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Tennant 7200 Service Manual - Performance Systems Janitorial

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2. Q POWER HEAD WAND LIGHT e 136 BLK 8 BLU 37 BLU 81 GRN KEY SW HR METER 5 BRN 4 YEL 30 50 15 ESTOP inen BLU 64A PUR 62A BLU 4 YEL 6A BLU 37 BLU CB 8 R H BRUSH 3 MOTOR 10 YEL 4 4 YEL 4 4 12 GRN V 12 YEL 41 BLU LOWER UPPER IOF YEL v 26 ORN J M 3 6 MOTOR 27B J CONTROLLER 88056 a MEE Q 100 YEL AD _ IA RED M 2 NIMM M B 8 ne BRN O FAN 2 ORA 35 GRN M SER DI P IN Ie _ 7 PUR Y 3 s 3 8 BLU Noc a ou 25 GRY m eem E 4 ll I ll 62 BLU BLU 7 bs u 2 d 1 BLK 06 22 BRN S2 NO SI ot we ON UPPER LOWER 64 PUR 64C PUR __13AC BLK 07 D4 22 BRN NC pu SSS 41 mN x 27E GRN 21 BLU BLK 05 I3F BLK 32B ORA 32 ORA LECTRICAL PANEI EFIE Q 34 ORA 33 PUR INSIDE VIEW M5 M4 S J 24 d ox TO MOTOR 7200 330045 3 02 Home fl Find To 4 68 OPERATING MODES The Model 7200 has 4 different operating modes The machine operator can access each mode by pressing various buttons on the control panel holding them and turning on the key The common operating modes are detailed in the following cha
3. 4 42 REPLACE REAR SQUEEGEE LIFT ACTUATOR 4 46 ES PUMP 225449 er RR Ren 4 49 REPLACE ES PUMP early machines 4 49 REPLACE ES PUMP later machines 4 53 SOLUTION SOLENOID VALVE 4 56 TO REPLACE SOLUTION SOLENOID VALVE 4 56 VACUUM FAN 4 59 TO REPLACE VACUUM FAN 4 60 ELECTRICAL SCHEMATIC 000000 008237 4 62 ELECTRICAL SCHEMATIC 008238 4 64 WIRE HARNESSES GROUP 000000 008237 4 66 ELECTRICAL CONTENTS Page INTRODUCTION 4 3 OPERATING MODES 4 69 BATTERIES 4 4 NORMAL MODE 4 70 CHARGING THE BATTERIES 4 5 SCRUB BUTTON 4 70 TO REPLACE BATTERIES 4 8 SQUEEGEE BUTTON 4 71 INSTRUMENT PANEL 4 10 ES BUTTON 4 71 TO REPLACE TOUCH PANEL 4 10 OVERFLOW FLOAT 4 71 CONTROL PANEL 4 15 BATTERY GAUGE 4 72 TO ACCESS CONTROL PANEL 4 15 HOUR METER 4 72 TO REPLACE CIRCUIT BOARD 4 17 INTERLOCKS 4 72 CIRCUIT BREAKERS 4 20 SELF TEST MODE 4 74 RESETABLE CIRCUIT SELF TEST ERROR CODES 4 76 BREAKERS 4 20 ACTUATOR GROUP SQUEEGEE TO REPLACE CIRCUIT BUTTON PRESSED 4 76 BREAKER 4 21 BRU
4. ri 3 3 S S 5 TRACTION 3 d a 3 MOTOR z 2 P z gt mg M B 3 o o o r 595 NE a cS CURTIS 1207 1133 SPEED CONTROLLE m E Bo Do bo n si x 79 79 n o o ES a 5 5 5 4 N 5 m 2 c m THROTTLE T s lalala B 8 8 lg Y Y E E o o 0 5VDC BLK IVEY 5 lala amp 8 to 2 38 D 3 d 2 Y ora pRa gt lt 2 FORWARD 5 9 RE ar F 1 13M BLK 3 a Qj GROUND W BRN I3M LK 5 9 28 BRN BACK UP ALARM m a m 5 1 lt SQ ser WS WAT 32B 0RA 34C OR B KEY SWITCH L 36V REV B WHT EEA LR o RUN START A 27C GRN REVERSE SSe VDE GRN 32 0RA 2 34 0RA o ZUA a 27E GRN 0 8 ISAKYBLK EMERGENCY STOP dX e TT 27B GRN E 27D GRN 4 27 GRN t bre MAIN v v v X CLOSED CONTACT 4 5 6 7 8 350764 ALL 4 62 7200 330045 3 02 ELECTRICAL ELECTRICAL SCHEMATIC 000000 008237 FWD SENSE P4 6 BR MOTOR 22A BRN REV SENSE P4 7 SSAAORA SENSE LINE 25A GRY BATTERY SENSE pm IOA YEL POWER d I3AA SHIELD IOB YEL P
5. NY TOP VIEW 1025 mm 40 35 in 2032 80 0 1360 mm 5 5 KA 5 5 CJ 1 3 Y Y 1 X 1092 mm 405 mm 43 0 in 16 0 in 1830 810 mm 72 0 in 32 0 in 915 mm SIDE VIEW 36 0 in FRONT VIEW 350790 MACHINE DIMENSIONS 7200 330045 3 02 1 7 Home fl Find Go To GENERAL INFORMATION MAINTENANCE 1 2 E 7 350790 GENERAL INFORMATION MAINTENANCE CHART No of Lubricant Service Interval Key Description Procedure Fluid Points Daily Side and rear squeegees Check for damage and wear Scrub brushes Check for damage wear debris Ls Recovery tank Clean solution supply filter 11 Cylindrical brushes only Clean debris trough Pre Sweep brushes Check for damage and wear 12 Pre Sweep debris hop Clean per 50 Hours 15 Pre Sweep cylindrical Check taper brushes 5 C
6. 2 24 TO REPLACE DRIVE ASSEMBLY PIVOT CONE BEARING 2 29 7200 330045 10 99 2 1 CHASSIS 2 2 7200 330045 10 99 Home fl Find To CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat steering front drive assembly brakes and tires 7200 330045 10 99 2 3 CHASSIS SEAT OPERATOR SEAT The standard operators seat is a fixed back style The seat can be adjusted forward and backward The 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 2 4 7200 330045 10 99 CHASSIS 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 7200 330045 10 99 CHASSIS TO INSTALL SEAT ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Position the seat assembly in the operators compartment 2 Line up the two hinge pins on the seat assembly and seat support Slide the seat assembly all
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8. This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT Model 7200 ride on scrubber The set is organized into four major groups General Information Chassis Scrubbing and Electrical General Information Safety precautions machine transport machine jacking machine storage chassis lubrication machine specifications and 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 electrical schematics diagnostics and electrical troubleshooting Manual Number 330045 Revision 02 Published 3 02 Copyright 1999 2002 TENNANT Printed in U S A GENERAL INFORMATION CONTENTS Page SAFETY PRECAUTIONS 1 3 SPECIFICATIONS 1 5 GENERAL MACHINE DIMENSIONS CAPACITIES 1 5 GENERAL MACHINE PERFORMANCE 1 5 POWERTYPE ua RR statin act s 1 6 TIRES uui rx UE Heese Deni 1 6 MACHINE DIMENSIONS 1 7 MAINTENANCE 1 8 PUSHING TOWING AND TRANSPORTING THE MACHINE 1 10 PUSHING OR TOWING THE MACHINE 1 10 TRANSPORTING THE MACHINE
9. 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 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 4 32 7200 330045 10 99 ELECTRICAL 5 Remove the four screws holding the brush motor to the scrub head 6 Start the machine and lower the scrub 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 7200 330045 10 99 4 33 ELECTRICAL 9 Position the new motor on the scrub head 10 Reconnect the motor wires to 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 Ib 4 34 7200 330045 10 99 ELECTRICAL 13 Install the square key a
10. 5 Push the squeegee suction hose onto the squeegee fitting 3 58 7200 330045 10 99 TO LEVEL REAR SQUEEGEE Leveling of the squeegee assures even contact for the length 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 7200 330045 10 99 SCRUBBING 3 59 SCRUBBING 4 Look at the deflection of the squeegee over the full length of the squeegee blade 5 If the deflection is not the same over the full length of the blade turn the squeegee leveling knob to make adjustments The squeegee leveling knob is located directly behind the squeegee suction hose DO NOT disconnect the suction hose from the squeegee frame when leveling squeegee 47 cal Z 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 squeegee blade deflection 7 Readjust the squeegee blade deflection if necessary 3 60 7200 330045 10 99 TO ADJUST REAR SQUEEGEE BLADE DEFLECTION Deflection is the amo
11. GHHSUa B 456 ETEN eet gt gt aay d AIOIINOS rea lt lt Tw 2 Mg 4 19 15 S 33033 E amp gt Td ara BSR 4 oi yx 8d Y GIONETIOS HELM idi el 33033 41 4 RBAB L lt lt 3 JOS 1 58 HOO P NM 5 T Pme 8 N E lt D o e nN o e 4 65 7200 330045 3 02 Home fl Find Go To ELECTRICAL WIRE HARNESSES GROUP 000000 008237 TAILL IGHT LH 7 FLOAT SW REC TANK ES OPTION 20 GRY Q ES PUMP 816 GRN N BU BLK 23 GRN j I3R BLK j 24 GRY EAR SQU LIFT A OPTION 5 BLK zl I6 YEL FLOAT SW REC TANK VAC FANS 14 GRY BLK FLOAT SW K ON SOL T ES 4 66 I3T BLK TAILLIGHT RH GRY j ISAF BLK 17 BL 2 RED De AJ VOLVING LIGHT OPTION gt 5 7200 330045 3 02 ELECTRICAL WIRE HARNESSES GROUP 000000 008237 j TE
12. gt P3 1 REC TANK FULL 2 6 a 2 P2 7 5 BIS CIN m DOWN PRES 3 P2 8 28 te Um P3 9 DOWN 2 2 9 eae m DOWN PRES 1 2 106 4 DOWN PRES 0 P2 11 5 517 4 P2 125 TE 4 LEGEND 39 GRN CB CIRCUIT BREAKER FU FUSE X_ RIBBON CABLE 2 MTR MOTOR D DIODE STATIC GND P CONNECTOR PIN M RELAY COIL TO FRAME S SWITCH R RESISTOR ARM ARMATURE HM HOURMETER N O NORM OPEN CONTACT C COMMON CONTACT 4 96 7200 330045 10 99 ELECTRICAL 7200 330045 10 99 4 97 Home fl Find To ELECTRICAL OPERATION To lower the squeegee actuator the following conditions must e 1 Vacuum fan squeegee system selected on the touch panel e 2 Machine in neutral or forward position e 3 No battery condition sensed e 4 No full recovery tank condition sensed SQUEEGEE ACTUATOR EXTEND OR RETRACT e 1 16 YEL at P3 10 and 17 GRY at P3 15 are both at battery voltage in the off position e 2 Is pulsed low to extend is pulsed low to retract the squeegee actuator gt MACHINE POWERS UP TOUCH PANEL AND PROPEL SYSTEMS TEST GOOD KEY SWITCH ON ARE ANY OF THE FOLLOWING CONDITIONS TRUE LOW BATTERY 1 BATTERY LED BLINKING NO RECOVERY TANK FULL RED OVERFLOW LED ON CHARGE BATTERIES OR DRAIN RECOVERY TANK RUN SELF TEST DIAGNOSTIC SOFTWARE RED HOLD SQ VAC BUTTON TURN ON KEY RELEASE BUTTON A
