Tennant 7200 Service Manual Download Page 248

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ELECTRICAL

4-90

7200 330045 (10--99)

TABLE 2: TROUBLESHOOTING CHART (continued)

LED

CODE:

PROGRAMMER LCD

DISPLAY:

EXPLANATION:

POSSIBLE CAUSE:

2 -- 4

THROTTLE FAULT 2

Pot low broken or

shorted

1. Pot low wire open.

2. Pot low wire shorted.

3. Wrong throttle type

selected.

3 -- 1

CONT DRVR OC

Driver output

overcurrent

1. Direction contactor coil

shorted.

2. Shunt field shorted.

3 -- 2

DIR CONT WELDED

Welded direction

contactor

1. Direction contactor stuck

closed.

3 -- 4

MISSING

CONTACTOR

Missing contactor or

shunt

1. Direction contactor coil

open.

2. Direction contactor missing.

3. Shunt field open.

4. Wire to shunt or direction

contactor.

4 -- 1

LOW BATTERY

VOLTAGE

Low battery voltage

1. Battery voltage

16 volts.

2. Corroded battery or

controller terminal.

3. Loose battery or controller

terminal.

4 -- 2

OVERVOLTAGE

Overvoltage

1. Battery voltage

45 volts.

2. Vehicle operating with

charger attached.

4 -- 3

THERMAL

CUTBACK

Over--/under--temp.

cutback

1. Temperature

C or

2. Excessive load on vehicle.

3. Improper mounting of

controller.

4. Operation in extreme

environments.

Summary of Contents for 7200

Page 1: ...330045 Rev 02 3 02 Service Manual 7200 ...

Page 2: ...d machine maintenance chart Chassis Tire wheel replacement brake adjustment and replacement steering adjustment and replacement 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 electric motor removal ele...

Page 3: ...ACHINE DIMENSIONS 1 7 MAINTENANCE 1 8 PUSHING TOWING AND TRANSPORTING THE MACHINE 1 10 PUSHING OR TOWING THE MACHINE 1 10 TRANSPORTING THE MACHINE 1 10 MACHINE JACKING 1 13 TO JACK UP MACHINE 1 13 STORAGE INFORMATION 1 14 FREEZE PROTECTION 1 14 HARDWARE INFORMATION 1 15 STANDARD BOLT TORQUE CHART 1 15 METRIC BOLT TORQUE CHART 1 15 BOLT IDENTIFICATION 1 15 THREAD SEALANT AND LOCKING COMPOUNDS 1 15 ...

Page 4: ...GENERAL INFORMATION 1 2 7200 330045 10 99 ...

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

Page 6: ...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 350656 ...

Page 7: ...0 mm 32 in Cylindrical scrub brush diameter 150 mm 6 in Cylindrical brush length for 700 mm 28 in scrub head 700 mm 28 in Cylindrical brush length for 900 mm 36 in scrub head 900 mm 36 in Squeegee width for 700 mm 28 in scrub head 950 mm 37 5 in Squeegee width for 900 mm 36 in scrub head 1155 mm 45 5 in Scrubbing path width for 700 mm 28 in scrub head 700 mm 28 in Scrubbing path width for 900 mm 3...

Page 8: ... 45 0 60 Scrub brush disk 36 0 56 0 75 Scrub brush disk 36 0 56 0 75 Scrub brush cyl 36 0 56 0 75 Vacuum fan 36 0 6 0 8 Vacuum fan 36 0 6 0 8 Propelling 36 1 1 1 5 Propelling 36 1 1 1 5 Type VDC amp Hz Phase VAC Chargers Smart 36 20 60 1 120 36 20 50 1 230 36 20 50 1 245 36 30 60 1 120 36 30 50 1 230 36 30 50 1 245 TIRES Location Type Size Front 1 Solid 100 mm wide x 305 mm OD 4 in wide x 12 in OD...

Page 9: ... 3 02 TOP VIEW SIDE VIEW 2032 mm 80 0 in 1360 mm 53 5 in 921 mm 36 25 in 1155 mm 45 5 in 1092 mm 43 0 in 1830 mm 72 0 in 1020 mm 40 25 in 1025 mm 40 35 in 405 mm 16 0 in 810 mm 32 0 in FRONT VIEW 915 mm 36 0 in 350790 MACHINE DIMENSIONS ...

Page 10: ...GENERAL INFORMATION 1 8 7200 330045 3 02 MAINTENANCE 1 2 2 3 4 1 1 5 5 6 7 8 9 10 10 11 13 12 14 350790 ...

Page 11: ...ls and pivot points Lubricate SPL 4 4 Battery cells Check electrolyte level DW 3 1 Side and rear squeegees Check deflection and leveling 6 14 Pre Sweept skirts and seals Check for damage and wear 4 100 Hours 5 Cylindrical scrub brush drive belts Check tension and wear 2 13 Pre Sweept brush drive belts Check tension and wear 2 3 Steering caster pivot bear ing Lubricate SPL 1 200 Hours 4 Battery ter...

Page 12: ...ot exceed 3 2 kp h 2 mph It is NOT intended to be pushed or towed for a long distance or at a high speed ATTENTION Do not push or tow machine for a long distance or damage may occur to the propelling system TRANSPORTING THE MACHINE 1 Position the rear of the machine at the loading edge of the truck or trailer FOR SAFETY Use truck or trailer that will support the weight of the machine NOTE Empty th...

Page 13: ...of the machine frame near the rear bumper FOR SAFETY When loading machine onto truck or trailer use winch Do not drive the machine onto the truck or trailer unless the loading surface is horizontal AND is 380 mm 15 in or less from the ground 4 Position the machine onto the truck or trailer as far as possible If the machine starts to veer off the centerline of the truck or trailer stop and turn the...

Page 14: ...r than 380 mm 15 in from the ground use a winch to unload machine If the loading surface is horizontal AND is 380 mm 15 in or less from the ground the machine may be driven off the truck or trailer FOR SAFETY When unloading machine off truck or trailer use winch Do not drive the machine off the truck or trailer unless the loading surface is horizontal AND 380 mm 15 in or less from the ground ...

Page 15: ...SAFETY When servicing machine jack machine up at designated locations only Block machine up with jack stands 7 TO JACK UP THE FRONT Place blocks behind the rear tires when jacking up the front of the machine Place jack stands under the machine frame after the machine is at the desired level 8 TO JACK UP THE REAR The front of the machine must be placed on jack stands before the rear of the machine ...

Page 16: ...mp 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 ESt system to circulate the washer solution through th...

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 7200 330045 3 02 ...

Page 19: ...ONT WHEEL SUPPORT CASTER BEARING ASSEMBLY 2 19 TO REMOVE FRONT DRIVE ASSEMBLY 2 20 TO INSTALL FRONT DRIVE ASSEMBLY 2 22 TO REPLACE DRIVE ASSEMBLY CASTER BEARING AND THRUST WASHERS 2 24 TO REPLACE DRIVE ASSEMBLY PIVOT CONE BEARING 2 29 Page PLANETARY GEAR BOX 2 32 TO REMOVE PLANETARY GEAR BOX 2 32 TO INSTALL PLANETARY GEAR BOX 2 34 TO REPLACE FRONT TIRE AND WHEEL ASSEMBLY 2 36 TO REPLACE FRONT DRIV...

Page 20: ...CHASSIS 2 2 7200 330045 10 99 ...

Page 21: ...CHASSIS 2 3 7200 330045 10 99 INTRODUCTION This section includes information on the main chassis related components for example the seat steering front drive assembly brakes and tires ...

Page 22: ...he operator seat is equipped with a switch that prevents the machine from propelling unless someone is sitting on it TO REMOVE SEAT ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Lift the seat assembly until the prop rod is engaged 2 Unplug the seat switch wire harness plug from the main harness ...

Page 23: ...30045 10 99 3 Lift the seat assembly slightly and remove the prop rod from the slot in the prop rod bracket 4 Slide the seat assembly to the right until is off the two mount pins Remove the seat assembly from the machine ...

Page 24: ...in the operators compartment 2 Line up the two hinge pins on the seat assembly and seat support Slide the seat assembly all the way on the pins 3 Install the prop rod in the bracket slot 4 Route the seat switch harness through the hole in the seat support plate 5 Plug the seat switch harness into the main harness plug 6 Disengage the prop rod and lower the seat assembly ...

Page 25: ...e front center of the seat 3 Push the adjustment lever to the left 4 Move the seat forward or backward until the desired position is achieved 5 Release the adjustment lever The seat will now be locked in the new position STATIC DRAG CHAIN The static drag chain prevents the buildup of static electricity in the machine It is attached the the rear squeegee mount frame Make sure the chain is in contac...

Page 26: ...assembly It is actuated with a foot brake pedal in the operators compartment PARKING BRAKE The parking brake is located on the front wheel assembly It is actuated with a smaller toe lever on the top of the foot brake pedal in the operators compartment It is deactivated by simply pushing on the foot brake pedal ...

Page 27: ...es to the drive support The beginning adjustment should be 1 375 in of conduit showing on the cable end 3 Turn the steering wheel all the way to the right NOTE Spin the tire wheel assembly to make sure the brakes are not dragging with the brake pedal NOT engaged 4 Loosen the two jam nuts on the brake cable where it attaches to the drive support casting 5 Move the cable away from the brake lever fa...

