegee assembly 6 Pull the retainer plate back and pull the front squeegee blade out of the squeegee frame 7 Insert the rotated or new squeegee blade in the squeegee frame lining up the slots in the blade with the tabs on the retainer plate ...

Page 160: ... Tighten the two rear blade retainer knobs until the ends of the front and rear squeegee blades touch Do not over tighten 10 Install the squeegee assembly on the squeegee pivot See TO INSTALL SQUEEGEE ASSEMBLY instructions 11 Adjust the squeegee blade leveling and deflection as stated in TO LEVEL SQUEEGEE and ADJUST SQUEEGEE BLADE DEFLECTION instructions 03719 12 mm 0 50 in ...

Page 161: ...e squeegees control water spray and channel water into the path of the rear squeegee Check the side squeegees for damage and wear daily Replace the side squeegee blades if they become damaged or lose their shape Replace the squeegee deflectors if they become worn ...

Page 162: ...ADES 1 Raise the scrub head 2 Turn the machine power off and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 Remove the cotter pin clevis pin deflector and the retainer bracket from the side squeegee ...

Page 163: ...10 00 4 Pull the squeegee out of the squeegee frame 5 Slide a new squeegee blade into the frame 6 Replace the retainer bracket deflector clevis pin and cotter pin 7 Repeat for the side squeegee on the other side of the scrub head ...

Page 164: ...acuum at the squeegee vacuum hose This vacuum pulls water from the lowered squeegee into the recovery tank The vacuum fan is equipped with a easily serviceable air filter TO REMOVE VACUUM FAN ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the recovery solution tank cover 2 Locate the vacuum fan between the solution and recovery tanks ...

Page 165: ... out of the top of the tank Let it rest on the edge of the tank 4 Disconnect the vacuum fan exhaust hose from the bottom of the fan outlet port 5 Disconnect the vacuum fan motor from the main electrical harness 6 Remove the vacuum fan assembly from the machine Be careful not to loose the rubber seal on the outlet of the vacuum housing ...

Page 166: ...n Level Surface Set Parking Brake 1 Open the recovery solution tank cover Position the vacuum fan to the edge of the tanks 2 Reconnect the vacuum fan exhaust hose to the bottom of the fan outlet port 3 Reconnect the plug from the vacuum fan motor into the main electrical harness See schematic in the ELECTRICAL section ...

Page 167: ...seal is in place on the outlet of the vacuum housing 5 Reinstall the three screws holding the vacuum fan to the top of the tanks Tighten to 18 24 Nm 15 20 ft lb 6 Close the tank cover and operate the machine Make sure the top of the vacuum fan seal contacts the bottom of the tank cover Check the vacuum fan for proper operation ...

Page 168: ... circuit breaker tripped Reset circuit breaker Little or no solution flow to the floor Solution tank empty Fill solution tank Solution control rod broken or out of adjustment Replace and or adjust rod Solution flow turned off Turn solution flow on Solution supply lines plugged Flush solution supply lines Solution solenoid clogged or stuck Clean or replace ES mode option ES switch off Turn ES switc...

Page 169: ...7100XXX00001 02699 4 77 ELECTRICAL SCHEMATIC S N 7100XXX00001 02699 4 78 ELECTRICAL SCHEMATIC S N 7100xxx00001 02699 4 79 Page WIRE HARNESS GROUP S N 7100XXX02700 4 80 WIRE HARNESS GROUP S N 7100XXX02700 4 81 WIRE HARNESS GROUP S N 7100XXX02700 4 82 WIRE HARNESS GROUP S N 7100XXX02700 4 83 WIRE HARNESS GROUP S N 7100XXX00001 02699 4 84 WIRE HARNESS GROUP S N 7100XXX00001 02699 4 85 WIRE HARNESS GR...

Page 170: ... IT WILL KEEP RUNNING UNTIL SWITCH S6 OPENS FOR 30 SECONDS 4 111 ES SYSTEM 4 112 HORN 4 113 SHROUD LIGHT HEAD LIGHTS 4 115 PROPEL CONTROLLER 4 117 PROPEL CONTROLLER 4 118 POWER WAND BACKUP ALARM 4 119 POWER UP TESTING 4 121 SCRUB SYSTEM 4 123 SCRUB SYSTEM 4 125 SOLUTION EMPTY 4 127 SOLUTION VALVE 4 129 SQUEEGEE SYSTEM 4 131 TOUCH PANEL 4 133 VACUUM FAN 4 135 VACUUM FAN 4 136 ...

Page 171: ...ELECTRICAL 4 3 7100 330695 8 11 INTRODUCTION The 7100 electrical system consists of the batteries instrument panel drive motor switches relays and circuit breakers ...

Page 172: ...ingly over the battery tops terminals and cable clamps Do not allow any baking soda solution to enter the batteries Use a wire brush to clean the terminal posts and the cable connectors After cleaning apply a coating of clear battery post protectant to the terminals and the cable connectors Keep the tops of the batteries clean and dry Keep all metallic objects off the top of the batteries which ma...

Page 173: ...subtract to the specific gravity reading 0 004 4 points for each 6 C 10 F above or below 25 C 77 F TO CHARGE BATTERIES 1 Drive the machine to a flat dry surface in a well ventilated area 2 Stop the machine set the parking brake and turn the machine power off FOR SAFETY Before leaving or servicing machine stop on level surface set parking brake turn off machine and remove key 3 Open the seat suppor...

Page 174: ...tomatically When the batteries are fully charged the Tennant charger will automatically turn off NOTE Use a charger with the proper rating for the batteries to prevent damage to the batteries or reduce the battery life NOTE If the charger needs to be disconnected from the machine before the batteries are fully charged and the charger has not automatically shut off turn off the charger before disco...

Page 175: ...aving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries FOR SAFETY Disconnect Battery Connections Before Working On machine 3 Remove the five small battery cables from the batteries ...

Page 176: ...y from the batteries 5 Remove the batteries one at a time Note the orientation of the battery neg and pos 6 Install the new batteries into the battery tray Note the orientation of the battery neg and pos 7 Reinstall the five small battery cables onto the new batteries ...

Page 177: ...8 Reinstall the connector assembly onto the batteries 9 Reconnect the battery connect to the machine connector 10 Disengage the prop rod and lower the seat support 11 Start the machine and check the new batteries for proper operation ...

Page 178: ...the operator informed on machine performance TO REPLACE TOUCH PANEL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the control panel See TO ACCESS CONTROL PANEL instructions Make sure to disconnect the machine batteries FOR SAFETY Disconnect Battery Connections Before Working On machine 2 Locate the circuit board cover on the inside front wall of the ...

Page 179: ...olding the circuit board cover onto the frame 4 Pull the circuit board cover back to access the circuit board 5 Un plug the ribbon cable from the circuit board 6 Locate the six touch panel lock clips on the under side of the dash panel Remove the lock clips ...