13. 7 Remove the brush drive belt from the machine NOTE It is a tight fit for the belt in the area of the lower belt cover and bottom drive plug Carefully work the belt past the lower cover DO NOT remove the lower cover 3 50 7200 330045 10 99 8 Slip the new drive belt into position Push the rest of the drive belt up toward the motor belt pulley Slip the drive belt over the motor belt pulley 9 Reinstall the brush drive plug Install the drive 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 Ibs 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 ft Ib Re check the belt tension 7200 330045 10 99 SCRUBBING 3 51 SCRUBBING 13 Reinstall the belt cover Tighten the screws to 11 14 Nm 7 10 ft Ib 14 Reinstall the scrub brushes See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions 15 Operate the machine and check the scrub brushes for proper operation 3 52 7200 330045 10 99 MANUAL SOLUTION VALVE The manual solution valve is located under the floor plate on the left side of the machine This valve controls the amount of water being sent to t
14. P2 4 m ES 2 5 5 P2 6 1 REC TANK FULL P2 6 DEB a 2 L3 2 7 5 p5 g m DOWN PRES 3 P2 8 5 28 te m P3 9 DOWN PRES2 P2 9 5 eae m DOWN PRES 1 2 106 4 DOWN PRES 0 P2 11 5 SQ VA 2 12 5 4 LEGEND 39 GRN gt gt CB CIRCUIT BREAKER FU FUSE X_ RIBBON CABLE 2 MTR MOTOR D DIODE STATIC GND P CONNECTOR PIN M RELAY COIL TO FRAME S SWITCH R RESISTOR ARM ARMATURE HM HOURMETER N O NORM OPEN CONTACT C COMMON CONTACT 4 100 7200 330045 10 99 ELECTRICAL 7200 330045 10 99 4 101 Home fl Find To ELECTRICAL SCRUB SYSTEM gt MACHINE POWERS UP TOUCH PANEL AND PROPEL SYSTEMS TEST GOOD KEY ON TURN ON SCRUB SYSTEM PROPEL FORWARD IS THE SCRUB YES TOUCH PANEL LED TURNS OFF SYSTEM AUTOMATICALLY TURNED OFF 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 DID THE MACHINE PASS SELF TEST YES NO ee LED S FLASH OPEN BRUSH CIRCUIT BREAKER SENSED DID THE BRUSH HEAD NO YES LOWER AND LIFT DURING SELF TEST YES RUN MANUAL MODE HOLD ES BUTTON TURN KEY ON RELEASE BUTTON AFTER 5 SEC 3 BATTE
15. 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 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 7200 330045 10 99 4 21 ELECTRICAL 5 Remove the metal lock ring from the circuit breaker The lock ring may have to be cut to remove or remove the two screws holding the CB to the panel 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 E breaker lower 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 4 22 7200 330045 10 99 ELECTRICAL 9 Install the new lock ring on the new circuit breaker or reinstall the two screws Hand tighten 10 Reconnect the wires 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 Ib 12 Lift the operator seat and reconnect the battery connector at the front of the so
16. VALVE 10J YEL OR 38 ORA IS OPEN SYSTEM IS TESTING GOOD REVIEW OPERATION DESCRIPTION IS SYSTEM PROPERLY ENABLED 7200 330045 10 99 4 109 ELECTRICAL ES FILTER FLUSH SYSTEM BATTERIES VD GROUND Y 6VDC 6VDC 6VDC 6VDC 6VDC 6VDC Y ELECTRONIC CONTROL CIRCUIT BOARD o hT FWD SENSE P4 6 gt SHT P4 10 REV SENSE P4 7 gt 0 5 P5 35 P4 11 15 P5 2b P3 2 SHIELD 5 1 P d P3 7 POWER gt P4 1 9 2 P3 8 POWER 13B BLK w 13C BLK c P3 12 CL P4 5 CONTROL J P4 3 by Q gw P4 2 P3 11 a P4 9 J P3 13 MEMBRANE TOUCH PANEL m pr P3 10 GND P1 15 P1 1 2 P3 15 ES 1 2 P1 2 P3 4 SCRUB P1 4 P1 4 P3 5 SQ VAC 1 6 ua ers 14 2 3 AMPS pc P2 1 P2 1 Q BAT 2 P2 2 5 52 2 ES PUMP 2 3 5 52 3 lt SV BATO P2 4 5 2 4 4 10J YEL 38 ORA ES 5 5 PES gt P3 1 REG TAM 62 6 5 92 6 44 gt ES FILTER FLUSH DOWN PRES 3 3 8 P2 8 dP3 9 RESET ES W 9 P5 1 P2 11 5 12 p2 12 4 39 GRN RIBBON CABLE 2 STATIC GND TO FRAME LEGEND CB CIRCUIT BREAKER FU FUSE MTR MOTOR D DIODE P CONNECTOR PIN M RELAY COIL S SWITCH R RESISTOR ARM ARMA
17. 19 20 21 7200 330045 10 99 wheel into the top of the steering U joint Tighten the set screws tight Go under the machine and reinstall the steering chain around the small steering sprocket Reinstall the master link 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 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 Ib Remove the jack stands and lower the machine to the floor Operate the machine and check the steering chain for proper operation 2 55 CHASSIS TO REPLACE STEERING U JOINT FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 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 2 56 7200 330045 10 99 CHASSIS 5 Install the new U joint and square key on the top of the steering housing Tighten the set scre
18. 27 GRN 13D BLK 81 75 iin MAIN X CLOSED CONTACT LEGEND CIRCUIT BREAKER FU FUSE MOTOR D DIODE P CONNECTOR PIN M RELAY COIL S SWITCH R RESISTOR ARM ARMATURE HM HOURMETER N O NORM OPEN CONTACT C COMMON CONTACT 7200 330045 10 99 4 85 ELECTRICAL PROPEL OPERATION e e e Throttle assembly gives speed and direction information to the controller Controller turns on forward or reverse contactors Controller provides variable speed control of the propel motor by pulsing M terminal to ground B terminal NOTE Assume that machine has passed power up testing ERROR CODES KEY ON 1242 Slide the cover open on the edge of the Curtis 1207 1133 motor controller Read error code displayed by blinking light on the motor controller Use the error code chart information to determine what section of the propel System to trouble shoot If you have no blinking light check the power and ground wires to the controller before replacing the controller See MOTOR CONTROLLER LED DIAGNOSTICS POWER AND GROUND CONNECTIONS CHECK VERIFY BATTERY VOLTAGE FOR THE FOLLOWING 27C GRN at the throttle 27A GRN at the motor controller 27 GRN at M1 contactor coil B terminal of the motor controller Normally open terminal of M4 and M5 VERIFY GROUND CONTINUITY FOR THE FOLLOWING POINTS 13M BLK at the throttle B terminal of motor controller gt ACTIVATE THE SEAT SWITC
19. Remove the cotter pin and long clevis pin from just behind the lift cable drum 6 Remove the cotter pin and clevis pin 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 7200 330045 10 99 3 71 SCRUBBING 9 Reinstall the long clevis pin 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 3 72 7200 330045 10 99 SIDE SQUEEGEE BLADES The side squeegees control water spray and channel water into the path of the rear squeegee Check the side squeegees for damage and wear daily Replace the side squeegee blades if they become damaged or lose their shape Replace the squeegee deflectors if they become worn 7200 330045 10 99 SCRUBBING 3 73 SCRUBBING TO REPLACE SIDE SQUEEGEE BLADES 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
20. SQUEEGEES The rear squeegee assembly channels water into the vacuum fan suction The front blade channels the water and the rear blade wipes the floor Check the squeegee blades for damage and wear daily Rotate or replace either of the squeegee blades if the leading edge is torn or worn half way through the thickness 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 floor 2 Turn the machine power off and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 56 7200 330045 10 99 SCRUBBING Ey M 3 Remove the squeegee suction hose from the squeegee 4 Remove both squeegee mounting knobs 5 Pull the squeegee off the machine 7200 330045 10 99 3 57 SCRUBBING TO INSTALL REAR SQUEEGEE ASSEMBLY 1 Make sure the squeegee pivot is lowered FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Place the squeegee under the squeegee pivot 3 Push the squeegee frame onto the squeegee pivot 4 Tighten the mounting knobs
21. battery connector Lower the seat assembly 16 Operate the machine and check the scrub head lift actuator for proper operation 7200 330045 10 99 4 45 ELECTRICAL TO REPLACE REAR SQUEEGEE LIFT ACTUATOR 1 Start the machine and lower the rear squeegee Shut off the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake a 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 4 46 7200 330045 10 99 ELECTRICAL 6 Remove the cotter pin and clevis from the tube end of the 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 7200 330045 10 99 4 47 ELECTRICAL 11 Position the squeegee mount channel and squeegee assembly back into position on the back of the machine frame Reinstall the four screws Tighten to 37 48 Nm 26 34 ft Ib 12 Reconnect the squeegee lift ac
22. option 455 mm 18 in Disk brush diameter for Pre Sweep option Disk brush diameter for 700 mm 28 in scrub head Disk brush diameter for 900 mm 36 in scrub head Cylindrical sweep brush diameter for Pre Sweep option Cylindrical sweep brush length for Pre Sweep option Cylindrical brush length for 700 mm 28 in scrub head Cylindrical brush length for 900 mm 36 in scrub head 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 36 in scrub head 900 mm 36 in Solution tank capacity 130 L 35 gallons Recovery tank capacity 210 L 55 gallons 1134 Kg 2500 bs GENERAL MACHINE PERFORMANCE 2060 mm Aisle turnaround width with Pre Sweep 2770 mm 109 in 7200 330045 3 02 GENERAL INFORMATION POWER TYPE Batteries B 235 9 20 hr rate 30 kg 67 e s gt rouw Electric Motors Pre Sweep brush disk 08 08 TIRES Front 1 100 mm wide x 305 mm OD 4 in wide x 12 in OD Rear 2 90 mm wide x 305 mm OD 3 5 in wide x 12 in OD 7200 330045 3 02 GENERAL INFORMATION 1 1155 45 5 in 921 mm 1020 mm 36 25 in 40 25 in ee