Page 28: ...s to the drive support The beginning adjustment should be 1 375 in of conduit showing on the cable end 3 Turn the steering wheel all the way to the right NOTE Spin the tire wheel assembly to make sure the brakes are not dragging with the brake pedal NOT engaged 4 Loosen the two jam nuts on the brake cable where it attaches to the drive support casting 5 Move the cable away from the brake lever far...

Page 29: ...Stop On Level Surface Block Rear Wheels 1 Raise the seat support and unplug the battery connectors 2 Raise the front of the machine and place jack stands under the frame 3 Mark and remove the electrical cables leading to the drive motor 4 Remove the four hex screws holding the outer plate motor and planetary gear box to the main drive assembly 5 Pull the planetary gear box outer plate and motor ou...

Page 30: ... the drive assembly This will expose the brake shoes 10 Loosen the two jam nuts on the brake cable where it attaches to the drive support casting Pull the brake cable off the drive assembly 11 Remove the large C spring holding the two brake shoes together Remove the brake shoes NOTE There is a great deal of tension on the C spring Care must be used when spreading the spring for removal or installa...

Page 31: ...ng 15 Reinstall the outer bearing and hex sleeve assembly this is a left hand thread nut Tighten to at least 100 ft lbs and then back off the hex sleeve to 0 ft lbs Re torque hex sleeve to 30 ft lbs 16 Install the lock bolt in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft lb while holding the hex sleeve from turning 17 Reinstall the hub cap in the drive assembly ...

Page 32: ...agging with the brake pedal NOT engaged 20 Go to the other side of the drive assembly and install the planetary gear box outer plate and motor assembly into the wheel assembly and onto the pins of the drive assembly 21 Install the 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 22 Reconnect the electrical cables to the drive motor 23 Remove the jack stands and lower the machine 24 Reconne...

Page 33: ... Set Parking Brake 1 Jack up the rear corner of the machine where the tire needs to be removed 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 Go under the machine in the area of the rear tire Locate the lock nut holding the axle shaft to the machine frame Remove the lock nut and washer 3 Support the tire while y...

Page 34: ... the hole in the wheel bearing with the axle hole in the frame NOTE The lug nuts must face the outside of the machine 2 Install the axle shaft in the machine from the outside of the frame NOTE The axle has a flat portion that must line up with the flat in the axle mount hole 3 Install the washer and nut on the axle Tighten to 68 81 Nm 50 60 ft lb 4 Remove the jack stands and lower the machine 5 Dr...

Page 35: ...ke 1 Remove the rear wheel assembly See TO REMOVE REAR TIRE instructions 2 Remove the three lug nuts holding the bearing housing to the wheel assembly Remove the bearing housing 3 Use a press to remove the wheel bearings from the housing 4 Press the new wheel bearings into the housing Press the bearing in until the flange is seated on the housing ...

Page 36: ...l on the bearing housing coining on wheel facing lug nuts Tighten the three lug nuts to 58 76 Nm 43 56 ft lb NOTE The lug nuts must face the outside of the machine 6 Reinstall the rear wheel assembly in the machine See TO INSTALL REAR TIRE instructions ...

Page 37: ...steering The brakes are actuated with a cable and uses a sprocket and chain assembly for the steering Forward and reverse is accomplished with an electric motor and planetary gearbox FRONT WHEEL SUPPORT CASTER BEARING ASSEMBLY The front wheel support caster bearing is located between the bottom swivel plate and the upper swivel plate weldment The bearing is a flat needle bearing style ...

Page 38: ... support and unplug the battery connectors 2 Raise the front of the machine and place jack stands under the frame 3 Mark and remove the electrical cables leading to the drive motor 4 Go in operators compartment and loosen the lower steering shaft mount screws 5 Pull the mount back to give the steering chain slack Locate and remove the master link and steering chain ...

Page 39: ... the wheel support Remove the brake cable from the wheel support 8 Position a floor jack or transmission jack under the drive wheel This will support the drive assembly when the hardware is removed 9 Go to the operators compartment and locate the 4 button head screws holding the drive assembly to the floor plate Remove the 4 screws while supporting the drive assembly 10 Remove the drive assembly f...

Page 40: ...osition the drive assembly under the machine in front 5 Raise the drive assembly up until the mount holes in the floor plate are aligned with the mount holes in the upper swivel plate weldment on top of the drive assembly NOTE Make sure to position the grease zerk in the access hole in the machine floor plate 6 Install the four button head screws and tighten to 64 83 Nm 47 61 ft lb 7 Reinstall the...

Page 41: ...t The beginning adjustment should be 1 375 in of conduit showing on the cable end NOTE Spin the tire wheel assembly to make sure the brakes are not dragging with the brake pedal NOT engaged 12 Reinstall the electrical cables on the drive motor 13 Remove the jack stands and lower the machine 14 Reconnect the battery cables 15 Operate the machine and check for proper operation Check the brakes for p...

Page 42: ...On Level Surface Set Parking Brake 1 Remove the drive assembly from the machine See TO REMOVE FRONT DRIVE ASSEMBLY instructions 2 Remove the four hex screws holding the outer plate motor and planetary gear box to the main drive assembly 3 Pull the planetary gear box outer plate and motor out of the drive wheel and away from the drive assembly ...

Page 43: ... assembly to the drive assembly 5 Remove the sprocket from the pivot assembly 6 Remove the cotter pin and castle nut from the upper swivel plate weldment 7 Remove the flat washer and cone bearing from the bottom swivel plate 8 Lift the bottom swivel plate off the upper swivel plate weldment ...

Page 44: ...tion the new caster bearing on top of the new lower thrust washer 12 Reinstall the second new thrust washer on top of the new caster bearing 13 Reinstall the bottom swivel plate on the upper swivel plate weldment Make sure the grease seal is in place on the upper swivel plate weldment 14 Reinstall the bearing cone and flat washer on the bottom swivel plate Make sure the bearing cone is greased ...

Page 45: ... Reduce torque if necessary 16 Reinstall the sprocket on the front drive assembly 17 Reinstall the pivot and sprocket assembly on the drive assembly Reinstall the four screws and tighten to 68 81 Nm 50 60 ft lb 18 Install the planetary gear box outer plate and motor assembly into the wheel assembly and onto the pins of the drive assembly 19 Install the 4 hex screws and washers Tighten to 18 24 Nm ...

Page 46: ...the drive assembly in the machine See TO INSTALL FRONT DRIVE ASSEMBLY instructions 21 Operate the machine and check for smooth steering operation Check the brakes for proper operation Adjust if necessary See TO ADJUST SERVICE BRAKES instructions ...

Page 47: ...l Surface Set Parking Brake 1 Remove the drive assembly from the machine See TO REMOVE FRONT DRIVE ASSEMBLY instructions 2 Remove the four hex screws holding the outer plate motor and planetary gear box to the main drive assembly 3 Pull the planetary gear box outer plate and motor out of the drive wheel and away from the drive assembly ...

Page 48: ...nut from the upper swivel plate weldment 7 Remove the flat washer and old cone bearing from the bottom swivel plate 8 Install the new cone bearing and flat washer on the bottom swivel plate Make sure the new cone bearing is greased 9 Reinstall the castle nut and tighten to 200 Nm 150 ft lbs Then tighten to the next nearest hole and install the cotter pin 10 Reinstall the sprocket on the pivot asse...

Page 49: ... motor assembly into the wheel assembly and onto the pins of the drive assembly 13 Install the 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 14 Reinstall the drive assembly in the machine See TO INSTALL FRONT DRIVE ASSEMBLY instructions 15 Operate the machine and check for smooth steering operation Check the brakes for proper operation Adjust if necessary See TO ADJUST SERVICE BRAKES in...

Page 50: ...ont tire TO REMOVE PLANETARY GEAR BOX FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Raise the seat support and unplug the battery connectors 2 Raise the front of the machine and place jack stands under the frame 3 Mark and remove the electrical cables leading to the drive motor 4 Remove the 4 hex screws holding the electric drive motor to the drive assemb...

Page 51: ... holding the outer plate to the main drive assembly 6 Remove the 6 socket screws holding the outer plate to the planetary gear box Remove the outer plate 7 Pull the old planetary gear box out of the drive wheel Remove the old planetary gear box from the machine ...

Page 52: ...que The planetary gearbox is made from a softer grade of cast iron and the threads could strip out 2 Reinstall the outer motor mount plate and gear box on the drive assembly Tighten the four screws to 18 24 Nm 15 20 ft lb NOTE When installing the motor on the drive assembly make sure the terminals are pointing up and slightly forward for proper electrical cable installation 3 Reinstall the electri...

Page 53: ...200 330045 10 99 4 Reconnect the electrical cables to the drive motor 5 Remove the jack stands and lower the machine 6 Reconnect the battery cables 7 Operate the machine and check the new gearbox for proper operation ...

Page 54: ...e and place jack stands under the frame 3 Mark and remove the electrical cables leading to the drive motor 4 Remove the four hex screws holding the outer plate motor and planetary gear box to the main drive assembly 5 Pull the planetary gear box outer plate and motor out of the drive wheel and away from the drive assembly 6 Go to the other side of the drive assembly and remove the hub cap This wil...

Page 55: ...e inner bearing axle shaft and tire wheel assembly can now be removed from the drive assembly Use a press to remove the inner bearing from the existing tire wheel assembly 10 Install the inner bearing on the new tire wheel assembly 11 Reinstall the new tire wheel assembly in the drive assembly Make sure the inner and outer wheel bearings are completely greased when re assembling ...