Page 180: ...eful when removing the ribbon cables from the slot in the dash panel 9 Position the new touch panel on the machine Route the ribbon cable through the slot in the dash panel 10 Place the touch panel bezel over the touch panel Line up the posts on the bezel with the mount holes in the dash panel 11 Install the six lock clips on the bezel posts ...

Page 181: ...t board 13 Position the circuit board cover back to the inside front wall of the control panel 14 Reinstall the six nuts on the circuit breaker cover Hand tighten lightly 15 Pivot the control panel back in position Reinstall the four screws and tighten to 18 24 Nm 15 20 ft lb ...

Page 182: ...LECTRICAL 4 14 7100 330695 8 11 16 Open the operator seat and reconnect the battery connector at the front of the solution tank 17 Close the seat support Start the machine and check for proper operation ...

Page 183: ...mount plate down against the seat support TO ACCESS CONTROL INSTRUMENT PANEL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Lift the operator seat to access the batteries The support arm automatically engages when the seat is lifted all the way up 2 Disconnect the battery connector from the machine FOR SAFETY Disconnect Battery Connections Before Working O...

Page 184: ... plate and the four screws at the sides of the control panel plate 5 Pivot the control panel plate and steering wheel down until it is resting against the seat support 6 Make any necessary repairs to the electrical components 7 Pivot the control panel plate and steering wheel up until it is positioned into the front shroud ...

Page 185: ...top of the instrument panel mount plate and the four screws at the sides of the control panel plate 9 Open the operator seat and reconnect the battery connector at the front of the solution tank 10 Close the seat support Start the machine and check for proper operation ...

Page 186: ...ake 1 Open the control panel See TO ACCESS CONTROL INSTRUMENT PANEL instructions Make sure to disconnect the machine batteries FOR SAFETY Disconnect Battery Connections Before Working On machine 2 Locate the circuit board cover on the inside front wall of the control panel 3 Remove the six nuts holding the circuit board cover onto the frame ...

Page 187: ... access the circuit board 5 Un plug the ribbon cable from the circuit board 6 Un plug the three wire connectors from the circuit board 7 Pop the circuit board off the six plastic stand offs Remove the circuit board from the machine Note the orientation of the circuit board ...

Page 188: ...sh the board down until the stand off snaps in place 9 Reconnect the three wire connectors and two ribbon cables to the new circuit board See schematic in this section 10 Reconnect the ribbon cable to the new circuit board 11 Position the circuit board cover back to the inside front wall of the control panel ...

Page 189: ...tly 13 Pivot the control panel back in position Reinstall the six screws and tighten See TO ACCESS CONTROL INSTRUMENT PANEL instructions 14 Open the operator seat and reconnect the battery connector at the front of the solution tank 15 Close the seat support Start the machine and check for proper operation ...

Page 190: ...t the circuit breaker will continue to stop current flow until the problem is corrected The circuit breakers are located at the lower left corner of the control panel The chart below shows the circuit breakers and the electrical components they protect Circuit Breaker Rating Circuit Protected CB1 2 5 A Machine power CB2 2 5 A Lights CB3 10 A Horn CB4 10 A Power wand Back up alarm CB5 10 A Control ...

Page 191: ...Parking Brake 1 Lift the operator seat to access the batteries The support arm automatically engages when the seat is lifted all the way up 2 Disconnect the battery connector from the machine FOR SAFETY Disconnect Battery Connections Before Working On machine 3 Locate the circuit breakers on the lower left corner of the control panel ...

Page 192: ...eaker chart to locate the circuit breaker that needs to be changed 5 Disconnect the wires from the back of circuit breaker 6 Remove the nut boot from the front of the circuit breaker 7 Push the circuit breaker out of the mount hole from the back of panel ...

Page 193: ...ut boot onto the new circuit breaker 10 Reconnect the wires to the back of the new circuit breaker See the schematic in this section 11 Lift the operator seat and reconnect the battery connector at the front of the solution tank 12 Close the seat support Start the machine and check for proper operation ...

Page 194: ...ator console Access the fuse by lowering the operator console Fuse Rating Circuit Protected FU 1 40 A Propelling TO REPLACE FUSE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the control panel See TO ACCESS CONTROL INSTRUMENT PANEL instructions in this section FOR SAFETY Disconnect Battery Connections Before Working On machine 2 Locate the electrical...

Page 195: ...de and remove 5 Position the new fuse on the two red stand offs under the two bolts and power cables Hand tighten the hardware See the schematic in this section 6 Pivot the control panel back in position Reinstall the six screws and tighten to 18 24 Nm 15 20 ft lb 7 Lift the operator seat and reconnect the battery connector at the front of the solution tank 8 Start the machine and check for proper...

Page 196: ...he directional pedal with the upper part of your foot NOTE A machine power shut off switch is located under the operator seat If there is no weight on the operator seat the machine WILL NOT propel in any direction Reverse Press the bottom of the directional pedal with the heel of your foot When the directional pedal is placed into the reverse position the rear squeegee will automatically raise Aft...

Page 197: ...ore Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries 3 Go under the machine in the area of the right hand side brush Locate the wires and connector leading from the directional pedal ...

Page 198: ...rness Remove any plastic ties holding the directional pedal harness to the main harness 5 Go the the operators compartment and locate the directional pedal assembly Remove the four thread rolling screws holding the directional pedal to the floor plate 6 Remove the pedal assembly from the machine ...

Page 199: ... Parking Brake 1 Position the directional pedal assembly in the machines operators compartment 2 Feed the pedal harness down through the access hole in the floor plate 3 Line up the mount holes in the pedal assembly plate with the mount holes in the machines floor plate Reinstall the four thread rolling screws and tighten to 8 10 Nm 6 7 ft lb ...

Page 200: ...ect the directional pedal connector to the main harness Reinstall any plastic ties that were holding the directional pedal harness to the main harness 6 Reconnect the batteries 7 Disengage the prop rod and lower the seat support 8 Start the machine and check for proper operation Set the pedal neutral if needed See TO SET POTENTIOMETER NEUTRAL instructions in this section ...

Page 201: ...ace Set Parking Brake 1 Remove the directional pedal assembly from the machine See TO REMOVE DIRECTIONAL PEDAL ASSEMBLY instructions in this section 2 Loosen the hex screw and nut holding the accelerator lever to the potentiometer Remove the accelerator lever from the potentiometer shaft 3 Remove the thin hex nut from the potentiometer shaft ...

Page 202: ...utral position reinstall the accelerator lever onto the shaft of the potentiometer Hand tighten the hex screw and nut 7 Check the length of the threaded rod ball joint assembly Measure the distance between the ball joint centers The dimension should be approximately 4 inches If an adjustment needs to be made loosen the upper jam nut and turn the rod Re tighten the jam nut 8 Reinstall the direction...

Page 203: ...CTRICAL 4 35 7100 330695 8 11 9 Check the new potentiometer for neutral See TO SET POTENTIOMETER NEUTRAL instructions in this section 10 Operate the machine Check the new potentiometer for proper operation ...