23. 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 7200 330045 3 02 1 1 GENERAL INFORMATION 12 7200 330045 10 99 Home fl Find Go To GENERAL INFORMATION SAFETY PRECAUTIONS The following symbols are used throughout this manual as indicated in their description WARNING To warn of hazards or unsafe practices that could result in severe personal injury or death FOR SAFETY To identify actions that must be followed for safe operation of equipment This machine is designed solely for scrubbing dirt and dust in an indoor environment Tennant does not recommend using this machine in any other environment The following information signals potentially dangerous conditions to the operator or equipment Read this manual carefully Know when these conditions can exist Locate all safety devices on the machine Then take necessary steps to train machine operating personnel Report machine damage or faulty operation immediately Do not use the machine if it is not in proper operating condition WARNING Batteries emit hydrogen gas Explosion or fire can result Keep sparks and open flame away
24. 3 Lift the operator seat to access the batteries The support arm automatically engages when the seat is lifted all the way up 4 Check the water level in all battery cells 7200 330045 3 02 ELECTRICAL 04380 ELECTRICAL If the level is low add just enough distilled water to cover the plates DO NOT OVERFILL The batteries can overflow during charging due to expansion NOTE Make sure the battery caps are in place while charging 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 4 6 7200 330045 3 02 ELECTRICAL 7 Plug the battery charger into the wall outlet NOTE If the red ABNORMAL CYCLE lamp lights when the TENNANT charger is plugged into a wall outlet the charger cannot charge the battery and there is something wrong with the battery 2 2 e 2 e 2 2 2 2 8 TENNANT charger will start automatically When the batteries are fully charged the TENNANT charger will automatically turn off 9 After the charger has turned off unplug the charger from the wall outlet 07224 10 Unplug the charger connector from the battery connector on the machine FOR SAFETY When maint
25. CHART SAE Grade 5 SAE Grade 8 Thread Torque ft Ib Torque ft Ib Size Nm Nm 7 10 9 14 10 13 14 38 15 20 20 27 20 26 27 35 27 35 37 47 36 47 49 64 43 56 58 76 53 76 72 103 7115 0 50in 65 85 88 115 89 116 121 157 0 62 in 130 170 117 265 176 231 159 359 0 75 in 215 280 313 407 291 380 424 552 1 00 in 500 650 757 984 678 881 1026 1334 NOTE Decrease torque by 20 when using a thread lubricant METRIC BOLT TORQUE CHART Class 10 9 Torque ft Ib Class 8 8 Torque ft Ib NOTE Decrease torque by 2096 when using a thread lubricant Exceptions to the above chart Check the machine for exceptions BOLT IDENTIFICATION Identification Specification and Grade Marking Grade A ISO Grade 8 8 9 ISO Grade 10 9 01395 THREAD SEALANT AND LOCKING COMPOUNDS Thread sealants and locking compounds may be used on this machine They include the following Locktite 515 sealant gasket forming material TENNANT Part No 75567 15 oz 440 ml cartridge Locktite 242 blue medium strength thread locking compound TENNANT Part No 32676 0 5 ml tube Locktite 271 red high strength thread locking compound TENNANT Part No 19857 0 5 ml tube GENERAL INFORMATION 1 16 7200 330045 3 02 Home fl Find Go To CHASSIS CONTENTS Page Page INTRODUCTION 2 3 PLANETARY GEAR BOX 2 32 Sls PET 2 4 TO REMOVE PLANETARY GEAR OPE
26. Company Address City State Zip Code EE Joe eT SALVS AHL NI 3l AYVSSAOAN ADVLSOd ON NW SMOdVANNIA 2766 0 9 NIN siodeeuun xog Od YHON LOZ S 91 LNVNN3 L Ad 38 THM 39 150 v6 LI NH3d IVAW 55 15 15014 TVN Aldad SSANISNG seui Buoje pjoJ
27. 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 electric motor on the drive assembly Make sure to line up the splines on the motor shaft with the splines of the planetary gear box Tighten the 4 hex screws to 18 24 Nm 15 20 ft Ib 2 34 7200 330045 3 02 CHASSIS 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 7200 330045 10 99 2 35 CHASSIS TO REPLACE FRONT TIRE AND WHEEL ASSEMBLY 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 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 will expose the outer bearing hex sleeve and lock bolt 2 36 7200 330045 10 99 7 Remove the lock bolt this is a rig
28. P2 7 5 p2 g 4 r DOWN PRES 3 2 8 5 pog 4 m P3 9 DOWN PRES 2 2 9 5 iv DOWN PRES 1 2 10 5 s DOWN PRES 0 P2 115 0 4 SQ VAC 2 125 e i4 39 GRN M RIBBON CABLE 2 STATIC GND LEGEND TO FRAME CB CIRCUIT BREAKER FU FUSE MTR MOTOR D DIODE P CONNECTOR PIN M RELAY COIL S SWITCH R RESISTOR ARM ARMATURE HM HOURMETER NORM OPEN CONTACT COMMON CONTACT 7200 330045 10 99 4 93 ELECTRICAL VACUUM FAN S OPERATION To enable the vacuum fan the following conditions must e 1 Vacuum fan squeegee system selected on the touch panel e 2 Machine in neutral or forward position e 3 No battery condition sensed e 4 No full recovery tank condition sensed VACUUM MOTOR TURNS ON e 1 11 BRN is switched to ground at control board P3 12 turning on M2 contactor e 2 2 contactor supplies battery voltage to the vacuum fan s turning them on gt MACHINE POWERS UP TOUCH PANEL AND PROPEL SYSTEMS TEST GOOD KEY SWITCH ON ARE ANY OF THE FOLLOWING CONDITIONS TRUE LOW BATTERY 1 BATTERY LED BLINKING NO RECOVERY TANK FULL RED OVERFLOW LED ON CHARGE BATTERIES OR PEREGO EN TANK RUN SELF TEST DIAGNOSTIC SOFTWARE RED 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 READ
29. P2 9 5 cl Pe SQ VAC P5122 P2 122 39 GRN RIBBON CABLE 2 STATIC GND TO FRAME LEGEND CB CIRCUIT BREAKER FU FUSE MTR MOTOR D DIODE P CONNECTOR PIN M RELAY COIL S SWITCH R RESISTOR ARM ARMATURE HM HOURMETER N O INORM OPEN CONTACT COMMON CONTACT 4 108 7200 330045 10 99 ELECTRICAL ES FILTER FLUSH SYSTEM OPERATION To enable the ES flush system the vacuum fan and ES system must be turned on e P3 14 will switch to ground for 5 seconds every 45 seconds turning on SV 1 e Every time SV 1 is turned on an air burst clears debris from the ES pump filter gt MACHINE POWERS UP TOUCH PANEL AND PROPEL SYSTEMS TEST GOOD 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 ERROR 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 NO ERROR RUN MANUAL MODE TEST HOLD ES BUTTON TURN KEY ON RELEASE BUTTON AFTER 5 SEC REPLACE BOARD 3 BATTERY LED WILL BLINK IN MANUAL MODE TURN ON ES SYSTEM DOES SV 1 TURN REPLACE SV 1 YES STILL HAVE DISCONNECT ES ERROR 1 FLUSH SOLENOID AND RE TEST NO ERROR 38 ORA IS SWITCHED TO GROUND AT P3 1 VALVE SHOULD TURN ON
30. RUN UNTIL ONE RED FAIL OR GREEN PASS LIGHT COMES ON DO YOU GET ES PUMP OUTPUT ERROR RED FAIL LIGHT ON HOLD ES BUTTON DOWN DOWN PRESSURE LED 2 IS LIT NO ERROR RUN MANUAL MODE TEST HOLD ES BUTTON TURN KEY ON RELEASE BUTTON AFTER 5 SEC 3 BATTERY LED WILL BLINK IN MANUAL MODE TURN ON ES SYSTEM STILL HAVE DISCONNECT ES PUMP IS THE PUMP RUNNING ERROR AND RE TEST YES NO ERROR 20 GRY IS SWITCHED TO GROUND AT 3 14 MOTOR SHOULD RUN ES PUMP MOTOR OR 10H YEL OR RUN INPUT 20 GRY IS OPEN TEST MODE VERIFY THAT 20 GRY IS NOT SHORTED TO GROUND THEN REPLACE THE ES PUMP HOLD SCRUB BUTTON TURN ON KEY RELEASE SCRUB BUTTON AFTER 5 SEC 2 DOWN PRESS LIGHT WILL BLINK IN INPUT MODE VERIFY FLOAT OPERATION PERLACE TAE ROARD WHEN RECOVERY TANK 1 2 FULL SWITCH S 5 IS CLOSED FLOAT IN UP POSI TION THE ES TOUCH PANEL LIGHT TURNS ON IS THE ES LIGHT ON WHEN 8 5 CLOSES YES SEE NEXT PAGE 4 106 7200 330045 10 99 ELECTRICAL CONTINUED FROM PREVIOUS PAGE YES NO DOES ES LIGHT TURN OFF WHEN 85 515 23 GRN 13R BLK OPEN FLOAT DOWN PORN pice OR 5 5 FLOAT SWITCH IS OPEN YES 5 5 IS SHORTED WITH THE FLOAT DOWN OR 23 GRN IS SHORTED TO GROUND WHEN SOLUTION TANK FULL SWITCH 5 9 IS CLOSED FLOAT IN UP POSITION THE OVERFLOW LIGHT TURNS ON IS THE OVERFLOW LIGHT ON WHEN S 9 CLOSES DOE
31. SELF TEST ERROR BREAKDOWN 7200 330045 10 99 IF ERROR READS BRUSH CONTACTOR OUTPUT ES BUTTON HELD DOWN PRESSURE LED 4 IS LIT DISCONNECT 12A GRN AT AND RERUN SELF TEST NO ERROR NOW REPLACE M3 SAME ERROR STILL DISCONNECT CONTROL BOARD VERIFY 12A GRN IS NOT SHORTED TO GROUND THEN REPLACE THE CONTROL BOARD IF ERROR READS NO BRUSH ACTUATOR ZERO CURRENT SQUEEGEE BUTTON HELD DOWN PRESSURE LED 3 IS LIT REPLACE THE CONTROL BOARD IF ERROR READS EARLY BRUSH STALL SQUEEGEE BUTTON HELD DOWN PRESSURE LED 74 IS LIT DISCONNECT BRUSH HEAD ACTUATOR AND RE RUN SELF TEST SAVE ERROR 18 BRN AND 19 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 THE BRUSHES TURN ON AND OFF DURING SELF TEST THE CIRCUIT BOARD SHOULD BE REPLACED IF ERROR READS ZERO BRUSH MOTOR CURRENT SQUEEGEE BUTTON HELD DOWN PRESSURE LED 2 IS LIT AND BRUSHES TURNED ON DURING SELF TEST THE SHUNT SIGNAL IS NOT GETTING TO THE CONTROL BOARD CHECK WIRES 88 BLK 87 CLR AND THE SHUNT HARNESS CONNECTIONS VERIFY THA