Page 56: ...s Re torque hex sleeve to 30 ft lbs 13 Install the lock bolt in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft lb while holding the hex sleeve from turning 14 Reinstall the hub cap in the drive assembly 15 Go to the other side of the drive assembly Install the planetary gear box outer plate and motor assembly into the wheel assembly and onto the pins of the drive assembly ...

Page 57: ...he 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 17 Reconnect the electrical cables to the drive motor 18 Remove the jack stands and lower the machine 19 Reconnect the battery cables 20 Drive the machine and check for proper operation ...

Page 58: ...the frame 3 Go to the side of the drive assembly opposite the drive motor and remove the hub cap This will expose the outer bearing hex sleeve and lock bolt 4 Remove the lock bolt this is a right hand thread screw 5 Remove the hex sleeve and outer bearing cone assembly this is a left hand thread nut 6 Use a press to remove the old outer bearing cone from the hex sleeve Install a new outer bearing ...

Page 59: ...eve to 0 ft lbs Re torque hex sleeve to 30 ft lbs 8 Install the lock bolt this is a right hand thread screw in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft lb while holding the hex sleeve from turning 9 Reinstall the hub cap in the drive assembly 10 Remove the jack stands and lower the machine 11 Reconnect the battery cables 12 Drive the machine and check for proper operation ...

Page 60: ...achine and place jack stands under the frame 3 Mark and remove the electrical cables leading to the drive motor 4 Remove the four hex screws holding the outer plate motor and planetary gear box to the main drive assembly 5 Pull the planetary gear box outer plate and motor out of the drive wheel and away from the drive assembly 6 Go to the other side of the drive assembly and remove the hub cap Thi...

Page 61: ... and tire wheel assembly can now be removed from the drive assembly Use a press to remove the inner bearing from the existing tire wheel assembly Discard the old wheel bearing 10 Press a new inner wheel bearing on the wheel shaft Apply grease to the new bearing 11 Reinstall the tire wheel assembly in the drive assembly Make sure the inner and outer wheel bearings are completely greased when re ass...

Page 62: ...s Re torque hex sleeve to 30 ft lbs 13 Install the lock bolt in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft lb while holding the hex sleeve from turning 14 Reinstall the hub cap in the drive assembly 15 Go to the other side of the drive assembly Install the planetary gear box outer plate and motor assembly into the wheel assembly and onto the pins of the drive assembly ...

Page 63: ...he 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft lb 17 Reconnect the electrical cables to the drive motor 18 Remove the jack stands and lower the machine 19 Reconnect the battery cables 20 Drive the machine and check for proper operation ...

Page 64: ...ed by following the adjustment procedure listed below TO ADJUST STEERING CHAIN FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Go into the operators compartment and locate the two hex screws holding the lower steering shaft bearing assembly to the floor plate Loosen these two hex screws 2 Push the lower steering shaft assembly forward until the slack has be...

Page 65: ... the frame 3 Go under the machine and locate the steering chain 4 Rotate the steering wheel until the master link on the chain is accessible 5 Remove the chain master link Remove the steering chain from both sprockets 6 Remove and discard the steering chain from the machine 7 Route the new chain around both steering sprockets Install the master link 8 Remove the jack stands and lower the machine 9...

Page 66: ...rive assembly from the machine See TO REMOVE FRONT DRIVE ASSEMBLY instructions 2 Remove the four hex screws holding the pivot and sprocket assembly to the drive assembly 3 Remove the old sprocket from the pivot assembly 4 Install the new sprocket on the pivot assembly NOTE Make sure the roll pin in the top of the drive assembly lines up with the hole in the sprocket ...

Page 67: ...sprocket assembly on the drive assembly Reinstall the four screws and tighten to 68 81 Nm 50 60 ft lb 6 Reinstall the drive assembly in the machine See TO INSTALL FRONT DRIVE ASSEMBLY instructions 7 Operate the machine and check for smooth steering operation ...

Page 68: ...nt of the machine and place jack stands under the frame 3 Go into the operators compartment and locate the lower steering shaft mount assembly Loosen the two screws and pull the mount back to give the steering chain slack 4 Go under the machine and locate the steering chain 5 Rotate the steering wheel until the master link on the chain is accessible 6 Remove the chain master link Remove the steeri...

Page 69: ... the new small sprocket on the lower steering shaft Firmly tighten the set screws 9 Route the steering chain around both steering sprockets Install the master link 10 Adjust the steering chain See TO ADJUST STEERING CHAIN instructions 11 Remove the jack stands and lower the machine 12 Operate the machine and check the steering for proper operation ...

Page 70: ...s 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 4 Pull the steering wheel and long steering shaft up and out of the top of the steering U joint 5 Remove the two hex screws holding the steering bearing housing to the machine frame Push the bearin...

Page 71: ...7 Locate the master link on the steering chain Remove the master link and steering chain from the small steering sprocket 8 Remove the steering housing from the machine 9 Loosen the two set screws holding the U joint to the top of the short steering shaft Remove and retain the U joint and square key ...

Page 72: ...ard the bearings Retain the short shaft NOTE Note the orientation of the shaft in the housing 12 Use the arbor press to install the new bearings into the steering housing 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 join...

Page 73: ... 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 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...

Page 74: ... 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 4 Loosen the two set screws holding the U joint to the top of the short steering shaft Remove and discard the U joint and square key...

Page 75: ...are 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 76: ...CHASSIS 2 58 7200 330045 10 99 ...

Page 77: ...RUB BRUSHES 3 41 DISC SCRUB BRUSHES 3 41 TO REPLACE DISC SCRUB BRUSHES 3 41 CYLINDRICAL SCRUB BRUSHES 3 43 TO REPLACE CYLINDRICAL SCRUB BRUSHES 3 43 TO CHECK AND ADJUST CYLINDRICAL BRUSH PATTERN 3 46 CYLINDRICAL BRUSH DRIVE BELT 3 49 TO REPLACE BRUSH DRIVE BELT 3 49 MANUAL SOLUTION VALVE 3 53 TO REPLACE SOLUTION VALVE 3 53 Page SQUEEGEES 3 56 TO REMOVE REAR SQUEEGEE ASSEMBLY 3 56 TO INSTALL REAR S...

Page 78: ...SCRUBBING 3 2 7200 330045 10 99 ...

Page 79: ...from the solution tank through the solution valve and down to the scrub brushes The brushes rotate to 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 80: ...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 ta...

Page 81: ... 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 5 Remove the drain hose cap from the access caps at the rear of the solution tank ...

Page 82: ...r 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 ESt outlet filter clean reinstall 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 hoses in the tanks ...

Page 83: ...e recovery tank must be removed first See TO REMOVE RECOVERY TANK instructions 2 Remove the seat assembly See TO REMOVE SEAT ASSEMBLY instructions in CHASSIS section 3 Disconnect the battery plug from the batteries Remove the two screws holding the battery connector bracket to the front of the solution tank 4 Remove the battery nearest the right rear corner of the battery compartment ...

Page 84: ...ne is equipped with an overhead guard it must be removed 7 Make sure the solution tank is drained and the tank clean out caps removed 8 Remove the four hex screws holding the plastic rear drain splash tray Let it drop down for access to the solution tank hardware 9 Remove the screw on the right side of the solution tank drain cap ...

Page 85: ... the hardware holding the air flush valve and bracket to the solution tank 13 Disconnect the clear water hose from the top front corner of the solution tank 14 Disconnect the float switch electrical plug from the main harness NOTE Make sure to note the orientation of the electrical harness before removing the solution tank It is very important to position the harness in the same location when inst...

Page 86: ...he 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 87: ...frame 2 Connect the hose coming from the water valve to the nipple on the bottom of the solution tank Tighten the worm drive clamp 3 Drop the solution tank down in place Be careful to route the electrical harness properly 4 Move the tank around until all the mount holes in the tank are lined up with the holes in the frame 5 Install the hex screw in the area to the right of the tank drain cap Leave...

Page 88: ... seat support Leave loose for now 7 Install the air flush valve mount bracket on the side of the solution tank Tighten all four screws to 18 24 Nm 15 20 ft lb 8 Connect the water hose to the top front nipple on the solution tank Tighten the worm drive clamp 9 Connect the float switch to the main harness ...

Page 89: ... Reinstall the tank cover and plastic hinge rod 11 Reconnect the top of the prop arm to the tank cover 12 Reinstall the plastic rear drain splash tray over the tank drains Tighten the four screws 13 Reinstall the tank drain hose and caps ...

Page 90: ...rtment 15 Reinstall the battery connector mount bracket on the front of the solution tank Tighten the two screws to 18 24 Nm 15 20 ft lb 16 Reinstall the overhead guard if it was removed earlier 17 Operate the machine and check the solution tank for any leaks and for proper operation of the float switch ...

Page 91: ...ry 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 TO DRAIN AND CLEAN RECOVERY TANK 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 M...

Page 92: ...e 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 ESt outlet filter clean reinstall 9 Check the vacuum fan filter on top of the recovery tank Clean or replace if necessary ...

Page 93: ...SCRUBBING 3 17 7200 330045 10 99 10 Close the tank cover 11 Replace the drain hoses in the tanks ...

Page 94: ...re must be loosened or removed first See TO REMOVE SOLUTION TANK instructions 2 Tilt the seat support until the prop rod is engaged 3 If the machine is equipped with an overhead guard it must be removed 4 Make sure the recovery tank is drained and the tank clean out caps removed 5 Remove the four hex screws holding the plastic rear drain splash tray Let it drop down for access to the recovery tank...