Page 204: ...Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the seat support and engage the prop rod 2 Disconnect the machine batteries 3 Go under the machine in the area of the right hand side brush Locate the wires and connector leading from the directional pedal ...

Page 205: ... directional pedal harness to the main harness 5 Use a multimeter set to the OHMS setting Check the red B and white A of the connector with the meter 6 The meter reading should be 2500 OHMS 50 OHMS 7 Loosen the upper jam nut on the threaded rod Turn the rod to achieve the proper OHM reading Tighten the jam nut 8 Reconnect the batteries ...

Page 206: ...ELECTRICAL 4 38 7100 330695 8 11 9 Disengage the prop rod and lower the seat support 10 Operate the machine Check the machine for proper neutral operation ...

Page 207: ...ine Stop On Level Surface Set Parking Brake 1 Open the control panel See TO ACCESS CONTROL PANEL instructions FOR SAFETY Disconnect Battery Connections Before Working On machine 2 Locate the controller box in the center of the control panel 3 Disconnect the wires and power cables leading to the controller ...

Page 208: ...uts holding the controller to the panel Remove the controller from the machine 5 Position the new controller on the panel Reinstall the screws and nuts Hand tighten 6 Reconnect the power cables and electrical wires to the controller See the schematic in this section ...

Page 209: ...rol panel back in position Reinstall the two screws and tighten to 18 24 Nm 15 20 ft lb 8 Lift the operator seat and reconnect the battery connector at the front of the solution tank 9 Start the machine and check for proper operation of the propelling ...

Page 210: ...ub brush motors and propelling motor should be inspected after every 1000 hours of machine operation TO REPLACE DRIVE MOTOR ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake The front drive motor is part of the front drive assembly See TO REMOVE FRONT DRIVE ASSEMBLY instructions in the CHASSIS section if the front drive motor needs repair ...

Page 211: ...e side squeegees See TO REPLACE SIDE SQUEEGEE BLADES instructions in the SCRUBBING section 2 Remove the scrub brushes See TO REPLACE DISC SCRUB BRUSHES instructions in the SCRUBBING section 3 Go in under the scrub head and remove the screw and washer from the center of the brush drive plug 4 Drop the drive plug down off the motor shaft Make sure to retain the square key ...

Page 212: ... head Shut off the key 7 Go in on top of the scrub head and disconnect the scrub brush motor from the main harness Note the orientation of wire to motor 8 Lift the brush motor off the deck of the scrub head and remove it from the machine Note the orientation of the brush motor power cable The new motor must be orientated the same direction ...

Page 213: ...the main electrical harness See schematic in this section 11 Start the machine and raise the scrub head Shut off the key 12 Rotate the brush motor until it is orientated properly and the mount holes line up with the holes in the deck of the scrub head Install the four screws and tighten to 11 14 Nm 7 10 ft lb ...

Page 214: ...24 Nm 15 20 ft lb 14 Reinstall the scrub brush See TO REPLACE DISC SCRUB BRUSHES instructions in the SCRUBBING section 15 Reinstall the side squeegees See TO REPLACE SIDE SQUEEGEE BLADES instructions in the SCRUBBING section 16 Start the machine and operate the scrubbing function Check for proper operation and rotation of the new motor FRONT OF MACHINE SCRUB BRUSH ROTATION ...

Page 215: ...cing Machine Stop On Level Surface Set Parking Brake 1 Remove the side squeegees See TO REPLACE SIDE SQUEEGEE BLADES instructions in the SCRUBBING section 2 Remove the scrub brushes See TO REPLACE DISC SCRUB BRUSHES instructions in the SCRUBBING section 3 Start the machine and lower the scrub head Shut off the key ...

Page 216: ...ation of wire to motor 5 Loosen the pivot mount bolts on the brush motor 6 Remove the two screws holding the brush motor belt cover to the brush motor Remove the belt cover from the scrub head 7 Loosen the jam nut on the belt tension bolt under the brush motor Turn the tension bolt down far enough to slip the the belt off the cogged pulley ...

Page 217: ...or shaft Slide the pulley off the shaft Do not loose the square key 10 Install the cogged pulley and square key onto the shaft of the new brush motor Leave the set screws loose for now 11 Position the new brush motor on the scrub head Align the mounting holes on the motor with the holes in the pivot mount bracket Install the two screws Snug the hardware for now 12 Slip the brush belt over the cogg...

Page 218: ...e 242 blue on the threads 14 Use the hex screw under the brush motor to tension the belt Apply 2 5 2 7 lbs of force at the middle of the span that is opposite belt travel There should be 0 10 inch of deflection 15 Tighten the two motor pivot screws to 18 24 Nm 15 20 ft lb Re check the belt tension 16 Reconnect the brush motor into the main harness See schematic in this section ...

Page 219: ...t lb Apply a small amount of RTV sealant on the flange of the belt cover to keep dust out of the cogs of the belt 18 Reinstall the scrub brushes See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions in the SCRUBBING section 19 Operate the machine and check the scrub brush motor for proper operation ...

Page 220: ...ead or the rear squeegee TO REPLACE SCRUB HEAD LIFT ACTUATOR 1 Start the machine and lower the scrub head to the floor Shut off the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Go in on top of the scrub head and remove the cotter pin and clevis pin from the bottom of the scrub head lift actuator tube ...

Page 221: ... Locate the four screws holding the lift actuator mount bracket to the front of the seat support and the back of the actuator mount tower Remove the four screws 5 Lift the actuator and spring mount bracket up far enough to disconnect the actuator from the main harness 6 Lift the actuator and spring mount bracket out of the assembly and remove from the machine ...

Page 222: ...to the new actuator Install the clevis and cotter pins 9 Remove the cotter pin and clevis pin holding the top mount bracket to the existing lift actuator Install the mount plate onto the new actuator 10 Position the new actuator and spring mount bracket in the machine Slide the assembly down the into the mount tower Route the actuator wire and plug the connector into the main harness ...

Page 223: ...s to 18 24 Nm 15 20 ft lb 12 Go in on top of the scrub head and install the clevis and cotter pin in the bottom of the scrub head lift actuator tube and scrub head lift bracket 13 Plug in the battery connector Lower the seat assembly 14 Operate the machine and check the scrub head lift actuator for proper operation ...

Page 224: ... and lower the rear squeegee Shut off the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 Remove the hardware holding the drip tray to the back of the tanks Remove the drip tray from the machine 4 Remove the rear squeegee assembly See TO REMOVE REAR SQUEEGEE ASSEMBLY instructions in the SCRUBBING section ...

Page 225: ...tor from the main harness 6 Remove the three screws holding the squeegee mount channel to the back of the machine 7 Remove the two remaining screws located in front of the rear tires 8 Let the squeegee mount channel and squeegee assembly drop down to access the lift actuator ...

Page 226: ... pin and clevis pin from the motor end of the lift actuator Remove the actuator from the squeegee frame 11 Install the new actuator into the squeegee frame in the same orientation as the old one was removed Reinstall the two clevis pins and cotter pins 12 Position the squeegee frame assembly back onto the rear of the machine frame ...