32. 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 3 74 SCRUBBING VACUUM FAN The vacuum fan when activated creates air flow in the recovery tank With the recovery tank cover 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 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 7200 330045 10 99 3 75 SCRUBBING 3 Remove the two screws holding the vacuum fan to the top of 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 3 76 7200 330045 10 99 TO INSTALL VACUUM FAN ASSEMBLY FOR SAF
33. are completely greased when re assembling 7200 330045 10 99 CHASSIS 2 43 CHASSIS 12 13 Reinstall the outer bearing and hex sleeve assembly this is a left hand thread nut Tighten to at least 100 ft Ibs and then back off the hex sleeve to 0 ft Ibs Re torque hex sleeve to 30 ft Ibs Install the lock bolt in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft Ib 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 2 44 Install the planetary gear box outer plate and motor assembly into the wheel assembly and onto the pins of the drive assembly 7200 330045 10 99 CHASSIS 16 Install the 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft Ib 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 7200 330045 10 99 2 45 CHASSIS STEERING The steering on the model 7200 is controlled with two sprockets and one chain A large diameter sprocket is mounted on the top of the front drive assembly and a small diameter sprocket is mounted on the bottom of the steering shaft The steering chain runs around both of these sprockets After extended use the steering chain may stretch slightly A
34. button 5 Battery 3 LED will begin to blink MANUAL MODE The purpose of the manual mode is to allow the operator to exercise individual functions on the machine This mode disregards the effects of various interlocks Do not scrub with the machine in this mode FOR SAFETY When Servicing Machine Avoid Moving Parts Do Not Wear Loose Jackets Shirts Or Sleeves After entering the Manual Mode the control buttons assume the following functions SCRUB BUTTON Pressing the Scrub button will turn on and lower the main scrub 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 The head will stay down with the brushes running regardless of the state of the propel pedal reverse switch The head will automatically rise when the user turns off the brushes SQUEEGEE BUTTON Pressing the Squeegee button will turn on the vacuum fan and lower the squeegee Reverse is ignored ES BUTTON Pressing the ES button will toggle the ES pump on or off In the on position the ES pump will run regardless of the state of the floats Care should be taken not to run the ES pump dry for
35. cap from the access caps at the rear of the solution tank 7200 330045 10 99 SCRUBBING 3 5 SCRUBBING 6 Pull the tank drain hoses out and place them over the floor drain Remove the drain cap from the end of the hose Drain the tanks 7 Open the tank cover 8 Spray the inside of the solution and recovery tanks with a strong blast of warm water Do not use water hotter than 130 F 54 C or use steam to clean the tank because damage may occur Remove the ES outlet filter clean reinstall 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 3 6 SCRUBBING TO REMOVE SOLUTION TANK FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 In order to remove the solution tank the 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 7200 330045 10 99 3 7 SCRUBBING 5 Remove the two screws holding the front of the solution tank to the seat support 6 If the machine is equipped with
36. 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 machine 7200 330045 10 99 ELECTRICAL 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 4 16 7200 330045 10 99 TO REPLACE CIRCUIT BOARD 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 control panel 3 Remove the six nuts holding the circuit board cover on the frame 7200 330045 10 99 ELECTRICAL ELECTRICAL 4 Pull the circuit board cover back to access the circuit board 5 Un plug the two ribbon cables from the circuit board 6 Un plug the three wire connectors from the circuit board 7 Pop the circuit board off the six plastic stand offs Remove the circuit board from the machine Note the orientation of the circuit board 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 ri
37. operation of the machine The machine will normally start in this mode What follows is a brief description of each of the operations in the normal mode SCRUB BUTTON The purpose of the scrub button is to turn the scrubbing operations on and off and adjust the scrubbing down pressure Pressing the scrub button while the scrubbing operation is currently inactive will initiate the following actions 1 Illuminate the LED s that indicate the default down pressure Note Hold the scrub button down to get another down pressure setting See note 4 below 2 If the machine is not in reverse the vacuum fan 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 the scrub head 4 fthe operator holds the scrub button after the LED s become illuminated the machine will begin to scroll through the different scrub down pressures The controller stores the pressure displayed as the new default after the user releases the scrub button Pressing and releasing the scrub button while the machine is currently in the scrub mode will initiate the following actions 1 The scrub motors will tur
38. 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 3 46 7200 330045 10 99 SCRUBBING 5 Observe the shape of the brush patterns If the brush patterns have parallel sides the brushes do not need adjustment 10355 If one or both of the brush patterns are tapered the brushes need adjustment to straighten the brush pattern 10356 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 7200 330045 10 99 3 47 SCRUBBING 3 Turn the idler shaft to raise or lower the end of the brush as needed to straighten the brush pattern Tighten the mounting screw 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
39. sure the squeegee is raised off the floor 2 Turn the machine power off and set the parking brake if your machine has this option FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 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 3 66 7200 330045 10 99 SCRUBBING 5 Loosen the two remaining knobs on top of the squeegee assembly 6 Pull the retainer plate back and pull out the front squeegee blade of the squeegee frame 7 Insert the rotated or new squeegee blade in the squeegee frame lining up the slots in the blade with the tabs on the retainer plate 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 7200 330045 10 99 3 67 SCRUBBING 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 3 68 ZA rae ord LL 7200 330045 10 99 REAR SQUEEGEE WHEEL CAMS The squeegee wheel c
40. 10 Install the new ES 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 7200 330045 10 99 4 51 ELECTRICAL 13 Line up the mount plate with the holes in the recovery tank Reinstall the hardware and tighten to 18 24 Nm 15 20 ft Ib 14 Reinstall the vacuum fan assembly See TO INSTALL VACUUM FAN ASSEMBLY instructions 15 Operate the machine and check the ES pump for proper operation 4 52 7200 330045 10 99 TO REPLACE ES PUMP later 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 3 Locate the ES pump under the solution recovery tanks behind the rear squeegee mount frame 7200 330045 10 99 ELECTRICAL 4 53 ELECTRICAL 4 Disconnect the ES pump from the main electrical harness 5 Loosen the worm drive clamps holding the solution hoses to the ES pump Pull the hoses off the pump fittings 6 Loosen the large worm drive clamp holding the pump to the bracket 7 Pull the ES pump assembly out of the machine 8 Remov
41. 11 Reconnect the battery cables 12 Drive the machine and check for proper operation 7200 330045 10 99 2 41 CHASSIS TO REPLACE FRONT DRIVE ASSEMBLY INNER WHEEL BEARING 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 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 will expose the outer bearing hex sleeve and lock bolt 2 42 7200 330045 10 99 7 Remove the lock bolt this is a right hand thread screw 8 Remove the hex sleeve and outer bearing cone assembly this is a left hand thread nut 9 The 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 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