Page 95: ...ide of the solution tank drain cap 7 Open the tank cover Remove the hardware holding the top of the prop arm to the tank cover 8 Pull the vacuum hose out of the hole in the recovery tank 9 Remove the plastic tank cover hinge rod Remove the tank cover from the machine ...

Page 96: ...ctrical plug Remove the vacuum fan from the machine 11 Remove the hardware holding the air flush valve and bracket to the recovery tank 12 Go in the operators compartment and remove the screw from the left front corner of the recovery tank 13 Pull the recovery tank up far enough to access the ESt hose on the inside wall Remove the hose from the recovery tank ...

Page 97: ... plug from the main harness NOTE Make sure to note the orientation of the electrical harness before removing the solution tank It is very important to position the harness in the same location when installing a new tank 15 The recovery tank can now be removed from the machine ...

Page 98: ... frame 2 Connect the hose coming from the ESt pump to the nipple on the side of the recovery tank Tighten the worm drive clamp 3 Drop the recovery tank down in place Be careful to route the electrical harness properly 4 Move the tank around until the front and back mount holes in are lined up with the holes in the frame 5 Install the hex screw in the area to the left of the tank drain cap Leave lo...

Page 99: ...ent Leave loose for now 7 Install the air flush valve mount bracket on the front of the recovery tank Tighten all three screws to 18 24 Nm 15 20 ft lb 8 Reinstall the vacuum fan on the recovery tank Reconnect the vacuum fan to the main electrical harness Tighten the hardware to 18 24 Nm 15 20 ft lb 9 Reinstall the tank cover and plastic hinge rod ...

Page 100: ...nstall the plastic rear drain splash tray over the tank drains Tighten the four screws 12 Reinstall the tank drain hose and caps 13 Reinstall the overhead guard if it was removed earlier 14 Operate the machine and check the recovery tank for any leaks and for proper operation of the float switch ...

Page 101: ...ot 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 SCRUB 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 e...

Page 102: ... frame Remove the scrub head links from the machine NOTE The measurement for the new scrub head links should be 16 inches from the center of the front ball joint to the center of the rear balljoint 3 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 103: ...e 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 NOTE Mark the connectors for proper re assembly ...

Page 104: ...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 105: ...e end of the scrub head link into the mount 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 3 Position the scrub head as close as possible to the center Remove the jack stands and lower the machine until the clevis pins can be reinstalled in the front of the scrub head lift bracket and the bottom of the...

Page 106: ...7200 330045 10 99 5 Reconnect the water line 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 proper rotation ...

Page 107: ... 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 108: ...ad 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 Turn on the machine and raise the scrub head lift actuator Turn off the machine NOTE This will allow more clearance for the scrub head to slide out 7 The scrub head can now be pulled out from under the machine frame ...

Page 109: ...ink into the mount 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 3 Position the scrub head as close as possible to the center Turn on the machine and lower the scrub head lift actuator NOTE Do this in small increments until the mount hole in the scrub head lines up with the mount hole in the lift mech...

Page 110: ...ine 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 pattern and proper rotation See TO CHECK AND ADJUST CYLINDRICAL BRUSH PATTERN instructions 10355 ...

Page 111: ...heck 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 holding the retainer and skirt to the scrub head frame 3 Position the up or down as needed to achieve 1 8 to 1 4 inch c...

Page 112: ...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 113: ... 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 NOTE 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 Pull the hair pin out of...

Page 114: ...s 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 115: ...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 116: ... 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 117: ...ess 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 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 Turn the brush until you can see the brush sprin...

Page 118: ...the brush under the scrub head 6 Line up the brush drive socket with the drive plug 7 While pressing the brush spring clip together with your thumb and index finger lift the scrub brush onto the drive plug 8 Check to make sure the brush is securely mounted on the brush drive hub 9 Repeat for the other brush ...

Page 119: ...g 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 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 pow...

Page 120: ...4 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 5 Pull the old brush out of the scrub head 6 Position the brush with the double row end towards you Guide the new brush onto the drive hub ...

Page 121: ...rub head then pull up on the door to latch it into the spring 9 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 replacing the doors ...

Page 122: ...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 123: ...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 124: ...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 125: ...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 126: ...ush the drive belt down toward the lower brush drive plug NOTE Make sure the scrub head is slightly off the floor before attempting to remove the drive plug rubber seal 6 Cut the RTV sealant around the rubber seal Use a needle nose pliers to remove it from the brush drive plug Note the orientation of the seal Remove the drive plug 7 Remove the brush drive belt from the machine NOTE It is a tight f...

Page 127: ...rive belt over the drive plug 10 Reinstall the rubber seal on the drive plug Note the orientation of the seal Use RTV Blue sealant all around the seal when installing 11 Use the tension bolt under the drive motor to tighten the drive belt Apply 2 5 2 7 lbs of force to the drive belt in the middle of the span The belt should deflect 0 10 inch 12 Tighten the drive motor pivot bolts to 18 24 Nm 15 20...

Page 128: ... 99 13 Reinstall the belt cover Tighten the screws to 11 14 Nm 7 10 ft lb 14 Reinstall the scrub brushes See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions 15 Operate the machine and check the scrub brushes for proper operation ...

Page 129: ...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 130: ...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 7 Remove the two screws holding the valve to the machine frame Remove the manual valve from the machine ...

Page 131: ... 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 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 132: ...ckness of the blade The squeegee can be adjusted for leveling and deflection The deflection and leveling of the squeegee blades should be checked daily or when scrubbing a different type of floor The squeegee assembly can be removed from the squeegee pivot to prevent damage during transport of the machine TO REMOVE REAR SQUEEGEE ASSEMBLY 1 Lower the squeegee to approximately 25 mm 1 in from the fl...

Page 133: ...SCRUBBING 3 57 7200 330045 10 99 3 Remove the squeegee suction hose from the squeegee 4 Remove both squeegee mounting knobs 5 Pull the squeegee off the machine ...

Page 134: ...ee 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 4 Tighten the mounting knobs 5 Push the squeegee suction hose onto the squeegee fitting ...

Page 135: ...th of the 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 FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake ...

Page 136: ...d 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 sq...

Page 137: ...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 3 Drive the machine forward and look at the deflection of the squeegee blade The correct amount of deflection is 12 mm 0 50 in for scrubbing smooth floors and 15 mm 0 62 in for rough floors 03719 12 mm 0 50 in ...

Page 138: ... the squeegee deflection cams clockwise to decrease the blade deflection NOTE Turn the squeegee deflection cams counter clockwise to increase blade deflection 6 Drive the machine forward again to check the squeegee blade deflection 7 Readjust the squeegee blade deflection if necessary 03719 12 mm 0 50 in ...

Page 139: ...NNANT part no 01433 1 every 50 hours TO ADJUST REAR SQUEEGEE GUIDE ROLLER 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 in...

Page 140: ...t 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 raised off the floor 2 Turn the machine power off and set the parking brake FOR SAFETY Before Leavi...

Page 141: ...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 142: ...machine power off and set the parking brake if your machine has this option FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 Remove the squeegee from the machine See TO REMOVE SQUEEGEE ASSEMBLY instructions 4 Remove the rear squeegee blade and retainer See TO REPLACE OR ROTATE REAR SQUEEGEE REAR BLADE ...

Page 143: ...nsert the rotated or new squeegee blade in the squeegee frame lining up the slots in the blade with the tabs on the retainer plate 8 Push the retainer plate forward Tighten the two outside knobs on top of the squeegee assembly 9 Insert the rear squeegee blade and retainer Tighten the two rear blade retainer knobs until the ends of the front and rear squeegee blades touch Do not over tighten ...

Page 144: ...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 ...

Page 145: ...GEE LEVELING KNOB The squeegee leveling knob adjusts the deflection at the ends of the squeegee The squeegee leveling knob is located directly behind the squeegee suction hose NOTE DO NOT disconnect the suction hose from the squeegee frame when leveling squeegee Increase end deflection Turn the squeegee leveling knob counter clockwise to increase the deflection at the end of the squeegees Decrease...

Page 146: ...emoved FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 Remove the four hex screws holding the plastic rear drain splash tray Let it drop down for access to the rear squeegee lift cable 4 Locate the rear squeegee lift cable Remove the cotter pin and clevis pin from the end of the lift cable where it attaches to the lift pivot bracket ...

Page 147: ... from the end of the lift cable where it attaches to the squeegee frame Remove the cable from the machine 7 Position the new cable in the machine Start by attaching one end of the cable to squeegee frame Reinstall the clevis pin and cotter pin 8 Attach the other end of the new lift cable to the lift pivot bracket Reinstall the clevis pin and cotter pin ...

Page 148: ... and cotter pin in the mount hole just behind the lift cable drum 10 Reinstall the plastic rear drain splash tray Hand tighten the mounting hardware 11 Reinstall the tank caps 12 Start the machine and raise the rear squeegee Check the new cable for proper operation ...

Page 149: ...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 CYLINDRICAL SCRUB HEAD DISC SCRUB HEAD ...

Page 150: ...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 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 151: ...vacuum 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 on the left front of the recovery tank ...

Page 152: ... the tank Pull the vacuum fan assembly out of the top of the tank Let it rest on the edge of the tank 4 Disconnect the vacuum fan motor from the main electrical harness 5 Remove the vacuum fan assembly from the machine Be careful not to loose the rubber seal on the outlet of the vacuum housing ...