Page 227: ...chine Tighten to 18 24 Nm 15 20 ft lb 14 Reinstall the two remaining screws located in front of the rear tires Tighten to 18 24 Nm 15 20 ft lb 15 Reconnect the squeegee lift actuator to the main electrical harness See schematic in this section 16 Reinstall the drip tray Tighten the two hex screws to 18 24 Nm 15 20 ft lb ...

Page 228: ... 4 60 7100 330695 8 11 17 Reinstall the squeegee assembly See TO INSTALL REAR SQUEEGEE ASSEMBLY instructions in the SCRUBBING section 18 Start the machine and check the rear squeegee actuator for proper operation ...

Page 229: ...ed float switches in the recovery tank and solution tank are used to turn the pump on and off automatically TO REPLACE ES PUMP FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Make sure the solution and recovery tanks are empty 2 Remove the solution tank See TO REMOVE SOLUTION TANK instructions in the scrubbing section ...

Page 230: ...r bottom edge of the recovery tank 4 Disconnect the ES pump from the main electrical harness 5 Loosen the worm drive clamps holding the solution hoses to the ES pump Pull the hoses off the pump fittings 6 Loosen the worm drive clamp holding the ES pump to the mount bracket ...

Page 231: ... of the machine 8 Remove the plastic fittings from the old pump and install in the new pump in the same orientation 9 Install the new ES pump on the mount plate Hand tighten the worm drive clamp 10 Reinstall the hoses onto the inlet and outlet ports on the new pump ...

Page 232: ...onnect the pump to the main electrical harness See schematic in this section 12 Reinstall the solution tank See TO INSTALL SOLUTION TANK instructions in the scrubbing section 13 Operate the machine and check the ES pump for proper operation ...

Page 233: ...n the machine is either propelling forward or in neutral This valve is used along with the manual valve which controls the amount of water that flows to the scrub head TO REPLACE SOLUTION SOLENOID VALVE 1 Drain the solution tank 2 Lower the scrub head to the floor FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake ...

Page 234: ... in front of the rear tire 4 Locate the solution solenoid valve in the area of the manual valve 5 Mark and disconnect the wires leading to the solenoid valve 6 Loosen the two worm drive clamps holding the water hoses to the valve Mark the hoses and pull them off the fittings ...

Page 235: ...osition the new solenoid valve in the machine Reinstall the hardware and lightly hand tighten 9 Re connect the two water hoses to the new valve Hand tighten the two worm drive clamps 10 Re connect the wires to the new solenoid valve See schematic in the section 11 Start the machine and operate Check the new valve for proper operation ...

Page 236: ...ACE VACUUM FAN FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Remove the vacuum fan assembly from the machine See TO REMOVE VACUUM FAN ASSEMBLY instructions in the SCRUBBING section NOTE Make sure to note the position of the vacuum fan exhaust outlet when removing the fan from the housing 2 Remove the three screws and sleeves holding the vacuum fan to the ...

Page 237: ...ation as the old fan 4 Reinstall the three screws and sleeves Tighten to 8 10 Nm 6 7 ft lb NOTE On a machine equipped with the HD vacuum fan option there are two fans 5 Reinstall the vacuum fan assembly in the machine See TO INSTALL VACUUM FAN ASSEMBLY instructions in the SCRUBBING section ...

Page 238: ...arking brake FOR SAFETY Before leaving or servicing machine stop on level surface set parking brake turn off machine and remove key 3 Lift the operator seat to access the batteries The support arm automatically engages when the seat is lifted all the way up 4 Unplug the machine connector from the batteries 5 Push the battery cart to the right hand side of the machine Line up the battery cart locks...

Page 239: ...e rolling out the batteries The battery cart rollers must be the same height as the machine battery rollers Raise battery cart rollers With a wrench loosen the jam nut and turn the bolt clockwise Then tighten the jam nuts Lower battery cart rollers With a wrench loosen the jam nut and turn the bolt counter clockwise Then tighten the jam nuts 9 Turn the knob on the machine s battery latch plate cou...

Page 240: ...ring slot 11 Raise the cart s battery stop bar by pushing down on the handle 12 Grab the battery case slot and pull the battery case onto the battery cart 13 Lower the cart s battery stop bar by pulling up on the handle This will keep the batteries from rolling off the cart when moving ...

Page 241: ...hing the battery cart locks towards the outside of the battery cart 15 Release the battery cart floor lock To release floor lock step down on the right side of floor lock 16 Pull the battery cart away from the machine 17 Reverse the previous steps to re install batteries in the machine ...

Page 242: ...ELECTRICAL 4 74 7100 330695 8 11 Fig 1 Electrical Schematic S N 7100xxx02700 1 2 3 4 5 6 7 8 ...

Page 243: ...ELECTRICAL 4 75 7100 330695 8 11 Fig 1 Electrical Schematic S N 7100xxx02700 1 2 3 4 5 6 7 8 10 9 ...

Page 244: ...ELECTRICAL 4 76 7100 330695 8 11 Fig 1 Electrical Schematic S N 7100xxx02700 9 10 ...

Page 245: ... 40A CB8 25A CB7 25A S13 EMERGENCY SW CB1 5A M1B BRUSH MOTOR CONTACTOR M3B VAC FAN PWRCON2A BATT CHARGER CONN PWRCON3A BATT CHARGER CONN 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC x CLOSED CONTACT START RUN OFF X X X X X S14 KEYSW 50 83 15 75 30 D7 DIODE HRNSS D6 DIODE HRNSS PWRCON1A CON N PWR D4 DIODE HRNSS D1 MTR4 LEFTBRUSH MOTOR MTR3 RIGHTBRUSH MOTOR MTR7 OPTIONAL MTR6 VAC FAN MOTORS D2 DIODE HRNSS D3...

Page 246: ...ELD POWER GND POWER GND CNTRL GND REC TANK FULL REC TANK 1 2 FULL SOL TANK FULL LED 5VDC ES LED REC TANK FULL LED HOUR METER ENABLE VAC OR PROPEL ES BR DN PRESS ES FILTER FLUSH ES PUMP BRUSH HD ACT SQUEEGEE ACT SQUEEGEE ACT WATER SOL MAIN BRUSH VAC FAN 36VDC CONTROL 36VDC POWER BATT SENSE BRUSH MTR FAULT SENSE 36VDC POWER NEUTRAL SENSE BRUSH HD ACT BATT LEDS LED 2 LED 1 LED 4 SQ VAC LED SOL TANK L...