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43. 4 Press the brush spring clip together with your thumb and index finger The brush will drop off of the brush drive hub Pull the brush out from under the scrub head 7200 330045 10 99 SCRUBBING 3 41 SCRUBBING 5 3 42 Place the new scrub brush on the floor in front of the scrub head Push the brush under the scrub head Line up the brush drive socket with the drive plug While pressing the brush spring clip together with your thumb and index finger lift the scrub brush onto the drive plug Check to make sure the brush is securely mounted on the brush drive hub Repeat for the other brush 7200 330045 10 99 SCRUBBING CYLINDRICAL SCRUB BRUSHES Check the brush taper and rotate the brushes from front to rear every 50 hours of machine operation for maximum brush life and best scrubbing performance The cylindrical brushes should be replaced if large amounts of bristles are missing or if the remaining 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 power off 2 Set the parking brake FOR SAFETY Bef
44. 5 10 99 SCRUBBING 3 39 SCRUBBING TO REPLACE DEBRIS TRAY SKIRT 1 Remove the debris tray See TO REMOVE DEBRIS TRAY instructions FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface 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 3 40 7200 330045 10 99 SCRUB BRUSHES The machine can be equipped with either disk or cylindrical scrub brushes Check scrub brushes daily for wire or string tangled around the brush or brush drive hub Also check for brush damage and wear DISC SCRUB BRUSHES The disk brushes should be replaced if a large number of bristles are missing or if bristle length is less than 10 mm 0 38 in NOTE Replace worn brushes in pairs Scrubbing with brushes of unequal bristle length will result in diminished scrubbing performance TO REPLACE DISC SCRUB BRUSHES 1 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 spring clip
45. 5 10 99 CHASSIS TO ADJUST SERVICE BRAKES The service brakes should be adjusted when an excessive amount of brake pedal stroke is needed to stop the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Block Rear Wheels 1 Go under the machine in the front right corner 2 Locate the area where the brake cable attaches 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 enough to remove the slack in the pedal movement 6 Re tighten the two jam nuts firmly Operate the machine and check the brake pedal for a shorter stroke 7200 330045 10 99 2 9 CHASSIS TO ADJUST PARKING BRAKE The parking brake should be adjusted when an excessive amount of brake pedal stroke is needed to hold the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Block Rear Wheels 1 Go under the machine in the front right corner 2 Locate the area where the brake cable attaches to the drive support The beginning adjustment should be 1 375 in of conduit showing on the cable end 3 Turn the steering whe
46. 5 SCRUB HEAD FLOOR SKIRTS 3 35 TO ADJUST DISC SCRUB HEAD SKIRTS eese cete 3 35 TO REPLACE DISC SCRUB HEAD SKIRTS 3 36 CYLINDRICAL BRUSH HEAD DEBRIS tds 3 37 TO REMOVE DEBRIS TRAY 3 37 TO INSTALL DEBRIS TRAY 3 39 TO REPLACE DEBRIS TRAY SKIRT 3 40 SCRUB 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 7200 330045 10 99 SQUEEGEE REAR BLADE 3 64 TO REPLACE OR ROTATE REAR SQUEEGEE FRONT BLADE 3 66 REAR SQUEEGEE WHEEL CAMS 3 69 REAR SQUEEGEE LEVELING KNOB 3 69 TO REPLACE REAR SQUEEGEE LIFT CABLE 3 70 SIDE SQUEEGEE BLADES 3 73 TO REPLACE SIDE SQUEEGEE BLADES 3 74 VACUUM FAN 3 75 TO REMOVE VACUUM FAN 3 75 INSTALL VACUUM 3 77 SCRUBBING TROUBLESHOOTING 3 79 3 1 SCRUBBING 3 2 7200 330045 10 99 Home Go To SCRUBBING INTRODUCTION When scrubbi
47. 5 4 135 NO REC TANK FULL 10E YEL 12A GRN P4 2 l CLOSED VAC SQGE A A L nS qe DISABLE BRUSH P4 9 by P3 13 MEMBRANE TOUCH PANEL P3 10 GND P1 1 Pica 5 P3 15 ES P1 2 ly 1 2 e 18 BRN 4 SCRUB P1 4 P1 4 m Ap 19 pa 5 P1 6 Hc 2 P3 14 2 3 BRUSH HEAD UP DN 479 B 2 30 2 1 Q D m 2 P2 3 P3 1 BALO p2 p24 K P2 6 4 gt pom las a Ee 76 2 7 4 m D 3 5 8 P2 9 4 B mE a 5 12 12 4 P3 9 39 GRN LEGEND X RIBBON CABLE 2 CIRCUIT BREAKER FU FUSE STATIC GND MTR MOTOR D DIODE P CONNECTOR PIN M RELAY COIL S SWITCH R RESISTOR ARM ARMATURE HM HOURMETER N O NORM OPEN CONTACT C COMMON CONTACT 7200 330045 10 99 4 105 ELECTRICAL ES SYSTEM OPERATION When ES system selected on the touch panel and input floats are in the proper position Recovery tank is 1 2 full 2 S 5 is closed e Solution tank NOT full S 9 is opened e 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 or until S 9 closes solution tank full gt MACHINE POWERS UP TOUCH PANEL AND PROPEL SYSTEMS TEST GOOD RUN SELF TEST DIAGNOSTIC SOFTWARE HOLD SQ VAC BUTTON TURN ON KEY RELEASE BUTTON AFTER 5 SEC ERROR ES OUTPUT BATTERY LED 4 WILL BLINK IN THIS MDE 3A LET MACHINE
48. B HEAD LINKS The scrub head links attach the scrub head frame to the machine frame The two scrub head links allow the scrub head to follow the contour of the floor The links have a pivot point on each end and no regular lubrication 7200 330045 10 99 SCRUBBING CYLINDRICAL 3 25 SCRUBBING TO REPLACE SCRUB HEAD LINKS 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 Go under the machine on each side and remove the nyloc nut holding the scrub head links to the machine frame and scrub head 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 head and the rear frame mount hole for the disc scrub head 4 Start the machine and raise the scrub head Check the scrub head links for proper operation 3 26 7200 330045 10 99 TO REMOVE DISC SCRUB HEAD 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 Discon
49. ER FLUSH SYSTEM 4 109 4 1 ELECTRICAL 4 2 7200 330045 10 99 Home fl Find Go To ELECTRICAL INTRODUCTION The machines electrical system consists of the batteries instrument panel drive motor actuators switches relays and circuit breakers 7200 330045 10 99 ELECTRICAL BATTERIES The batteries are designed to hold their power for long periods of time The lifetime of the batteries is limited to number of charges the batteries receive To get the most life from the batteries recharge them immediately when the battery discharge indicator begins to blink After every 200 hours of use check for loose battery connections and clean the surface of the batteries including terminals and cable clamps using a strong solution of baking soda and water Brush the solution sparingly over the battery tops Do not allow any baking soda solution to enter the 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 or damaged wires Check the electrolyte level in each battery cell before and after charging and after every 50 hours of operation Do not charge the ba
50. ERROR CODES BY HOLDING DOWN EACH OF THE 3 TOUCH PANEL SWITCHES GREEN IS THERE A VAC FAN OUTPUT ERROR _ PASS CIRCUIT BOARD VACUUM FAN OUTPUT TEST GOOD DISCONNECT 11 BRN AT M8 CONTACTOR RE RUN THE SELF TEST VERIFY THAT 11 BRN IS NOT SHORTED TO GROUND THEN REPLACE M3 REPLACE THE CONTACTOR CONTROL BOARD DID FAN TURN ON OFF DURING SELF TEST RUN MANUAL MODE TO TEST THE LOADS RUN INPUT TEST MODE SEE NEXT PAGE SEE NEXT PAGE 4 94 7200 330045 10 99 ELECTRICAL CONTINUED FROM PREVIOUS PAGE CONTINUED FROM PREVIOUS PAGE RUN MANUAL MODE TO RUN INPUT TEST THE LOADS TEST MODE HOLD ES BUTTON TURN KEY ON RELEASE BUTTON AFTER 5 SEC 3 BATTERY LED WILL BLINK IN MANUAL MODE HOLD SCRUB BUTTON TURN ON KEY RELEASE SCRUB BUTTON AFTER 5 SEC 2 DOWN PRESS LIGHT WILL BLINK IN INPUT MODE YES IS BATTERY LED 42 ON NO SECOND FROM LEFT MACHINE TESTS GOOD ACTIVATE SQUEEGEE VAC FAN TOUCH PANEL BUTTON DOES THE VAC FAN TURN ON GO TO INPUT TESTING MODE 34A ORA AT 4 7 IS SWITCHED 0 VOLTAGE TO GROUND THIS SHOULD ONLY CHECK FOR BATTERY VOLTAGE FROM SA GRY TO 13AF BLK AT THE VAC FAN HAPPEN IN REVERSE GO TO PROPEL SYSTEM TESTING BATTERY VOLTAGE REPLACE VAC FAN THE CONTROL BOARD IS SWITCHING 11 BRN AT P3 12 TO GROUND TO TURN ON M2 M2 IS BAD OR 10D YEL 11 BRN 1A ORA CB 7 3 GRY
51. ETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open the 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 7200 330045 10 99 SCRUBBING 3 77 SCRUBBING 5 Install the two screws and tighten to 18 24 Nm 15 20 ft Ib 6 Close the tank cover and operate the machine Check the vacuum fan for proper operation 3 78 7200 330045 10 99 SCRUBBING TROUBLESHOOTING SCRUBBING Problem Cause Remedy Trailing water poor or no water pickup Worn squeegee blades Rotate or replace squeegee blades Squeegee out of adjustment Adjust squeegee Vacuum hose clogged Flush vacuum hoses Vacuum fan inlet filter dirty Clean inlet filter Debris caught on squeegee Remove debris Vacuum hose to squeegee or recovery tank disconnected or damaged Reconnect or replace vacuum hose Tank cover not completely closed Check for obstructions Torn seals on recovery tank Replace seals Vacuum fan will not turn on Recovery tank full Drain recovery tank Foam filling recovery tank Empty recove