Page 153: ...e recovery solution tank cover 2 Position the vacuum fan assembly on the edge of the recovery tank 3 Connect the plug from the vacuum fan motor to the main electrical harness See schematic in the ELECTRICAL section 4 Drop the vacuum fan assembly straight down into the tank mounting area Make sure the rubber seal is in place on the outlet of the vacuum housing ...

Page 154: ...SCRUBBING 3 78 7200 330045 10 99 5 Install the two screws and tighten to 18 24 Nm 15 20 ft lb 6 Close the tank cover and operate the machine Check the vacuum fan for proper operation ...

Page 155: ...ess or change detergent Use a de foamer Vacuum fan 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 ...

Page 156: ...SCRUBBING 3 80 7200 330045 10 99 ...

Page 157: ...000000 008237 4 62 ELECTRICAL SCHEMATIC 008238 4 64 WIRE HARNESSES GROUP 000000 008237 4 66 Page OPERATING MODES 4 69 NORMAL MODE 4 70 SCRUB BUTTON 4 70 SQUEEGEE BUTTON 4 71 ESt BUTTON 4 71 OVERFLOW FLOAT 4 71 BATTERY GAUGE 4 72 HOUR METER 4 72 INTERLOCKS 4 72 SELF TEST MODE 4 74 SELF TEST ERROR CODES 4 76 ACTUATOR GROUP SQUEEGEE BUTTON PRESSED 4 76 BRUSH MOTOR GROUP SCRUB BUTTON PRESSED 4 76 ACCE...

Page 158: ...ELECTRICAL 4 2 7200 330045 10 99 ...

Page 159: ...ELECTRICAL 4 3 7200 330045 10 99 INTRODUCTION The machines electrical system consists of the batteries instrument panel drive motor actuators switches relays and circuit breakers ...

Page 160: ...he batteries Use a wire brush to clean the terminal posts and the cable connectors Wipe off all cleaning solution residue 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 Objects made of metal can potentially short circuit the batteries Keep all metallic objects off the batteries Replace any worn ...

Page 161: ... 27_ C 80_F CHARGE 1 265 100 Charged 1 223 75 Charged 1 185 50 Charged 1 148 25 Charged 1 110 Discharged NOTE If the readings are taken when the battery electrolyte is any temperature other than 27 C 80 F the reading must be temperature corrected Add or subtract to the specific gravity reading 0 004 4 points for each 6 C 10 F above or below 27 C 80 F CHARGING THE BATTERIES 1 Drive the machine to a...

Page 162: ...ion NOTE Make sure the battery caps are in place while charging FOR SAFETY When maintaining or servicing machine avoid contact with battery acid 5 Unplug the machine connector from the batteries 6 Plug the charger connector into the battery connector WARNING Batteries emit hydrogen gas Explosion or fire can result Keep sparks and open flame away Keep covers open when charging ...

Page 163: ...cally turn off 9 After the charger has turned off unplug the charger from the wall outlet 10 Unplug the charger connector from the battery connector on the machine FOR SAFETY When maintaining or servicing machine avoid contact with battery acid 11 Connect the battery connector to the machine connector 12 Check the electrolyte level in each battery cell after charging If needed add distilled water ...

Page 164: ...d set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 Lift the operator seat to access the batteries The support arm automatically engages when the seat is lifted all the way up 4 Un plug the battery connector from in front of the solution tank FOR SAFETY Disconnect Battery Connections Before Working On machine ...

Page 165: ... baking soda and water to clean the battery compartment area 9 Install the new batteries in the same orientation as the old batteries 10 Reconnect all of the battery cables 11 Check the batteries and charge if necessary See TO CHARGE BATTERIES instructions 12 Reconnect the battery connector at the front of the solution tank 13 Lower the seat support and operate the machine Check for proper operati...

Page 166: ... lights keep 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 FOR SAFETY Disconnect Battery Connections Before Working On machine 2 Locate the circuit board cover on the inside front wall of the steering support behind the contr...

Page 167: ...ding the circuit board cover onto the frame 4 Pull the circuit board cover back to access the circuit board 5 Un plug the two ribbon cables from the circuit board 6 Locate the four touch panel lock clips on the under side of the dash panel Remove the lock clips ...

Page 168: ...areful 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 four lock clips on the bezel posts ...

Page 169: ...ition the circuit board cover back up to the inside front wall of the steering support behind 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 two screws and tighten to 18 24 Nm 15 20 ft lb ...

Page 170: ...LECTRICAL 4 14 7200 330045 10 99 16 Lift 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 171: ...e down against the seat support TO ACCESS CONTROL 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 Un plug the battery connector from in front of the solution tank FOR SAFETY Disconnect Battery Connections Before Working On mach...

Page 172: ...ELECTRICAL 4 16 7200 330045 10 99 3 Lower the seat support 4 Remove the two screws at the top of the control panel mount plate 5 Pivot the mount plate down until it is resting against the seat support ...

Page 173: ...e 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 circuit board cover on the inside front wall of the steering support behind the control panel 3 Remove the six nuts holding the circuit board cover on the frame ...

Page 174: ...ic stand offs Remove the circuit board from the machine Note the orientation of the circuit board 8 Position the new circuit board on the six plastic stand offs Gently push 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 Position the circuit board cover back up to the inside fron...

Page 175: ... tighten lightly 12 Pivot the control panel back in position Reinstall the two screws and tighten to 18 24 Nm 15 20 ft lb 13 Lift the operator seat and reconnect the battery connector at the front of the solution tank 14 Close the seat support Start the machine and check for proper operation ...

Page 176: ...d the circuit breaker to trip is still present the circuit breaker will continue to stop current flow until the problem is corrected The circuit breakers are located on the operator console The chart below shows the circuit breakers and the electrical components they protect Circuit Breaker Rating Circuit Protected CB1 10 A Machine power CB2 10 A Battery discharge indicator CB3 15 A Head lights CB...

Page 177: ...ce 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 circuit breakers on the upper edge of the control panel 3 Locate the circuit breaker that needs changing 4 Disconnect the wires from the back of circuit breaker ...

Page 178: ...anel 6 Push the circuit breaker out of the mount hole or remove the CB from the back of panel 7 Remove the rubber boot from the old circuit breaker and install it on the new circuit breaker lower amp only 8 Position the new circuit breaker in the mount hole Note that the circuit breaker and mount hole are D shaped The circuit breaker can only be installed one way lower amp only ...

Page 179: ...es to the back of the new circuit breaker See the schematic in this section 11 Pivot the control panel back in position Reinstall the two screws and tighten to 18 24 Nm 15 20 ft lb 12 Lift the operator seat and reconnect the battery connector at the front of the solution tank 13 Close the seat support Start the machine and check for proper operation ...

Page 180: ...ehind the operator console Access the fuse by lowering the operator console Fuse Rating Circuit Protected FU 1 80 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 PANEL instructions FOR SAFETY Disconnect Battery Connections Before Working On machine 2 Locate the electrical fuse on the ...

Page 181: ...ide 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 two 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 prope...

Page 182: ...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 NOTE When the directional pedal is placed into the reverse position the rear squeegee will automatically rais...

Page 183: ...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 184: ...ontroller 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 7 Pivot the control panel back in position Reinstall the two screws and tighten to 18 24 Nm 15 20 ft lb ...

Page 185: ...front of the solution tank 9 Start the machine and check for proper operation of the propelling TO REPLACE TAILLIGHT BULB 1 Drain the tanks then remove tank drain caps 2 Loosen the bottom screws holding the drip tray 3 Rotate the tray outward from the bottom This allows access to the taillight assembly ...

Page 186: ...inspected after every 1000 hours of machine operation TO REPLACE DRIVE MOTOR FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Raise the seat support and unplug the battery connectors FOR SAFETY Disconnect Battery Connections Before Working On machine 2 Raise the front of the machine and place jack stands under the frame 3 Mark and remove the four electrical ...

Page 187: ...r electrical cable installation 5 Install the new electric motor on the drive assembly NOTE Make sure to line up the splines on the motor shaft with the splines of the planetary gear box 6 Tighten the 4 hex screws to 18 24 Nm 15 20 ft lb 7 Reconnect the electrical cables to the drive motor See the schematic in this section 8 Remove the jack stands and lower the machine 9 Reconnect the battery cabl...

Page 188: ...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 189: ... 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 190: ...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 191: ... 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 192: ...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 193: ...f wire to motor 5 Loosen the front and rear 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 194: ...haft Slide the pulley off the shaft NOTE Do not loose the square key 10 Install the cogged pulley and square key onto the shaft of the new brush motor NOTE 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 th...

Page 195: ...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 NOTE 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 NOTE See schematic in this section ...

Page 196: ...ft 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 197: ...ELECTRICAL 4 41 7200 330045 10 99 LIFT ACTUATORS The lift actuators are electric devices that with a push of a switch raise and lower either the scrub head or the rear squeegee ...

Page 198: ...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 3 Go into the operators compartment and locate the two screws holding the lift actuator mount bracket to the front of the seat support Remove the two screws 4 Raise the seat support and unplug the battery connector FOR SAFETY Disconnect Battery Connections Be...

Page 199: ... lift actuator spring mount bracket Remove the two screws holding the mount bracket to the actuator mount assembly 7 Lift the actuator and spring mount bracket out of the assembly and remove from the machine 8 Remove the cotter pin and clevis pin holding the actuator to the bottom of the spring mount bracket Remove the actuator Note the orientation of the actuator on the bracket ...

Page 200: ...nt bracket Route the wires and plug in the connector Make sure the wires are located in the slot on the of the actuator bracket before installing the spring mount bracket 11 Reinstall the two screws in the spring mount bracket Leave loose for now 12 Go around to the front of the seat support and install the two screws that hold the front of the spring mount bracket to the seat support Tighten all ...