Page 247: ...U BLK 13R BLK 13CA BLK 13P BLK 13N BLK 13M BLK 6B BLU 6C BLU 81D GRN 81A GRN 81 GRN 13LL BLK 13AA BLK 80A YEL 42B BRN 80 YEL 42A BRN 42C BRN UNUSED CONNECTION UNUSED CONNECTION UNUSED CONNECTION CB2 10A S7 HORN BUTTON BACK UP ALARM D5 CB3 10A HORN SHROUD LEFT HEAD LIGHT RIGHT HEAD LIGHT M7B BACK UP ALARM RELAY 30 87 MTR2 POWER WAND PUMP OPTIONAL CB4 10A S9 POWER WAND SW C1 1 7 S12 LIGHT SW C1 1 ...

Page 248: ...ELECTRICAL 4 80 7100 330695 8 11 Fig 3 Wire Harness Group S N 7100xxx02700 ...

Page 249: ...ELECTRICAL 4 81 7100 330695 8 11 Fig 3 Wire Harness Group S N 7100xxx02700 ...

Page 250: ...ELECTRICAL 4 82 7100 330695 8 11 Fig 3 Wire Harness Group S N 7100xxx02700 ...

Page 251: ...ELECTRICAL 4 83 7100 330695 8 11 Fig 3 Wire Harness Group S N 7100xxx02700 ...

Page 252: ...ELECTRICAL 4 84 7100 330695 8 11 Fig 4 Wire Harness Group S N 7100xxx00001 02699 ...

Page 253: ...ELECTRICAL 4 85 7100 330695 8 11 Fig 4 Wire Harness Group S N 7100xxx00001 02699 ...

Page 254: ...ELECTRICAL 4 86 7100 330695 8 11 Fig 4 Wire Harness Group S N 7100xxx00001 02699 ...

Page 255: ...ELECTRICAL 4 87 7100 330695 8 11 Fig 4 Wire Harness Group S N 7100xxx00001 02699 ...

Page 256: ...ELECTRICAL 4 88 7100 330695 8 11 Fig 5 FaST Electrical Schematic S N 7100xxx01709 ...

Page 257: ...he machine in maintenance mode 2 Press and release the scrub button until pressure LED 3 is on 3 Press and release the squeegee key Manual Mode Manually operate discrete functions without interlocks In this mode the battery LED 3 will blink More info pages 4 92 thru 4 95 1 Place the machine in maintenance mode 2 Press and release the scrub button until pressure LED 2 is on 3 Press and release the ...

Page 258: ...utting the machine into reverse will raise the squeegee and after a slight delay turn off the vacuum fan 3 If the machine is in forward the brush head will drop water valve will turn on and the brushes will start turning Putting the machine into neutral while scrubbing will turn off the brushes turn off water and after a short delay slightly raise the scrub head 4 If the operator holds the scrub b...

Page 259: ...all three LED s will be lit and the lower two will blink 4 If the system downshifts to downpressure 1 the lowest down pressure LED will blink This system will reset itself each time the machine goes into neutral If the system had downshifted into pressure 2 and the machine goes into neutral the original down pressures will be re loaded and the panel LED s will go into there normal non blinking sta...

Page 260: ...egee functions are active they will become deactivated and the vacuum fan will turn off after a slight delay If the operator presses the squeegee button the squeegee will drop and the vacuum fan will run for about 30 seconds to pick up any excess water The overflow indicator will not turn off by simply emptying the recovery tank The overflow indicator will remain illuminated until at least one of ...

Page 261: ...rging The scrub and squeegee functions will shut off if the operator is scrubbing at this point If the user selects the squeegee button squeegee will lower and the vacuum fan will run for about 30 seconds to allow the operator to pick up any excess water The squeegee will then lift and the vacuum fan will shut off after a slight delay HOUR METER The hour meter logs hours if the machine is in one o...

Page 262: ...n the last battery LED is blinking about 31 5 volts SCRUB FUNCTION The scrub function will cancel as if someone toggled the scrub button The operator cannot restart the scrub functions until the meter is reset The operator can reset the battery gauge by unplugging the main battery connector SQUEEGEE AND VACUUM FAN The machine will cancel squeegee operation as if someone toggled the squeegee button...

Page 263: ...ing the recovery tank The LED will remain blinking until the machine is powered down or the scrub button is pushed BRUSH MOTOR ERROR The controller will cancel the following functions if an open breaker opens during scrub motor operation THE CONTROLLER will cancel scrub and squeegee operations as if someone toggled the scrub or squeegee buttons If the operator presses the squeegee button squeegee ...

Page 264: ...his mode is engaged various motors and accessories will be engaged at full power as part of the test Extreme care must be taken to be sure that technicians and bystanders are not injured as a result of this test TO PREVENT INJURY ALWAYS TURN THE MACHINE OFF AFTER THE DIAGNOSTIC MESSAGES HAVE BEEN DISPLAYED IF THE DIAGNOSTIC MESSAGES DO NOT APPEAR DO NOT ATTEMPT TO SERVICE THIS MACHINE WITHOUT FIRS...

Page 265: ... Wait for the actuator to stall flag error for always stalled early stall or never stalled 7 Check brush motor current with brush motors off Flag error for current sensed 8 Turn on the brush motors 9 Flag error for zero current low current or high current 10 Turn off the brush motors 11 Cycle and test the ES pump output 12 Cycle and test the Vacuum fan output 13 Cycle and test the Scrub brush moto...

Page 266: ...r code assignments are as follows ACTUATOR GROUP SQUEEGEE BUTTON PRESSED PRESSURE 1 PRESSURE 2 PRESSURE 3 ERROR On steady No H bridge zero current On steady Early squeegee stall On steady No squeegee stall Blinking Early brush stall Blinking No brush stall Blinking Blinking Blinking Fuse is blown BRUSH MOTOR GROUP SCRUB BUTTON PRESSED PRESSURE 1 PRESSURE 2 PRESSURE 3 ERROR On steady No brush motor...

Page 267: ...reen OVERFLOW LED red EMPTY SOLUTION LED red ERROR Blinking Systems other than ES Self test passed Blinking ES self test passed Blinking Self test failed Blinking ES self test failed ES OUTPUT GROUP ES BUTTON PRESSED PRESSURE 1 PRESSURE 2 PRESSURE 3 ERROR On steady ES pump output ...

Page 268: ... off If the scrub system is off and the user presses and holds the scrub button the scrub head actuator will move downward The head will continue down as long as the technician holds the scrub button Care must be exercised by the technician not to hold the button too long The actuator can stall when fully extended Damage to the controller board and the actuator can result from continuing to provid...

Page 269: ...he manual mode the squeegee and vac fan will remain active regardless of the state of the propel pedal reverse switch ES BUTTON Tennant machines only Pressing the ES button will toggle the ES pump on or off In the on position the ES pump will run regardless of the state of the floats Care should be taken not to run the ES pump dry for more than a few seconds ...

Page 270: ...e SCRUB BRUSH OPERATION SCRUB BRUSH OPERATION ENABLED BY INDICATOR Scrub button One or more scrub pressure LED s on Forward or reverse propel Forward or reverse engaged SCRUB BRUSH OPERATION INHIBITED BY INDICATOR Scrub button All scrub pressure LED s off Neutral Forward and reverse disengaged Low battery Battery 1 LED blinking Open brush motor circuit breaker All three scrub pressure LED s blinki...