52. FTER 5 SEC BATTERY LED 4 WILL BLINK IN THIS MODE LET MACHINE RUN UNTIL ONE RED FAIL OR GREEN PASS LIGHT COMES ON READ ERROR CODES BY HOLDING DOWN EACH OF THE 3 TOUCH PANEL SWITCHES GREEN ARE THERE ANY SQUEEGEE OUTPUT PASS ERRORS CIRCUIT BOARD SQUEEGEE OUTPUTS IF THE ERROR NO SQUEEGEE ACTUATOR TEST GOOD ZERO CURRENT SQUEEGEE BUTTON HELD DOWN PRESSURE 1 LIGHT ON REPLACE THE CONTROL BOARD IF THE ERROR EARLY SQUEEGEE STALL SQUEEGEE BUTTON HELD DOWN PRESSURE 2 LIGHT ON DISCONNECT SQUEEGEE ACTUATOR AND RETEST ERROR STILL EXISTS VERIFY WIRE 16 YEL AND 17 GRY ARE NOT SHORTED TO GROUND THEN REPLACE THE CONTROL BOARD NO YES RUN MANUAL MODE TO RUN INPUT TEST THE LOADS TEST MODE SEE NEXT PAGE SEE NEXT PAGE IF THE ERROR NO SQUEEGEE STALL SQUEEGEE BUTTON HELD DOWN PRESSURE 1 AND 2 ARE ON 16 YEL 17 GRY OR SQUEEGEE ACTUATOR ARE OPEN 4 98 7200 330045 10 99 ELECTRICAL CONTINUED FROM PREVIOUS PAGE CONTINUED FROM PREVIOUS PAGE RUN MANUAL MODE TO RUN INPUT TEST THE LOADS TEST MODE HOLD SCRUB BUTTON TURN ON KEY RELEASE SCRUB BUTTON AFTER HOLD ES BUTTON TURN KEY ON RELEASE BUTTON AFTER 5 SEC 3 BATTERY LED WILL BLINK IN MANUAL MODE 5 SEC 2 DOWN PRESS LIGHT WILL BLINK IN INPUT MODE YES IS BATTERY LED 42 ON ACTIVATE SQUEEGEE VAC FAN SECOND FROM LEFT TOUCH PANEL BUTTON DOES THE SQUEEGEE ACTUA
53. H VERIFY BATTERY VOLTAGE AT THESE POINTS THROTTLE TESTING 32C GRN at the speed control 32A GRN at M4 32 GRN at M5 VERIFY VOLTAGE FOR THE FOLLOWING TERMINALS A Battery voltage input B Battery voltage in reverse output C Battery voltage in forward output D Potentiometer ground input E 0 voltage in neutral 5VDC for full forward or reverse F Ground input CONTROLLER INPUTS 4 86 16 Battery voltage 15 Battery voltage when seat switch is closed 11 Battery voltage in reverse 12 Battery voltage in forward 6 0 voltage in neutral 5VDC for full forward or reverse 14 Ground when brush contactor is on low speed 14 B when M3 is off 7200 330045 3 02 ELECTRICAL CONTROLLER OUTPUTS P 7 Potentiometer ground for the throttle e P 3 Ground Forward B Reverse or Neutral P 2 G round Reverse B Forward or Neutral CONTROLLER POWER SECTION Check error codes for power output section Check all connections at the motor and motor controller Re check error codes Replace as per the error codes MOTOR CONTROLLER LED DIAGNOSTICS b C O O O Q MAIN PLUG ACCEL CREEP LOW CURRENT LIMIT SPEED LIMIT STATUS During normal operation with no faults 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 contin
54. Keep covers open when charging WARNING Flammable materials can cause an explosion or fire Do not use flammable materials in tank s WARNING Flammable materials or reactive metals can cause an explosion or fire Do not pickup FOR SAFETY 1 Do not operate machine Unless trained and authorized Unless operation manual is read and understood n 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 7200 330045 3 02 3 When using machine Go slow on inclines and slippery surfaces Use care when backing machine Follow mixing and handling instructions on chemical containers Before leaving or servicing machine Stop on level surface Set parking brake if equipped Turn off machine and remove key When servicing machine Avoid moving parts Do not wear loose jackets shirts or sleeves when working on machine Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands Use hoist or jack that will support the weight of the machine Wear eye and ear protection when using pressurized air or water Disconnect battery connections before working on machine Avoid contact with battery acid Use Tennant supplied or equivalent repl
55. Leave loose for now 3 22 7200 330045 10 99 SCRUBBING 6 Install the screw holding the left front of the recovery tank to the frame in the area of the operators compartment 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 Ib 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 Ib 9 Reinstall the tank cover and plastic hinge rod 7200 330045 10 99 3 23 SCRUBBING 10 Reconnect the top of the prop arm to the tank cover 11 Reinstall 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 3 24 7200 330045 10 99 SCRUB HEAD The model 7200 can be equipped with either a cylindrical or a disc style scrub head The scrub head houses the scrub brushes and their drive mechanisms The scrub head adjustments are factory set and should not be changed unless scrub head parts are damaged or replaced The scrub head also includes floor skirts to control water spray These skirts can be adjusted and need to be replaced if worn or damaged SCRU
56. NTOS NVL O38 9 w20 9 C Sy AHOZ e Ting 90A96 e 098 44053 e 9 098019 ans a eS Sane ea 0 Sa naue 62 H3MOd gt 92 35835 1 3 8898353 1 595 lt lt 4053 89 gd reg Tis 35085 angsa lt INNHS Soosva d uin sna 01 aud Y 098010 name 3SN3S THS lt lt coh 3943 39435 1 8 XNONOILdO yaaa 191939 le le 3NIHOVIN SHS Y Yom 19VINOO 035070 X 5 8 MSS WWW 3 MS lt an 1 NHDUAZ mm 9 MA NHOB Z 2 5 T 5 z 88 1 2 yaver 2 5 amp amp L B T1513 e amp 15 NOH 440 Q 5 TES WO E rS B RA d NS gos 0190 4 e 1 Aum nz 2010965 s e 27 T PTT aE JAWA Age T WANE I E o 07 lt lt 10 aN 6 zlz amp 1 lt 64 igoans 0 NHBIZE 515165 EENIG N d A XI 327358 SPS PS 95 9 9 5 S
57. OR 13AF BLK ARE OPEN 7200 330045 10 99 4 95 ELECTRICAL VACUUM FAN S BATTERIES 6VDC 6 0 36VDC Wie 4H ES GROUND nn yy nn yy nn yy M2 Y 1A RED 2 ORA 7 3A GRY D 1 a m 20A OR 40A VAC FANS Sept Mig 17 5AMPS PER MOTOR 3B GRY i 13AG BLK z gt CURTIS 1207 1133 SPEED CONTROLLER c 450 B A2 M B gt prr v v 5 V v Y vy v Y 4 S REVERSE mi lt M 34 ORA E D 8 FWD SENSEP4 6 gt P4 10 REV SENSE 4 7 34A ORA 2 P5 3 gt P4 11 Sz P5 2 10A YEL POWER 7 lt Q SHIELDP5 1 gt 10B YEL POWER 2 o 3 3 POWER 10C YEL CONTROL p4 4 0 POWER 13B BEK 10D YEL 1 BEN P3 12 S p4 5 CONTROL 13C BLK E P4 3 24 GRY 5 4 13S BLK C NO ELECTRONIC CONTROL REC TANK FULL CIRCUIT BOARD CLOSED P4 2 VAC SQGE P3 11 K DISABLE P4 95 P3 13 MEMBRANE TOUCH PANEL P3 10 GND P1 1 5 P1 1 E P3 15 ES 1 20 m P3 4 SCRUB P1 4 sil g P3 5 SQNAC P1 6 i ET d 45VDC P2 1 52 1 m P3 14 2 3AMPS BATZE2 2 p 2 3 4 2 3 5 psy P2 4 5 55 4 ia ES 2 5 gt P2 6
58. OR WAS CAUSING THE SELF TEST FAILURE TROUBLESHOOT THAT SECTION 7200 330045 10 99 ELECTRICAL SCRUB SYSTEM BATTERIES 36VDC GROUND i Y 6VDC 6VDC 6VDC 6VDC Y PE 13AB BLK 20 25 AMPS PER MOTOR AED _13DD BLK DN PRESS 4 BREDawEL 8 8 62D BLU 62B BLU 66A GRN 25A i RIGHT BRUSH MOTOR i CB 9 4D PUR 64B PUR LI oad 64D 18AJ BLK C X 4AYEL 25A I 62C BLU B a 64C PUR AP aes pn ne z 9 64 PUR 7 13AC BLK A D 5 LEFT BRUSH MOTOR 9 S 1_2 5 gt Uu 2 ia 5 3 w CURTIS 1207 1133 SPEED CONTROLLER c d N gt 20 59 P vv m 4 Eg LINE amp 1 Zo 9 SS Y Y y i mr oio x c m r 25 00 co ELECTRONIC CONTROL 22 CIRCUIT BOARD 33A PUR BR MOTOR FAULT Sag rar SENSE LINE 22A BRN 4P4 10 REV SENSE 7 3 gt ps3 88 B P4 11 5 2 87 CLR 10A YEL FOWEH pide pea 13AA SHIELD 10B YEL POWER p3 7 pa a POWER 1 10C YEL CONTROL 5 9 POWER 13B BLK 4 P3 12 2 5 CONTROL 13C BLK 3 24 GRY
59. OWER a POWER I3ABLK lt IOC YEL CONTROL POWER I3B 8LK lOD YEL gt s LI BRN I E CONTROL I3C BLK Vp TAN 5 4 I3s BLK CLOSED g p 24 0RY REC TANK FULL Wac sace ere N O DISABLE N ES ay Ig 2 g g REC TANK 8 2 2 23 GRN 15 72 FULL I3R BLK es OPTION X I2A GRN c ot WO CLOSED t nu pn BRUSH 2 g g SOLUTION TANK iso s OPTION I4 GRY 2 FULL I0G YEL s IB PUR O Gt ONO WATER SOLENOID i IG YEL gt PI I v 2 lt gt B A 17 6RY m mg OA ss pie I SQUEEGEE UP DN 8 BRN A ScRUB PI 4 A B 19 98 B oL du lt gt SQ VAC PI 6 ere a e BRUSH HEAD UP DN E E 2 1 PZ ojm EO KTHS 20 GRY BAT P2 2 S P2 3 E lt BAT P2 3 4 ES PUMP P2 4 lt 2 4 TIS I0J YEL ove 38 0RA Bed C 52 c a 98129 REC TANK FULL 2 6 lt i m ES FILTER FLUSH BAT 3 P2 7 E27 ye m E DOWN PRES 3 2 8 lt 52 9 r z I0 YEL 9 4I BLU P3 9 DOWN PRES 2 P2 9 lt P2 10 4 m m HOURMETER ENABLE DOWN PRES P2 IO S 221 P VAG OR PROPEL DOWN PRES 0 2 11 4 sawac 2 12 2 12 4 39 0RN srATIC GND TO FRAME M RIBBON CABLE 21 6B BLU 2 7 36 GRN L HORN BUTTON 2IA BLU HORN I3L BLK o Zi BLU AMP 10 5 7 21 BLU a 4 S 6 0 5 I3E BLK 6D BLU SA BR I POWE
60. R WAND sw 9470RA I3v BLK P ot TRI 4 2 3 AMPS V VAC WAND ly PUMP I36 8LK 1 _40 0RA SOAZORA E ag ALARM c SEMPUS E TERE ZEEE 9 BRN 3087 m 81D GRN gt f OVER HEAD GUARD I3AM BLK 5 8 81B GRN I3VV BLK SHROUD I3P BLK 6C BLU 37 BLU 8I GRN 8IE GRN oes PN Uu LL ME 10 8ICA GRN s I3BA BLK LIGHT SW 8IA GRN m LEFT HEAD LIGHT I3J BLK Af UL 4 1 6 AMPS 8IC GRN f RIGHT HEAD LIGHT I3K BLK 4 1 6 AMPS 8IG GRN m LEFT TAIL LIGHT I3U BLK 2 4 35 5 8IF GRN f RIGHT TAIL LIGHT I3T BLK LEGEND iniri sr ERE 35 AMPS CB CIRCUIT BREAKER FU FUSE MTR MOTOR D DIODE P CONNECTOR PIN M RELAY COIL 5 SWITCH R RESISTOR ARMATURE HM HOURMETER 0 NORM OPEN CONTACT C COMMON CONTACT 350764 ALL 7200 330045 3 02 4 63 ELECTRICAL sd lt XINO NOILdO e SNIHOVIN s SNES NASAS 93315 SEES AD usaanugs xsid NV LN OS 9 uy 5 5 Nv OWA 105 O8 NUL Aan A O 8 U3d33MS ON va e NVLVOS 1104 NOIL
61. RATOR SEAT 2 4 BOX cess tibi ke ees 2 32 TO REMOVE SEAT ASSEMBLY 2 4 TO INSTALL PLANETARY GEAR TO INSTALL SEAT ASSEMBLY 2 6 BOX EMT 2 34 TO ADJUST SEAT POSITION 2 7 TO REPLACE FRONT TIRE AND STATIC DRAG CHAIN 2 7 WHEEL ASSEMBLY 2 36 BRAKES AND TIRES 2 8 TO REPLACE FRONT DRIVE SERVICE BRAKES 2 8 ASSEMBLY OUTER WHEEL PARKING BRAKE 2 8 BEARING 2 40 TO ADJUST SERVICE BRAKES 2 9 TO REPLACE FRONT DRIVE TO ADJUST PARKING BRAKE 2 10 ASSEMBLY INNER WHEEL TO REPLACE DRIVE ASSEMBLY BEARING 2 42 BRAKE SHOES 2 11 STEERING aea eec 2 46 REAR TIRES AND WHEELS 2 15 TO ADJUST STEERING CHAIN 2 46 TO REMOVE REAR TIRE 2 15 TO REPLACE STEERING CHAIN 2 47 TO INSTALL REAR TIRE 2 16 TO REPLACE LARGE STEERING TO REPLACE REAR WHEEL SPROCKET 2 48 BEARINGS 2 17 TO REPLACE SMALL STEERING FRONT TIRE AND WHEEL AND WHEEL SPROCKET 2 50 DRIVE SUPPORT 2 19 TO REPLACE STEERING HOUSING FRONT WHEEL SUPPORT CASTER BEARINGS 2 52 BEARING ASSEMBLY 2 19 TO REPLACE STEERING U JOINT 2 56 TO REMOVE FRONT DRIVE ASSEMBLY 2 20 TO INSTALL FRONT DRIVE ASSEMBLY 2 22 TO REPLACE DRIVE ASSEMBLY CASTER BEARING AND THRUST WASHERS