Page 201: ...the rod can still pivot 14 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 15 Raise the seat support and plug in the battery connector Lower the seat assembly 16 Operate the machine and check the scrub head lift actuator for proper operation ...

Page 202: ...p On Level Surface Set Parking Brake 2 Disconnect the squeegee lift actuator from the main electrical harness 3 Locate the four screws holding the squeegee mount channel to the back of the machine 4 Remove the four screws Let the squeegee mount channel and squeegee assembly drop down to access the lift actuator 5 Remove the long hex screw and nyloc nut from the motor end of the lift actuator ...

Page 203: ... lift actuator 7 Remove the actuator from the machine 8 Position the new actuator on the squeegee weldment and the tube end into the pivot weldment 9 Reinstall the hex screw and nut in the motor end of the lift actuator 10 Reinstall the cotter pin and clevis in the tube end of the lift actuator ...

Page 204: ...bly back into position on the back of the machine frame Reinstall the four screws Tighten to 37 48 Nm 26 34 ft lb 12 Reconnect the squeegee lift actuator to the main electrical harness See schematic in this section 13 Start the machine and check the rear squeegee actuator for proper operation ...

Page 205: ...ed float switches in the recovery tank and solution tank are used to turn the pump on and off automatically TO REPLACE ESt PUMP early machines 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 vacuum fan assembly See TO REMOVE VACUUM FAN ASSEMBLY instructions ...

Page 206: ...unt plate to the recovery tank Pull the pump and plate assembly up far enough to access the hoses and wires 5 Disconnect the ESt pump from the main electrical harness 6 Loosen the worm drive clamps holding the solution hoses to the ESt pump Pull the hoses off the pump fittings 7 Pull the ESt pump assembly out of the machine ...

Page 207: ...m the old pump and install in the new pump in the same orientation 10 Install the new ESt pump on the mount plate Hand tighten the hardware 11 Position the pump assembly in the tank area Place both solution hoses on the pump fittings Hand tighten the worm drive clamps 12 Reconnect the pump to the main electrical harness See schematic in this section ...

Page 208: ...t plate with the holes in the recovery tank Reinstall the hardware and tighten to 18 24 Nm 15 20 ft lb 14 Reinstall the vacuum fan assembly See TO INSTALL VACUUM FAN ASSEMBLY instructions 15 Operate the machine and check the ESt pump for proper operation ...

Page 209: ...ving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Make sure the solution and recovery tanks are empty 2 Remove the vacuum fan assembly See TO REMOVE VACUUM FAN ASSEMBLY instructions 3 Locate the ESt pump under the solution recovery tanks behind the rear squeegee mount frame ...

Page 210: ...m drive clamps holding the solution hoses to the ESt pump Pull the hoses off the pump fittings 6 Loosen the large worm drive clamp holding the pump to the bracket 7 Pull the ESt pump assembly out of the machine 8 Remove the plastic fittings from the old pump and install in the new pump in the same orientation ...

Page 211: ...hten tight 10 Place both solution hoses onto the pump fittings Hand tighten the worm drive clamps 11 Reconnect the pump to the main electrical harness See schematic in this section 12 Reinstall the vacuum fan assembly See TO INSTALL VACUUM FAN ASSEMBLY instructions 13 Operate the machine and check the ESt pump for proper operation ...

Page 212: ...ther 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 and recovery tanks 2 Start the machine and lower the scrub head Turn off the key FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake ...

Page 213: ... 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 214: ...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 215: ...eates air flow in the recovery tank With the recovery tank closed the air flow from the vacuum fan creates vacuum 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 ...

Page 216: ...CUUM 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 brackets holding the vacuum fan to the plastic housing Remove the vacuum fan NOTE Make sure to install a gasket on the bottom of the new fan 3 Position the new fan on the housing in the same orientation as ...

Page 217: ...he hardware only until the gasket starts to compress NOTE On a machine equipped with the HD vacuum fan option there is two fans and three added brackets and screws 5 Reinstall the vacuum fan assembly in the machine See TO INSTALL VACUUM FAN ASSEMBLY instructions in the SCRUBBING section ...

Page 218: ...ELECTRICAL 4 62 7200 330045 3 02 ELECTRICAL SCHEMATIC 000000 008237 1 2 7 3 4 5 6 8 350764 ALL ...

Page 219: ...ELECTRICAL 4 63 7200 330045 3 02 ELECTRICAL SCHEMATIC 000000 008237 1 2 3 4 5 6 7 8 350764 ALL ...

Page 220: ...TION ONLY DISK SCRUBBER MACHINE OPTION ONLY M2B CB 7 20 40A M3B FU 1 80A 100A w SWEEP ER UNIT M1B MAIN S 3 SEAT SWITCH S 2 EMERGENCY SW x CLOSED CONTACT START RUN OFF X X X X X S 1 KEYSW 50 83 15 75 30 CB 1 10A D 1 CB 2 10A M2A VAC FAN CB 9 25A MTR MTR LEFT BRUSH MOTOR A B B A 0 5VDC BLK POT LOW ORA GROUND W BRN 36V FWD WHT 36V REV B WHT 36VDC GRN THROTTLE CURTIS ET 10 3 A B C F D E D 8 MTR RIGHT ...

Page 221: ... CB 4 10A M6B BACK UP ALARM OPTION 30 87 BACK UP ALARM OPTION SHROUD LIGHT OVER HEAD GUARD LIGHT CB 3 10A ACT2 A B S 6 POWER WAND SW VAC WAND PUMP MTR HM S 10A UP DN 8 6 4 1 5 2 S 10B ONE TOUCH SWEEPER ON 10 9 S 11B 10 9 S 11A ON OFF 8 6 4 1 5 2 LEFT HEAD LIGHT M5B SWEEPER SYSTEM MTR S 8 LIGHT SW RIGHT HEAD LIGHT D 11 CB 1 0 25A HORN RIGHT TAIL LIGHT MTR MAIN SWEEP BRUSH MOTOR S 7 HORN BUTTON RIGH...

Page 222: ...ELECTRICAL 4 66 7200 330045 3 02 WIRE HARNESSES GROUP 000000 008237 1 5 2 3 4 ...

Page 223: ...ELECTRICAL 4 67 7200 330045 3 02 WIRE HARNESSES GROUP 000000 008237 1 5 2 3 4 ...

Page 224: ...ELECTRICAL 4 68 7200 330045 3 02 WIRE HARNESSES GROUP 000000 008237 ...

Page 225: ... 2 Turn on the key 3 Hold the Squeegee button for 5 seconds 4 Release the Squeegee button Manual Mode Manually operate discrete functions without interlocks In this mode the battery LED 3 will blink More info pages 4 73 thru 4 75 1 Push and hold the ESt button 2 Turn on the key 3 Hold the ESt button for 5 seconds 4 Release the ESt button Input Display Mode Display the state of floats limit switche...

Page 226: ...n will turn on the squeegee will drop and the brushes will drop Putting 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 and after a short delay slightly raise ...

Page 227: ...nd pump it into the solution tank If the operator has turned on the ESt system the recovery tank 1 2 full float is closed and the solution tank full float S 9 is open the ESt pump will begin to run The ESt pump will continue to run for about 30 seconds after the ESt float becomes uncovered OVERFLOW FLOAT If the recovery tank becomes full S 4 is closed the overflow system will shut off the scrub an...

Page 228: ... a slight delay HOUR METER The hour meter logs hours if the machine is in one of the following modes 1 Propelling 2 Vacuum fans running INTERLOCKS The 7200 has several interlocks which can inhibit or cancel machine functions D REVERSE When the operator engages the reverse contactor the following function will become inhibited SQUEEGEE will rise When the operator disengages the reverse contactor th...

Page 229: ...call the last state of charge and display it on the touch panel If the operator disconnects the main power connector the controller will assume the machine has been charged The battery meter will be reset the next time the key is turned on D FULL RECOVERY TANK The 7200 will cancel the following functions if the recovery tank float switch is turned on THE CONTROLLER will cancel scrub and squeegee o...

Page 230: ...s 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 D TO PREVENT INJURY ALWAYS TURN THE MACHINE OFF AFTER THE DIAGNOSTIC MESSAGES HAVE BEEN DISPLAYED D IF THE DIAGNOSTIC MESSAGES DO NOT APPEAR DO NOT ATTEMPT TO SERVICE THIS MACHINE WITHOUT FIRST TURN...

Page 231: ... 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 ESt pump output 12 Cycle and test the ESt air flush output 13 Cycle and test the Vacuum fan o...

Page 232: ... LED s The error code assignments are as follows ACTUATOR GROUP SQUEEGEE BUTTON PRESSED PRESSURE 0 PRESSURE 1 PRESSURE 2 PRESSURE 3 ERROR ON No squeegee actuator zero current ON Early squeegee stall ON ON No squeegee stall ON No brush actuator zero current ON Early brush stall ON ON No brush stall BRUSH MOTOR GROUP SCRUB BUTTON PRESSED PRESSURE 0 PRESSURE 1 PRESSURE 2 PRESSURE 3 ERROR ON No brush ...

Page 233: ...ub head Holding the Scrub button while scrub is active will cause the down pressure to scroll 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 provide power to a stalled actuator...