Page 271: ...covered or ES 30 second timer run ning The ES 30 second timer starts when the ES pump brings the solution level below the ES float ES PUMP INHIBITED BY INDICATOR ES button ES LED off More than 30 seconds has passed since the ES float has become uncovered Solution tank full float covered for more than 5 seconds ...

Page 272: ...on the instrument panel no longer correspond to the control status while in the Input Display Mode For instance in the normal mode if the squeegee LED is on this means that the squeegee and vacuum fan are active In the Input Display Mode this LED indicates that the solution tank full float is active The buttons however retain their normal functions Pressing the squeegee button will turn on the squ...

Page 273: ... When the solution empty LED is on the solution tank empty float is active P4 8 high Tennant only Pressure 1 When the pressure 1 LED is on the scrub is active and the brush current detected is below the minimum level for the selected pressure setting Pressure 2 When the pressure 2 LED is on the scrub mode is active Pressure 3 When the pressure 3 is on the scrub mode is active and the brush current...

Page 274: ...e squeegee key RESTRICTED DOWN PRESSURE MODE This mode is used to restrict the machine to the two lower down pressures Each time the machine enters this mode the machine will toggle in and out of the reduced down pressure mode 1 While holding the squeegee button turn the key to the start position and then release it 2 Keep holding the squeegee button until scrub pressure LED 3 is lit and then rele...

Page 275: ...re LED 3 is lit and then release it 3 Press and release the scrub button until scrub pressure LED 1 and 3 are on 4 Press and release the squeegee key The date of the current software will be flashed on the touch panel as follows 1 The number of times the center pressure LED flashes is the month of the software change date i e if it flashes 7 times the month is July 2 The number of times the squeeg...

Page 276: ...OUTPUTS REVERSIBLE 0 36V B P4 3 P4 2 P4 9 P4 8 INPUTS B 2 to 5V P4 7 P4 12 INPUTS B B P4 6 INPUTS B B P5 3 P5 2 SHUNT INPUTS 1 44mv A B P3 3 P5 1 P3 8 P4 5 GROUNDS B SCRUB BRUSH MOTOR CURRENT DRAW SPECIFICATIONS Brush motor current draw at 3 down pressure 16 19 amps per motor CURTISR PROPEL CONTROL LED OPERATION During normal operation with no faults present the Status LED is steadily on If the co...

Page 277: ...nable and throttle inputs 2 Misadjusted throttle pot 2 3 Proc Wiring fault HPD fault present for 5 sec 1 Misadjusted throttle 2 Broken throttle pot 3 Broken throttle mechanism 2 4 SPD Limit Pot fault speed limit pot fault 1 Speed limit pot wiper wire broken 2 Broken speed limit pot 3 1 BB Wiring Check emerg reverse wir ing fault 1 BB wire open 2 BB check wire open 3 2 EM Brake Drvr fault electroma...

Page 278: ...ELECTRICAL 4 110 7100 330695 8 11 TROUBLESHOOTING The following troublshooting section should be used to diagnos and repair the electrical system on the model 7100 ...

Page 279: ...AND THEN RELEASE IT 4 PRESS AND RELEASE THE SCRUB BUTTON UNTIL PRESSURE LED 2 IS ON 5 PRESS AND RELEASE THE SQUEEGEE BUTTON AGAIN TURN ON THE ES SYSTEM IS THE PUMP RUNNING NO ERROR BATT VOLTAGE ACROSS ES PUMP No IF CONNECTIONS TO ES PUMP ARE GOOD REPLACE PUMP Yes BATT VOLTAGE ON CIRCUIT 23 ORA THE PUMP No REPAIR REPLACE CIRCUIT 23 ORA BETWEEN CB5 THE PUMP No 22 BRN 13W BLK OR SWITCH S6 HAS FAILED ...

Page 280: ...L GND REC TANK FULL REC TANK 1 2 FULL SOL TANK FULL LED 5VDC ES LED REC TANK FULL LED HOUR METER ENABLE VAC OR PROPEL ES BR DN PRESS ES FILTER FLUSH ES PUMP BRUSH HD ACT SQUEEGEE ACT SQUEEGEE ACT WATER SOL MAIN BRUSH VAC FAN 36VDC CONTROL 36VDC POWER BATT SENSE BRUSH MTR FAULT SENSE 36VDC POWER NEUTRAL SENSE BRUSH HD ACT BATT LEDS LED 2 LED 1 LED 4 SQ VAC LED SOL TANK LOW PULL UP RESISTOR PULL DN ...

Page 281: ...LY SHORTING TO GND AND REPLACE REPAIR RECONNECT D5 TO HARNESS FAULT STILL GONE YES REPLACE D5 NO REPLACE HORN RECONNECT HORN TO HARNESS FAULT STILL GONE YES NO Yes BATTERY VOLTAGE ON 38A GRY WHEN HORN BUTTON PUSHED No BATT VOLTAGE ON 37 PUR THE HORN BUTTON No REPLACE HORN BUTTON Yes 37 PUR IS OPEN REPAIR REPLACE 37 PUR No BATTERY VOLTAGE ON 13J BLK THE HORN Yes 13J BLK IS OPEN REPAIR REPLACE 13J B...

Page 282: ...6A BLU 6B BLU 6C BLU 37 PUR 38 GRY 38A GRY 13H BLK 13J BLK PWRCON1B CONN PWR PWRCON2A BATT CHARGER CONN PWRCON3A BATT CHARGER CONN 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC CB2 10A PWRCON1A CONN PWR CB3 10A CB4 10A CB5 10A F1 40A M2B LINE S7 HORN BUTTON D5 HORN HORN ...

Page 283: ...IGHTS ON WHEN SWITCH S12 IS ON No SYSTEM WORKS Yes CB2 OPEN No OPEN LIGHT SWITCH S12 RESET CB2 CB2 OPEN AGAIN Yes 42 BRN CIRCUIT IS SHORTED TO GND Yes 81 GRN CIRCUIT OR LIGHT FIXTURE IS SHORTED TO GND No BATT VOLTAGE ON 81 GRN WHEN SWITCH S12 IS ON No IF CONNECTIONS TO SWITCH S12 ARE GOOD REPLACE IT No 13 BLK CIRCUIT IS NOT CONNECTED TO MACHINE GND REPAIR REPLACE 13 BLK CIRCUIT BATT VOLTAGE Yes IF...

Page 284: ...U 6B BLU 6C BLU 81D GRN 81A GRN 81 GRN 13LL BLK PWRCON1B CONN PWR PWRCON2A BATT CHARGER CONN PWRCON3A BATT CHARGER CONN 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC CB2 10A PWRCON1A CONN PWR CB3 10A SHROUD LEFT HEAD LIGHT RIGHT HEAD LIGHT CB4 10A CB5 10A F1 40A M2B LINE S12 LIGHT SW C1 1 SHROUD LIGHT HEAD LIGHTS ...