62. RD OK REPLACE TOUCH PANEL VERIFY BATTERY VOLTAGE ON 10A YEL AT P3 2 OF CONTROL BOARD 10B YEL AT P3 7 OF CONTROL BOARD 10C YEL AT P4 1 OF CONTROL BOARD NEXT VERIFY GROUNDS ON 13A BLK AT P3 3 OF CONTROL BOARD 13B BLK AT P3 8 OF CONTROL BOARD 13C BLK AT P4 5 OF CONTROL BOARD REPLACE TOUCH PANEL 4 92 7200 330045 10 99 ELECTRICAL TOUCH PANEL AND RIBBON TESTING BATTERIES 4 36VDC GROUND ili lili lili nn Jih IU 6VDC 6VDC 6VDC 6VDC 6VDC 6VDC Y 13AF BLK cric gt 5 2 z 6A BLU FWD SENSE 4 258 P4 10 REV SENSE 4 7 bed 2 2 XT P5 3l 4 11 ee 4 Z P2 10A YEL POWER E eee e PED 13A BLK 10B YEL POWER 4 p3_7 8 p3 3 POWER 13B BLK CONTROL p 9 9 P3 8 bp POWER 13C BLK P3 12 2 P4 55 CONTROL 4 3 ELECTRONIC CONTROL CIRCUIT BOARD 4 2 5 P3 11 4 9 5 P3 13 MEMBRANE TOUCH PANEL P3 10 GND P1 1 5 1 1 gt P3 15 ES 1 2 Pine m o P3 4 SCRUB 1 4 5 Pid P1 6 P3 5 SQ VAC P1 65 I m 45VDC 2 15 cbe 2 P2 2 P3 14 23AMPS P2 35 p2 3 4 BATO 2 4 5 Do 4 e ES P2 55 poe lt gt P3 1 REC TANK FULL 2 65 poy a BAT 3
63. RY LED WILL BLINK IN MANUAL MODE SCRUB SYSTEM IS PASSING SELF DIAGNOSTICS TURN ON SCRUB SYSTEM DO BOTH BRUSH MOTORS RUN RECORD ERROR THEN GO TO SELF TEST ERROR BREAK DOWN ON PAGES 4 63 AND 4 64 THE ACTUATOR IS STUCK REPLACE ACTUATOR 12A GRN IS BEING PULLED TO GROUND AT P3 11 THIS SHOULD TURN ON M3 CONTACTOR AND SUPPLY VOLTAGE TO 62A BLU AND 64A PUR M3 IS BAD OR 10E YEL 12A GRN 1B RED 4 YEL 4A YEL CB 8 CB 9 62 BLU OR 64 PUR IS OPEN NOTE A SHORTED MOTOR OR D 6 D 7 WILL OPEN CIRCUIT BREAKER 4 102 IS 1 BATTERY LED FLASHING ARE ALL 4 BRUSH DOWN TEST FOR LOW BATTERIES TEST Low IS THE OVERFLOW LED ON RED DRAIN RECOVERY TANK TURN SCRUB SYSTEM BACK ON IS OVERFLOW LED STILL ON YES YES GOOD REPLACE BOARD PERFORM BATTERY MAINTENANCE RUN INPUT TEST MODE HOLD SCRUB BUTTON TURN ON KEY RELEASE SCRUB BUTTON AFTER 5 SEC 2 DOWN PRESS LIGHT WILL BLINK IN INPUT MODE 22 BRN IS SHORTED TO GROUND OR CIRCUIT BOARD IS BAD NOTE IF BOARD IS BAD VERIFY THAT D 6 AND D 7 ARE GOOD LIFT AND LOWER RECOVERY TANK FULL FLOAT S 4 DOES THE OVERFLOW LED TURN ON THEN OFF YES SYSTEM TESTS GOOD ALWAYS OFF S 4 FLOAT SWITCH IS OPEN IN THE UP POSITION OR 24 GRY AND 13S BLK ARE OPEN 5 4 FLOAT SWITCH IS SHORTED IN THE DOWN POSITION OR 24 GRY IS SHORTED TO GROUND 7200 330045 10 99
64. S THE OVERFLOW LIGHT TURN OFF WHEN S 9 15 OPEN FLOAT DOWN 5 9 FLOAT SWITCH 14 GRY OR 13Q BLK IS OPEN SYSTEM TESTS GOOD 5 9 IS SHORTED WITH THE FLOAT DOWN OR 14 GRY IS SHORTED TO GROUND 7200 330045 10 99 4 107 ELECTRICAL ES SYSTEM BATTERIES 36VDC er c ER M T GROUND ll ll ll ll ll Y 6VDC 6VDC 6VDC 6VDC 6VDC Y ELECTRONIC CONTROL CIRCUIT BOARD o hT FWD SENSE P4 6p SHT P4 10 REV SENSE P4 7 zo z Uc P5 3 T2 4 11 gt P5 2 SHIELD 1 P 13A BLK P3 7 8 P3 3 POWER 3 4 P431 9 POWER BK E 4 12 9 p4 5 CONTROL 13C BLK 2 P4 REC TANK1 2 FULL 250 NK 9 5 OPTION 29 CLOSED eo C NO ES ENABLE 11 5 9 13Q BLK P4 9 14 GRY ES OPTION S C 0 NO CLOSED E P3 13 SOLUTION TANKFULL ES OFF m P3 10 GND P1 1 1 1 S amp P3 15 ES P1 2 Piscis 8 P3 4 SCRUB P1 4 pia o 1OH YEL MTR 20 GRY P3 5 SQ VAC P1 6 5 BAe f P3 14 2 3 ANPS p2 4 P2 1 d BMPs b2 2 m c BALI 2 3 1 0 BALO 52 4 boa v P3 1 REC TANK FULIPS 8 2 6 4 gt gt 5 2 8 4 m Z DOWN PRES 3 P2 8 2 2 8 4 DOWN PRES 2
65. SH MOTOR GROUP SCRUB FUSES i Ri 4 24 BUTTON PRESSED 4 76 TO REPLACE FUSE 4 24 ACCESSORY OUTPUT GROUP DIRECTIONAL CONTROL PEDAL 4 26 ES BUTTON PRESSED 4 76 TO REPLACE MOTOR MANUAL MODE 4 77 CONTROLLER 4 27 SCRUB BUTTON 4 77 TO REPLACE TAILLIGHT BULB 4 29 SQUEEGEE BUTTON 4 77 ELECTRIC MOTORS 4 30 ES BUTTON 4 77 TO REPLACE DRIVE MOTOR 4 30 INTERLOCKS 4 78 SCRUB BRUSH OPERATION 4 78 SQUEEGEE AND VACUUM FAN OPERATION 4 78 ES AIR FLUSH OPERATION 4 79 ES PUMP OPERATION 4 79 INPUT DISPLAY MODE 4 80 TROUBLESHOOTING 4 83 POWER UP TESTING 4 84 PROPEL Re RE asada 4 86 ERROR CODES 4 86 POWER AND GROUND CONNECTIONS CHECK 4 86 THROTTLE TESTING 4 86 CONTROLLER INPUTS 4 86 CONTROLLER OUTPUTS 4 87 CONTROLLER POWER SECTION 4 87 MOTOR CONTROLLER LED DIAGNOSTICS 4 87 PROGRAMMER DIAGNOSTICS 4 88 PROPEL 4 91 TOUCH PANEL AND RIBBON TESTING 4 92 VACUUM FAN S 4 94 SQUEEGEE 4 98 SCRUB SYSTEM 4 102 SELF TEST ERROR BREAKDOWN 4 103 SCRUB SYSTEM 4 105 ES SYSTEM 4 106 ES FILT
66. T THE SHUNT IS HOOKED UP AS PER SCHEMATIC REPLACE THE SHUNT AS NECESSARY ELECTRICAL 4 103 ELECTRICAL SELF TEST ERROR BREAKDOWN 4 104 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 GROUND AT P3 11 TURNING ON M3 AND SUPPLYING VOLTAGE TO BRUSH MOTORS IS BAD OR 12A GRN 10E YEL 1B RED 4 YEL 4A YEL CB 8 9 64 PUR 62 BLU 13AH BLK 13AJ BLK OR THE SHUNT HAR NESS IS OPEN CHECK FOR VOLTAGE FROM 62 BLU TO 66 GRN AND FROM 64 PUR TO 66 GRN AT THE BRUSH MOTORS IF VOLTAGE B REPLACE BRUSH MOTORS IF VOLTAGE 0 VOLTAGE GO TO STEP 6 IF ERROR READS LOW BRUSH CURRENT SCRUB BUTTON HELD DOWN PRESSURE LED Z3 IS LIT GO INTO MANUAL MODE TURN ON SCRUB BRUSHES VERIFY BOTH BRUSHES ARE OPERATING IF ONLY ONE MOTOR IS OPERATING REPLACE OPEN WIRE OR MOTOR NOTE CHECK FOR BROKEN BELTS ON THE CYLINDRICAL HEAD IF BOTH BRUSHES ARE TURNING IGNORE THIS ERROR SYSTEM IS TESTING GOOD IF ERROR READS HIGH BRUSH CURRENT SCRUB BUTTON HELD DOWN PRESSURE LED 4 IS LIT GO INTO MANUAL MODE TURN ON SCRUB BRUSHES MEASURE BRUSH CURRENT WITH 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 ERR
67. TOR LOWER MACHINE TESTS GOOD GO TO INPUT TESTING MODE 34A ORA AT P4 7 IS SWITCHED 0 VOLTAGE TO GROUND THIS SHOULD ONLY DISCONNECT SQUEEGEE ACTUATOR MEASURE VOLTAGE FROM 16 YEL TO 17 GRY AT SQUEEGEE ACTUATOR HAPPEN IN REVERSE GO TO PROPEL SYSTEM TESTING BATTERY VOLTAGE OR BATTERY VOLTAGE REPLACE ACTUATOR 16 YEL OR 17 GRY ARE OPEN 7200 330045 10 99 4 99 ELECTRICAL BATTERIES 6VDC GROUND 36VDC nn yy nn nn n Y Y 8n c SH L z gt CURTIS 1207 1133 SPEED CONTROLLER c 450 B A2 M B 229 U U U e Pg c de T v 2 9 33 PUR 34B ORA a 2 m 33A PUR FWD SENSE P4 6 gt 10 REV SENSE P4 7 5 e 84AORA 2 c P5 3 by 4 11 2 5 2 10A YEL POWER 2 SHIELD P5 1 P 1 10B YEL POWER ps 7 lt o r P3 3 POWER 10C YEL CONTROL p4 4 0 2 POWER 19B BEK c P3 12 2 P4 5 CONTROL 1SC BLK P4 3 ELECTRONIC CONTROL CIRCUIT BOARD P4 2 P3 11 P4 9 P3 13 MEMBRANE TOUCH PANEL 16 YEL MTR P3 10 GND P1 1 5 B 17 0 1 2 z C P3 15 ES 1 2 m SQUEEGEE UP pN 3 4 SCRUB 1 4 ee g P3 5 SQNVAC 1 6 b EE d 45VDC P2 1 52 1 m P3 14 23AMPS DATA p2 3 4
68. TURE HM HOURMETER N O NORM OPEN CONTACT C COMMON CONTACT 4 110 7200 330045 10 99 We Need Your Help As part of Tennant s Zero Defects Program we want to know about errors you have found or suggestions you may have 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 1 Suggestion Name Date Customer Number Company Address City State Zip Code EE Joe eT SALVS AHL NI 3l AYVSSAOAN ADVLSOd ON NW SMOdVANNIA 2766 0 9 NIN siodeeuun xog Od YHON LOZ S 91 LNVNN3 L Ad 38 THM 39 150 v6 LI NH3d IVAW 55 15 15014 TVN Aldad SSANISNG seui Buoje pjoJ We Need Your Help As part of Tennant s Zero Defects Program we want to know about errors you have found or suggestions you may have 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 1 Suggestion Name Date Customer Number
69. The operator can reset the battery gauge by unplugging the main battery connector SQUEEGEE AND VACUUM FAN The machine will cancel squeegee operation as if someone toggled the squeegee button If the operator presses the squeegee button after being canceled the squeegee and vacuum fan will resume operation for about 30 seconds The operator will reset the battery meter each time the main battery connector is removed Each time the operator powers down the controller the machine will store the current state of battery charge When the operator powers up the machine it will recall 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 e 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 operations as if someone toggled the scrub or squeegee buttons THE TANK FULL LED will start to blink This message will not turn off by simply emptying the recovery tank The LED will remain blinking until the machine is powered down or the scrub button is pushed e BRUSH MOTOR ERROR The controller will cancel the following functions if an open breaker opens during scrub motor operation THE CONTROLLER will cancel scrub and squeegee operations as if som