Page 234: ...N ENABLED BY INDICATOR D Scrub button D One or more scrub pressure LED s on D Forward or reverse propel D Forward or reverse contactors engaged SCRUB BRUSH OPERATION INHIBITED BY INDICATOR D Scrub button D All scrub pressure LED s off D Neutral D Forward and reverse contactors disengaged D Low battery D Battery 1 LED blinking D Open brush motor circuit breaker D All four scrub pressure LED s blink...

Page 235: ...NHIBITED BY INDICATOR D ESt button and Squeegee button D ESt and Squeegee LED s off ESt PUMP OPERATION ESt PUMP ENABLED BY INDICATOR D ESt button D ESt LED on D ESt float covered or ESt 30 second timer running The ESt 30 second timer starts when the ESt pump brings the solution level below the ESt float ESt PUMP INHIBITED BY INDICATOR D ESt button D ESt LED off D More than 30 seconds has passed si...

Page 236: ...el 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 squeegee even though the...

Page 237: ...evel for the selected pressure setting Pressure 2 When the pressure 2 LED is blinking the controller is in the input display mode Pressure 3 When the pressure 3 is on the scrub mode is active Pressure 4 When the pressure 4 LED is on the scrub is active and the brush current detected is above the maximum level for the selected pressure setting NOTE There is a clear folder at the end of this manual ...

Page 238: ...ELECTRICAL 4 82 7200 330045 10 99 ...

Page 239: ...7200 330045 10 99 TROUBLESHOOTING The troubleshooting charts that follow are organized so they lead you through the circuits They include flow charts and instructions for you as to where to insert your test instruments ...

Page 240: ... key switch terminal 15 holding M1 contactor on keeping machine powered up Key switch to off position M1 is turned off by key switch or emergency stop switch Machine turns off KEY SWITCH OFF BATTERY VOLTAGE O VOLTAGE TURN AND HOLD KEY SWITCH TO THE START POSITION CHECK FOR BATTERY VOLTAGE ON 27 GRN AT M1 BATTERY VOLTAGE O VOLTAGE KEY SWITCH PINS 50 TO 15 26 ORA S 2 OR 27 GRN ARE OPEN KEY IN START ...

Page 241: ...BLU MAIN M1 27B GRN S 2 26 ORA S 1 7 PUR 6 BLU D 1 10A M1 MAIN 80A 36VDC KEY SWITCH CLOSED CONTACT 75 15 83 START RUN OFF 30 50 6VDC 6VDC 6VDC 6VDC 6VDC 6VDC POWER UP TESTING COMMON CONTACT C NORM OPEN CONTACT N O HOURMETER HM R CONNECTOR PIN P LEGEND RELAY COIL ARMATURE RESISTOR DIODE FUSE SWITCH MOTOR CIRCUIT BREAKER ARM M D FU S MTR CB ...

Page 242: ...ode chart information to determine what section of the propel system to trouble shoot D If you have no blinking light check the power and ground wires to the controller before replacing the controller See L MOTOR CONTROLLER LED DIAGNOSTICS POWER AND GROUND CONNECTIONS CHECK VERIFY BATTERY VOLTAGE FOR THE FOLLOWING D 27C GRN at the throttle D 27A GRN at the motor controller D 27 GRN at M1 contactor...

Page 243: ...lts present the Status LED flashes a single flash at approximately 1 flash per second If the controller detects a fault a 2 digit code see table below is flashed continuously until the fault is corrected For example code 3 2 Welded direction contactor appears as 3 2 3 2 3 2 TABLE 1 LED CODES LED CODE LED STATUS EXPLANATION LED OFF JJJJJJ D No power or defective controller SOLID ON VVVVVV D Defecti...

Page 244: ...MMER DIAGNOSTICS With a programmer diagnostics and troubleshooting is more direct than with the LED alone The programmer presents complete diagnostic information in plain language no codes to decipher Faults are displayed in the Diagnostic Menu and the status of the controller inputs outputs is displayed in the Test Menu The following 4 step process is generally used for diagnosing and troubleshoo...

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Page 246: ......

Page 247: ...ubleshooting chart table 2 for suggestions covering a wide range of possible faults TABLE 2 TROUBLESHOOTING CHART LED CODE PROGRAMMER LCD DISPLAY EXPLANATION POSSIBLE CAUSE 1 2 HW FAILSAFE Hardware fail safe error 1 Controller defective 1 3 M FAULT M output shorted 1 M output shorted to ground 2 Direction contactor not closing 3 Direction contactor not closing fast enough 4 Internal motor short to...

Page 248: ...on contactor stuck closed 3 4 MISSING CONTACTOR Missing contactor or shunt 1 Direction contactor coil open 2 Direction contactor missing 3 Shunt field open 4 Wire to shunt or direction contactor 4 1 LOW BATTERY VOLTAGE Low battery voltage 1 Battery voltage 16 volts 2 Corroded battery or controller terminal 3 Loose battery or controller terminal 4 2 OVERVOLTAGE Overvoltage 1 Battery voltage 45 volt...

Page 249: ...TIS 1207 1133 SPEED CONTROLLER 36V REV 36V FWD THROTTLE CURTIS ET 103 GROUND POT LOW 0 5VDC GROUND 36 VDC MAIN M1 P 3 P 2 P 6 P 7 P 12 P 11 EMERGENCY STOP REV FWD 34B ORA 33 PUR S 3 31 YEL 30 ORA 30 ORA 28 BRN 29 GRY 29 GRY 27B GRN S 2 26 ORA S 1 7 PUR 6 BLU D 1 M1 MAIN 80A 36VDC KEY SWITCH CLOSED CONTACT 75 15 83 START RUN OFF 30 50 A1 A2 6VDC 6VDC 6VDC 6VDC 6VDC 6VDC TRACTION MOTOR B M A2 B ARM ...

Page 250: ...d to each switch D P1 2 Switched to ground when the ES switch is activated D P1 4 Switched to ground when the Scrub button is activated D P1 6 Switched to ground when the Squeegee button is activated KEY SWITCH ON MACHINE POWERS UP AND PROPELS DO ALL THE LIGHTS ON THE TOUCH PANEL TURN ON THEN OFF YES NO LED S OK YES PANEL OK NO CHECK RIBBON CABLE AT THE CONTROL BOARD OK REPLACE TOUCH PANEL DO SOME...

Page 251: ... 2 P5 3 P4 7 P4 6 REV SENSE FWD SENSE INPUTS SHUNT GROUND 36 VDC SHIELD DOWN PRES 0 BAT 1 SQ VAC ES DOWN PRES 3 5VDC DOWN PRES 1 DOWN PRES 2 FU 1 CIRCUIT BOARD ELECTRONIC CONTROL P2 11 P2 10 P2 9 P2 8 P2 7 P2 6 P2 1 P2 2 P2 3 P2 4 P2 5 P2 3 P1 6 P1 4 P1 2 P1 1 PANEL LEDS GROUND PANEL SWITCHES CONTROL POWER POWER CONTROL POWER POWER P1 6 P1 4 P1 2 P1 1 MEMBRANE TOUCH PANEL M1 MAIN 80A 36VDC 6VDC 6V...

Page 252: ...ng on M2 contactor D 2 M2 contactor supplies battery voltage to the vacuum fan s turning them on MACHINE POWERS UP TOUCH PANEL AND PROPEL SYSTEMS TEST GOOD YES NO CHARGE BATTERIES OR DRAIN RECOVERY TANK RUN SELF TEST DIAGNOSTIC SOFTWARE HOLD SQ VAC BUTTON TURN ON KEY RELEASE BUTTON AFTER 5 SEC BATTERY LED 4 WILL BLINK IN THIS MODE LET MACHINE RUN UNTIL ONE RED FAIL OR GREEN PASS LIGHT COMES ON GRE...

Page 253: ...TTERY LED 2 ON SECOND FROM LEFT NO MACHINE TESTS GOOD 34A ORA AT P4 7 IS SWITCHED TO GROUND THIS SHOULD ONLY HAPPEN IN REVERSE GO TO PROPEL SYSTEM TESTING YES HOLD ES BUTTON TURN KEY ON RELEASE BUTTON AFTER 5 SEC 3 BATTERY LED WILL BLINK IN MANUAL MODE NO YES GO TO INPUT TESTING MODE CHECK FOR BATTERY VOLTAGE FROM 3A GRY TO 13AF BLK AT THE VAC FAN 0 VOLTAGE BATTERY VOLTAGE REPLACE VAC FAN THE CONT...

Page 254: ...PUTS SHUNT GROUND 36 VDC SHIELD DOWN PRES 0 BAT 1 SQ VAC ES DOWN PRES 3 5VDC DOWN PRES 1 DOWN PRES 2 FU 1 CLOSED DISABLE VAC SQGE CIRCUIT BOARD ELECTRONIC CONTROL P 15 REVERSE M5 P2 11 P2 10 P2 9 P2 8 P2 7 P2 6 P2 1 P2 2 P2 4 P2 5 P2 3 P1 6 P1 4 P1 2 P1 1 PANEL LEDS CURTIS 1207 1133 SPEED CONTROLLER GROUND CB 7 PANEL SWITCHES CONTROL POWER POWER CONTROL POWER POWER P1 6 P1 4 P1 2 P1 1 MEMBRANE TOU...

Page 255: ...ELECTRICAL 4 97 7200 330045 10 99 ...