Page 285: ... ARE OPEN 0 VOLTS REPLACE THE PROPEL CONTROLLER VOLTAGES INCORREC T VERIFY THE THROTTLE SIGNAL VOLTAGES P1 2 0 5V 2 2V IN REVERSE P1 2 2 2V 2 8V IN NEUTRAL P1 2 2 8 4 5V FORWARD ALL VOLTAGES 0 3V VOLTAGES MEET SPEC THROTTLE POTENTIOMETER IS NOT CENTERED PROPERLY USE INPUT DISPLAY MODE TO RE ADJUST LINKAGE FOOT PEDAL NOTE MACHINE WILL NOT PROPEL UNTIL A NEUTRAL SIGNAL OF 2 2V 2 8V IS SENSED AT P1 2...

Page 286: ...CT SQUEEGEE ACT WATER SOL MAIN BRUSH VAC FAN 36VDC CONTROL 36VDC POWER BATT SENSE BRUSH MTR FAULT SENSE 36VDC POWER NEUTRAL SENSE BRUSH HD ACT BATT LEDS LED 2 LED 1 LED 4 SQ VAC LED SOL TANK LOW PULL UP RESISTOR PULL DN RESISTOR SCRUB DOWN PRESS LEDS LED 1 LED 2 LED 3 TOUCH PNL GND SQUEEGEE BACK UP ALARM SOL LOW LED LED 3 CTRL ELECTRONIC CONTROL CIRCUIT BOARD P1 1 P1 2 P1 3 P1 6 P2 1 P2 2 P2 3 P2 ...

Page 287: ...T GONE REPLACE POWER WAND PUMP Yes DISCONNECT BACKUP ALARM ITS RELAY M7 FAULT GONE No CIRCUIT 39 WHT IS SHORTED TO GND LOCATE SHORT REPAIR REPLACE M7 OR THE HORN IS BAD OR CIRCUIT 40 ORA IS SHORTED TO GND REPAIR REPLACE AS NEEDED Yes BATT VOLTAGE ON 41 PNK POWER WAND No SEARCH FOR INTERMITTANT SHORT IN THE SYSTEM THAT IS OPENING CB3 13U BLK IS NOT CONNECTED TO MACHINE GND REPAIR REPLACE 13U BLK BA...

Page 288: ... 12 12B BRN 12B BRN 13A BLK 17AMPS EA 13C BLK PWRCON1B CONN PWR S13 EMERGENCY SW CB1 5A PWRCON2A BATT CHARGER CONN PWRCON3A BATT CHARGER CONN 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC x CLOSED CONTACT START RUN OFF X X X X X S14 KEYSW 50 83 15 75 30 PW RCON1A CONN PWR D4 DIODE HRNSS D1 S1 0 CHARGER SW F1 40A M2A LINE M2B LINE aux M2C LINE ...

Page 289: ...E 1 TURN KEY SWITCH OFF 2 CHECK THAT MACHINE HAS GOOD GND CONNECTIONS BETWEEN 13 BLK WIRES NEGATIVE TERMINAL ON THE BATT BATT VOLTAGE ON 9 WHT TERMINAL 30 THE KEY SWITCH TURN AND HOLD KEY SWITCH TO START POSITION BATT VOLTAGE ON 12 BRN COIL OF M2 Yes SOME COMPONENT CONNECTION OR WIRE BETWEEN THIS POINT AND BATT POSITIVE IS OPEN No BATTERY VOLTAGE ON TERM 50 No REPLACE KEYSWITCH No CHECK FOR VOLTAG...

Page 290: ... 12B BRN 12B BRN 13A BLK 17AMPS EA 13C BLK PWRCON1B CONN PWR S13 EMERGENCY SW CB1 5A PWRCON2A BATT CHARGER CONN PWRCON3A BATT CHARGER CONN 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC 6 VDC x CLOSED CONTACT START RUN OFF X X X X X S14 KEYSW 50 83 15 75 30 PW RCON1A CONN PWR D4 DIODE HRNSS D1 S1 0 CHARGER SW F1 40A M2A LINE M2B LINE aux M2C LINE ...

Page 291: ...SQUEEGEE BUTTON TURN THE KEY TO THE START POSITION AND THEN RELEASE IT 3 KEEP HOLDING THE SQUEEGEE BUTTON UNTIL SCRUB PRESSURE LED 3 IS LIT AND THEN RELEASE IT 4 PRESS AND RELEASE THE SCRUB BUTTON UNTIL BOTH SCRUB PRESSURE LED S 2 3 ARE ON 5 PRESS AND RELEASE THE SQUEEGEE BUTTON AGAIN TEST SIMULATE THE RECOVERY TANK FULL SWITCH S1 DOES THE OVERFLOW LED TURN ON THEN OFF Yes Yes SYSTEM ALWAYS OFF SY...

Page 292: ...UTPUT BOTH SQUEEGEE AND BRUSH BUTTONS HELD DOWN PRESSURE LED 3 LIT DISCONNECT 25 GRN AT M1 AND RERUN SELF TEST NO ERROR NOW REPLACE M1 SAME ERROR STILL DISCONNECT CONTROL BOARD IF 25 GRN IS NOT SHORTED TO GND REPLACE CONTROL BOARD IF ERROR READS NO H BRIDGE ZERO CURRENT SQUEEGEE BUTTON HELD DOWN PRESSURE LED 3 LIT REPLACE CONTROL BOARD IF ERROR READS EARLY BRUSH STALL SQUEEGEE BUTTON HELD DOWN PRE...

Page 293: ...T3 BATT4 REC FULL SQ VFAN SCRUB1 SCRUB2 SCRUB3 ES SOL LOW TP 1 MEMBRANETOUCH PANEL P2 1 P2 2 P3 1 P1 1 P1 2 P1 4 P2 3 P2 4 P2 5 P2 6 P2 7 P2 8 P2 9 P2 10 P2 11 P2 12 P1 6 SHNT1 SHUNT MLD MTR BR HD UP DN D2 DIODE HRNSS BRN BLK S1 REC TANK FULL SW A B M1A BRUSH MOTOR CONTACTOR FWD SENSE SHUNT HIGH SHUNT LOW SHIELD POWER GND POWER GND CNTRL GND REC TANK FULL REC TANK 1 2 FULL SOL TANK FULL LED 5VDC E...

Page 294: ...ELECTRICAL 4 126 7100 330695 8 11 ...

Page 295: ... 2 3 ARE ON 4 PRESS AND RELEASE THE SQUEEGEE BUTTON AGAIN TEST SIMULATE OPENING CLOSING OF SWITCH S3 LIGHTS TURN ON OFF No SYSTEM WORKS Yes DISCONNECT SWITCH S3 LIGHT TURN ON No IF CONNECTIONS TO SWITCH S3 ARE GOOD REPLACE SWITCH S3 36 BLU IS SHORTING TO GND REPAIR REPLACE 36 BLU Yes No IF CONNECTIONS TO CONTROL BOARD ARE GOOD REPLACE CONTROL BOARD SHORT 36 BLU TO GND LIGHT TURN OFF Yes No OPERATI...