Page 256: ...low battery condition sensed D 4 No full recovery tank condition sensed SQUEEGEE ACTUATOR EXTEND OR RETRACT D 1 16 YEL at P3 10 and 17 GRY at P3 15 are both at battery voltage in the off position D 2 Is pulsed low to extend is pulsed low to retract the squeegee actuator YES NO CHARGE BATTERIES OR DRAIN RECOVERY TANK RUN SELF TEST DIAGNOSTIC SOFTWARE HOLD SQ VAC BUTTON TURN ON KEY RELEASE BUTTON AF...

Page 257: ...SS LIGHT WILL BLINK IN INPUT MODE IS BATTERY LED 2 ON SECOND FROM LEFT NO MACHINE TESTS GOOD 34A ORA AT P4 7 IS SWITCHED TO GROUND THIS SHOULD ONLY HAPPEN IN REVERSE GO TO PROPEL SYSTEM TESTING YES HOLD ES BUTTON TURN KEY ON RELEASE BUTTON AFTER 5 SEC 3 BATTERY LED WILL BLINK IN MANUAL MODE NO YES GO TO INPUT TESTING MODE 0 VOLTAGE BATTERY VOLTAGE OR BATTERY VOLTAGE REPLACE ACTUATOR DISCONNECT SQU...

Page 258: ...T GROUND 36 VDC SHIELD DOWN PRES 0 BAT 1 SQ VAC ES DOWN PRES 3 5VDC DOWN PRES 1 DOWN PRES 2 FU 1 CIRCUIT BOARD ELECTRONIC CONTROL P 15 P2 11 P2 10 P2 9 P2 8 P2 7 P2 6 P2 1 P2 2 P2 4 P2 5 P2 3 P1 6 P1 4 P1 2 P1 1 PANEL LEDS CURTIS 1207 1133 SPEED CONTROLLER GROUND PANEL SWITCHES CONTROL POWER POWER CONTROL POWER POWER P1 6 P1 4 P1 2 P1 1 MEMBRANE TOUCH PANEL P 3 P 2 P 6 P 7 P 12 P 11 M1 MAIN 80A 36...

Page 259: ...ELECTRICAL 4 101 7200 330045 10 99 ...

Page 260: ...CH IS OPEN IN THE UP POSITION OR 24 GRY AND 13S BLK ARE OPEN S 4 FLOAT SWITCH IS SHORTED IN THE DOWN POSITION OR 24 GRY IS SHORTED TO GROUND TEST FOR LOW BATTERIES REPLACE BOARD LOW RUN MANUAL MODE HOLD ES BUTTON TURN KEY ON RELEASE BUTTON AFTER 5 SEC 3 BATTERY LED WILL BLINK IN MANUAL MODE YES NO NOTE A SHORTED MOTOR OR D 6 D 7 WILL OPEN CIRCUIT BREAKER RUN SELF TEST DIAGNOSTIC SOFTWARE HOLD SQ V...

Page 261: ...GRN ARE SHORTED OR CONTROL BOARD IS BAD NOW GET NO BRUSH STALL ERROR REPLACE BRUSH HEAD ACTUATOR IF ERROR READS NO BRUSH STALL SQUEEGEE BUTTON HELD DOWN PRESSURE LED 3 AND 4 ARE LIT 18 BRN 19 GRN OR THE BRUSH HEAD ACTUATOR ARE OPEN IF ERROR READS NO BRUSH MOTOR ZERO CURRENT SCRUB BUTTON HELD DOWN PRESSURE LED 1 IS LIT IF THE BRUSHES ARE ALWAYS ON WHEN THE KEY SWITCH IS ON REPLACE M3 CONTACTOR IF T...

Page 262: ...ITH AMP PROBE REPLACE MOTORS WITH EXCESSIVE AMP DRAW IF NONE OF THESE ERRORS ARE FOUND ON THE MACHINE THE SCRUB SYSTEM IS PASSING SELF DIAGNOSTICS DETERMINE WHAT OTHER ERROR WAS CAUSING THE SELF TEST FAILURE TROUBLESHOOT THAT SECTION IF ERROR READS ZERO BRUSH CURRENT AND BRUSH MOTORS DID NOT TURN ON DURING SELF TEST RUN MANUAL MODE SEE PAGE 4 62 TURN ON SCRUB SYSTEM 12A GRN IS BEING SWITCHED TO GR...

Page 263: ... LINE P 16 REV SENSE FWD SENSE INPUTS SHUNT GROUND 36 VDC SHIELD DOWN PRES 0 BAT 1 SQ VAC ES DOWN PRES 3 5VDC DOWN PRES 1 DOWN PRES 2 FU 1 CLOSED DISABLE VAC SQGE CIRCUIT BOARD ELECTRONIC CONTROL P 15 P2 11 P2 10 P2 9 P2 8 P2 7 P2 6 P2 1 P2 2 P2 3 P2 4 P2 5 P1 6 P1 4 P1 2 P1 1 PANEL LEDS CURTIS 1207 1133 SPEED CONTROLLER GROUND CB 9 CB 8 PANEL SWITCHES CONTROL POWER POWER BR MOTOR FAULT 62B BLU CO...

Page 264: ...T ERROR RED FAIL LIGHT ON HOLD ES BUTTON DOWN DOWN PRESSURE LED 2 IS LIT ESt SYSTEM OPERATION When ES system selected on the touch panel and input floats are in the proper position D Recovery tank is 1 2 full S 5 is closed D Solution tank NOT full S 9 is opened D P3 14 is switched to ground turning on the ES pump NOTE Once ES pump is turned on it will keep running until S 5 opens plus 30 seconds o...

Page 265: ... SYSTEM TESTS GOOD DOES ES LIGHT TURN OFF WHEN S 5 IS OPEN FLOAT DOWN YES NO WHEN SOLUTION TANK FULL SWITCH S 9 IS CLOSED FLOAT IN UP POSITION THE OVERFLOW LIGHT TURNS ON IS THE OVERFLOW LIGHT ON WHEN S 9 CLOSES YES DOES THE OVERFLOW LIGHT TURN OFF WHEN S 9 IS OPEN FLOAT DOWN NO S 9 FLOAT SWITCH 14 GRY OR 13Q BLK IS OPEN S 9 IS SHORTED WITH THE FLOAT DOWN OR 14 GRY IS SHORTED TO GROUND ...

Page 266: ...OWN PRES 3 5VDC DOWN PRES 1 DOWN PRES 2 FU 1 CIRCUIT BOARD ELECTRONIC CONTROL P2 11 P2 10 P2 9 P2 8 P2 7 P2 6 P2 1 P2 2 P2 3 P2 4 P2 5 P1 6 P1 4 P1 2 P1 1 PANEL LEDS GROUND PANEL SWITCHES CONTROL POWER POWER P1 6 P1 4 P1 2 P1 1 MEMBRANE TOUCH PANEL M1 MAIN 80A 36VDC 6VDC 6VDC 6VDC 6VDC 6VDC 6VDC ESt SYSTEM COMMON CONTACT C NORM OPEN CONTACT N O HOURMETER HM R CONNECTOR PIN P LEGEND RELAY COIL ARMA...

Page 267: ...ASE BUTTON AFTER 5 SEC BATTERY LED 4 WILL BLINK IN THIS MODE LET MACHINE RUN UNTIL ONE RED FAIL OR GREEN PASS LIGHT COMES ON DO YOU GET AIR FLUSH VALVE ERROR RED OVERFLOW LIGHT ON FAIL SELF TEST PRESS ES BUTTON ES LED TURN ON OPERATION To enable the ESt flush system the vacuum fan and ESt system must be turned on D P3 14 will switch to ground for 5 seconds every 45 seconds turning on SV 1 D Every ...

Page 268: ...ROUND 36 VDC SHIELD DOWN PRES 0 BAT 1 SQ VAC ES DOWN PRES 3 5VDC DOWN PRES 1 DOWN PRES 2 FU 1 CIRCUIT BOARD ELECTRONIC CONTROL P2 11 P2 10 P2 9 P2 8 P2 7 P2 6 P2 1 P2 2 P2 3 P2 4 P2 5 P1 6 P1 4 P1 2 P1 1 PANEL LEDS GROUND PANEL SWITCHES CONTROL POWER POWER P1 6 P1 4 P1 2 P1 1 MEMBRANE TOUCH PANEL M1 MAIN 80A 36VDC 6VDC 6VDC 6VDC 6VDC 6VDC 6VDC ESt FILTER FLUSH SYSTEM COMMON CONTACT C NORM OPEN CON...

Page 269: ...ave regarding our machine manuals If you find an error or have a suggestion please complete this postage paid form and mail it to us Thank you for helping us make zero defects a way of life at Tennant Manual No Rev No Publish Date Page Machine Report Error Suggestion Name Date Customer Number Company Address City State Zip Code ...

Page 270: ...GE NECESSARY IF MAILED IN THE UNITED SATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 94 MINNEAPOLIS MN POSTAGE WILL BE PAID BY ADDRESSEE Technical Publications 15 701 North Lilac Drive P O Box 1452 Minneapolis MN 55440 9947 TENNANT COMPANY ...

Page 271: ...ave regarding our machine manuals If you find an error or have a suggestion please complete this postage paid form and mail it to us Thank you for helping us make zero defects a way of life at Tennant Manual No Rev No Publish Date Page Machine Report Error Suggestion Name Date Customer Number Company Address City State Zip Code ...

Page 272: ...GE NECESSARY IF MAILED IN THE UNITED SATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 94 MINNEAPOLIS MN POSTAGE WILL BE PAID BY ADDRESSEE Technical Publications 15 701 North Lilac Drive P O Box 1452 Minneapolis MN 55440 9947 TENNANT COMPANY ...

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