Page 296: ...REC TANK FULL REC TANK 1 2 FULL SOL TANK FULL LED 5VDC ES LED REC TANK FULL LED HOUR METER ENABLE VAC OR PROPEL ES BR DN PRESS ES FILTER FLUSH ES PUMP BRUSH HD ACT SQUEEGEE ACT SQUEEGEE ACT WATER SOL MAIN BRUSH VAC FAN 36VDC CONTROL 36VDC POWER BATT SENSE BRUSH MTR FAULT SENSE 36VDC POWER NEUTRAL SENSE BRUSH HD ACT BATT LEDS LED 2 LED 1 LED 4 SQ VAC LED SOL TANK LOW PULL UP RESISTOR PULL DN RESIST...

Page 297: ... MODE TEST THE FORWARD 14 YEL P4 6 REVERSE 16 BLU P4 12 SIGNALS FROM THE PROPEL CONTROLLER 1 TURN THE KEY OFF 2 WHILE HOLDING THE SQUEEGEE BUTTON TURN THE KEY TO THE START POSITION AND THEN RELEASE IT 3 KEEP HOLDING THE SQUEEGEE BUTTON UNTIL SCRUB PRESSURE LED 3 IS LIT AND THEN RELEASE IT 4 PRESS AND RELEASE THE SCRUB BUTTON UNTIL BOTH SCRUB PRESSURE LED S 2 3 ARE ON 5 PRESS AND RELEASE THE SQUEEG...

Page 298: ...P2 3 P2 4 P2 5 P2 6 P2 7 P2 8 P2 9 P2 10 P2 11 P2 12 P1 6 FWD SENSE SHUNT HIGH SHUNT LOW SHIELD POWER GND POWER GND CNTRL GND REC TANK FULL REC TANK 1 2 FULL SOL TANK FULL LED 5VDC ES LED REC TANK FULL LED HOUR METER ENABLE VAC OR PROPEL ES BR DN PRESS ES FILTER FLUSH ES PUMP BRUSH HD ACT SQUEEGEE ACT SQUEEGEE ACT WATER SOL MAIN BRUSH VAC FAN 36VDC CONTROL 36VDC POWER BATT SENSE BRUSH MTR FAULT SE...

Page 299: ...E BUTTON TURN THE KEY TO THE START POSITION AND THEN RELEASE IT 3 KEEP HOLDING THE SQUEEGEE BUTTON UNTIL SCRUB PRESSURE LED 3 IS LIT AND THEN RELEASE IT 4 PRESS AND RELEASE THE SCRUB BUTTON UNTIL BOTH SCRUB PRESSURE LED S 2 3 ARE ON 5 PRESS AND RELEASE THE SQUEEGEE BUTTON AGAIN ARE BATT LED S BOTH OFF No 16 BLU P4 12 IS BEING HELD GND 14 YEL P4 6 IS 0 5V THIS SHOULD ONLY HAPPEN IN REVERSE GO TO PR...

Page 300: ...PEL ES BR DN PRESS ES FILTER FLUSH ES PUMP BRUSH HD ACT SQUEEGEE ACT SQUEEGEE ACT WATER SOL MAIN BRUSH VAC FAN 36VDC CONTROL 36VDC POWER BATT SENSE BRUSH MTR FAULT SENSE 36VDC POWER NEUTRAL SENSE BRUSH HD ACT BATT LEDS LED 2 LED 1 LED 4 SQ VAC LED SOL TANK LOW PULL UP RESISTOR PULL DN RESISTOR SCRUB DOWN PRESS LEDS LED 1 LED 2 LED 3 TOUCH PNL GND SQUEEGEE BACK UP ALARM SOL LOW LED LED 3 CTRL ELECT...

Page 301: ...WERING UP DO ALL THE LEDS TURN ON FOR A MOMENT AND THEN OFF Yes LEDS ARE OKAY PUSH MEMBRANE BUTTON SWITCHES ON AND THEN OFF DO ASSOCIATED LEDS TURN ON AND OFF WITH EACH PUSH No RECONNECT 12 PIN RIBBON CABLE MAKING CERTAIN CONNECTIONS CONTROL BOARD ARE GOOD AND TEST AGAIN FAULT GONE Yes No SWITCHES ARE OKAY Yes DISCONNECT 12 PIN RIBBON CABLE FROM CONTROL BOARD CHECK FORWARD JUNCTION OF ALL LEDS ON ...

Page 302: ...E BRUSH MTR FAULT SENSE 36VDC POWER NEUTRAL SENSE BRUSH HD ACT BATT LEDS LED 2 LED 1 LED 4 SQ VAC LED SOL TANK LOW PULL UP RESISTOR PULL DN RESISTOR SCRUB DOWN PRESS LEDS LED 1 LED 2 LED 3 TOUCH PNL GND SQUEEGEE BACK UP ALARM SOL LOW LED LED 3 CTRL ELECTRONIC CONTROL CIRCUIT BOARD P1 1 P1 2 P1 3 P1 6 P2 1 P2 2 P2 3 P2 4 P2 5 P2 6 P2 7 P2 8 P2 9 P2 10 P2 11 P2 12 P3 1 P3 2 P3 3 P3 4 P3 5 P3 7 P3 8 ...

Page 303: ...NG No Yes No No GO TO MANUAL MODE 1 TURN THE KEY OFF 2 WHILE HOLDING THE SQUEEGEE BUTTON TURN THE KEY TO THE START POSITION AND THEN RELEASE IT 3 KEEP HOLDING THE SQUEEGEE BUTTON UNTIL SCRUB PRESSURE LED 3 IS LIT AND THEN RELEASE IT 4 PRESS AND RELEASE THE SCRUB BUTTON UNTIL PRESSURE LED 2 IS ON 5 PRESS AND RELEASE THE SQUEEGEE BUTTON AGAIN PUSH SQGE VAC FAN BUTTON VAC FAN TURN ON Yes REPLACE M3 C...

Page 304: ... ES LED REC TANK FULL LED HOUR METER ENABLE VAC OR PROPEL ES BR DN PRESS ES FILTER FLUSH ES PUMP BRUSH HD ACT SQUEEGEE ACT SQUEEGEE ACT WATER SOL MAIN BRUSH VAC FAN 36VDC CONTROL 36VDC POWER BATT SENSE BRUSH MTR FAULT SENSE 36VDC POWER NEUTRAL SENSE BRUSH HD ACT BATT LEDS LED 2 LED 1 LED 4 SQ VAC LED SOL TANK LOW PULL UP RESISTOR PULL DN RESISTOR SCRUB DOWN PRESS LEDS LED 1 LED 2 LED 3 TOUCH PNL G...

Page 305: ...ELECTRICAL 4 137 7100 330695 8 11 ...

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