70. UNDW BRN 7 c C 28 BRN BACK UP ALARM E 36 FWD WHT 32B GRN 86 23 34C ORA i mesure 5 36 REVB WHT 29 GRY Cx OFF RUN START A 27C GRN REVERSE gy 50 mene GAN 82 GRN 84 ORA 1 uec 83 SW X27E GRN D 8 13AK BLK n 15 26 27B GRN i p E 13D BLK 6 e e 1 5 2 2 n 75 EMERGENCY STOP dis x CLOSED CONTACT LEGEND CB CIRCUITBREAKER FU FUSE MTR MOTOR D DIODE P CONNECTOR PIN M RELAY COIL S SWITCH R RESISTOR ARM ARMATURE HM HOURMETER NORM OPEN CONTACT C COMMON CONTACT 7200 330045 10 99 4 91 ELECTRICAL TOUCH PANEL AND RIBBON TESTING OPERATION OF LED S e P2 1 Supplies 5VDC to each LED e P2 2 through P2 12 will light an LED if they are pulled to ground by the control board OPERATION OF SWITCHES P1 1 Supplies ground to each switch P1 2 Switched to ground when the ES switch is activated P1 4 Switched to ground when the Scrub button is activated P1 6 Switched to ground when the Squeegee button is activated gt MACHINE POWERS UP AND PROPELS KEY SWITCH ON YES DO ALLTHE LIGHTS ON THE TOUCH NO PANEL TURN ON THEN OFF LED S OK DO SOME OF THE YES LED S TURN ON NO REPLACE ACTIVATE EACH SWITCH TOUCH DOES THE ASSOCIATED PANEL LIGHT LIGHTS TURN ON THEN OFF VERIFY TOUCH PANEL YES CHECK RIBBON CABLE IS CONNECTED TO AT THE CONTROL CONTROL BOARD BOA
71. ables 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 7200 330045 10 99 ELECTRICAL 12 Connect the ribbon cables to the circuit board 13 Position 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 Ib 7200 330045 10 99 ELECTRICAL 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 7200 330045 10 99 ELECTRICAL CONTROL PANEL The control panel houses the directional controller relays contactors and fuses These components can be accessed by pivoting the control panel mount plate 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
72. acement parts When loading unloading machine onto off truck or trailer Turn off machine Use truck or trailer that will support the weight of the machine Use winch Do not push the machine onto off the truck or trailer unless the load height is 380 mm 15 in or less from the ground Set parking brake after machine is loading option Block machine tires Tie machine down to truck or trailer 1 3 GENERAL INFORMATION The safety labels appear on the machine in the locations indicated If these or any label becomes damaged or illegible install a new label in its place BATTERY CHARGING LABEL LOCATED ON FLAMMABLE MATERIALS LABEL LOCATED AND UNDERNEATH THE SEAT SUPPORT ON THE UNDERSIDE OF THE TANK COVER AND ON THE LEFT SIDE OF THE OPERATOR COMPARTMENT Emil Hydrogen Gaz n Qr Fire Flammable Materials Can Cause Explosion Or Fire Not Use Flammable Materials In Tank FLAMMABLE SPILLS LABEL LOCATED ON THE SEAT SUPPORT Flammable Materials Or Reactive Metals Can Cau Explosion Or Fire Do Not Pick Up Read Manual E Before Operating Machine FOR SAFETY LABEL LOCATED ON THE SEAT SUPPORT 350656 7200 330045 10 99 GENERAL INFORMATION SPECIFICATIONS GENERAL MACHINE DIMENSIONS CAPACITIES 1830 mm 2 in Length with Pre Sweep Width less squeegee Width with squeegee 1155 mm 45 5 in 2092 mm 80 in Disk brush diameter for side brush
73. actor stuck contactor closed MISSING Missing contactor or 1 Direction contactor coil CONTACTOR shunt open 2 Direction contactor missing 3 Shunt field open 4 Wire to shunt or direction contactor LOW BATTERY Low battery voltage 1 Battery voltage 16 volts VOLTAGE 2 Corroded battery or controller terminal 3 Loose battery or controller terminal OVERVOLTAGE Overvoltage 1 Battery voltage gt 45 volts 2 Vehicle operating with charger attached THERMAL Over under temp 1 Temperature gt 85 C or CUTBACK cutback lt 25 C 2 Excessive load on vehicle 3 Improper mounting of controller 4 Operation in extreme environments 4 90 7200 330045 10 99 ELECTRICAL PROPEL BATTERIES 36VDC FI FI FI FI GROUND 11 Y 6VDC 6VDC 6VDC 6VDC 6VDC 6VDC Y Gc I gt lm SION TRACTION 5 5 MOTOR z js 13AC BLK o 5 2 Al 0 o 1 2 REV o B A2 M B a y CURTIS 1207 1133 SPEED CONTROLLER gt a BU rou odo d Bm 5 sgg Q yg Y a Y FR g 2 THROTTLE e 5 8 m m wo Y 9 ama gle leig 9042 3 e g 2 R Cio o Poriowona D WORA 2 2 3 5 FORWARD 5 9 x z F 13M BLK 2AJGRN 13M BLK 3 2 GRO
74. ain 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 steering chain from both sprockets 2 50 7200 330045 10 99 CHASSIS 7 Loosen the set screws holding the small sprocket to the lower shaft Slip the small sprocket off the shaft 8 Install 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 7200 330045 10 99 CHASSIS TO REPLACE STEERING HOUSING BEARINGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Jack up the front of the machine at the jack point Install jack stands under the machine frame 2 Turn the steering wheel all the way to the left 3 Go to the operators compartment and locate the steering U joint Loosen the two set screws on the top of the steering U joint 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 beari
75. aining 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 to raise the electrolyte level to about 12 mm 0 4 in below the bottom of the sight tubes 13 Lower the seat support by slightly raising it while pushing the support arm inward 7200 330045 3 02 ELECTRICAL TO REPLACE BATTERIES 1 Drive the machine to a flat dry surface NOTE Make sure the area is well ventilated 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 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 4 8 7200 330045 10 99 5 Pull the rubber battery cable boots back to 10 11 12 13 7200 330045 10 99 access the cable end nuts Remove all of the battery cables Use the built in straps to lift and remove each battery Use a solution of baking soda and water to clean the battery compartment area Install the new batteries in the same orientation as the old batteries Reconnect all of the battery cables C
76. ams adjust the squeegee deflection along the entire length of the squeegee There is a wheel cams at either end of the squeegee Increase deflection Turn the cams counter clockwise Decrease deflection Turn the cams clockwise REAR SQUEEGEE 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 end deflection Turn the squeegee leveling knob clockwise to decrease the deflection at the end of the squeegees 7200 330045 10 99 SCRUBBING 3 69 SCRUBBING TO REPLACE REAR SQUEEGEE LIFT CABLE 1 Lower the squeegee to the floor 2 Make sure the solution tank is drained and the tank clean out caps removed 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 3 70 7200 330045 10 99 SCRUBBING 5
77. 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 3 8 7200 330045 10 99 10 Open the tank cover Remove the hardware holding the top of the prop arm to the tank cover 11 Remove the plastic tank cover hinge rod Remove the tank cover from the machine 12 Remove 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 installing a new tank 7200 330045 10 99 SCRUBBING SCRUBBING 15 Lift the solution tank up far enough to access the clamp on the hose running from the bottom of the solution tank to the water valve Loosen this clamp and remove the hose from the solution tank 16 The solution tank can now be removed from the machine 7200 330045 10 99 SCRUBBING TO INSTALL SOLUTION TANK FOR SAFETY Before Leaving Or Servicing Machine Stop On Leve
78. bbon cables to the new circuit board See schematic in this section 10 Position the circuit board cover back up to the inside front wall of the steering support behind the control panel 7200 330045 10 99 ELECTRICAL 11 Reinstall the six nuts on the circuit board cover Hand tighten lightly 12 Pivot the control panel back in position Reinstall the two screws and tighten to 18 24 Nm 15 20 ft Ib 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 7200 330045 10 99 ELECTRICAL CIRCUIT BREAKERS RESETABLE CIRCUIT BREAKERS Circuit breakers are resetable electrical circuit protection devices designed to stop the flow of current in the event of a circuit overload Once a circuit breaker is tripped reset it manually by pressing the reset button after the breaker has cooled down If the overload that caused 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 Circuit Protected CB2 10A Battery discharge indicator 4 20 7200 330045 10 99 ELECTRICAL TO REPLACE CIRCUIT BREAKER FOR SAFETY Before Leaving Or
79. blem has been corrected NOTE Refer to the troubleshooting chart table 2 for suggestions covering a wide range of possible faults TABLE 2 TROUBLESHOOTING CHART LED PROGRAMMER LCD EXPLANATION POSSIBLE CAUSE CODE DISPLAY HW FAILSAFE Hardware fail safe 1 Controller defective error 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 ground SRO fault 1 Improper sequence of KSI brake and direction inputs 2 Wrong SRO type selected 3 Brake or direction switch circuit open 4 Sequencing Delay too short THROTTLE FAULT 1 5kQ 0 wiper fault 1 Throttle input wire open 2 Throttle input wire shorted to ground 3 Throttle pot defective 4 Wrong throttle type selected BB WIRING CHECK Emergency reverse 1 BB wire open wiring fault 2 BB check wire open HPD sequencing fault 1 Improper sequence of KSI brake throttle inputs 2 Wrong HPD type selected 3 Mistrusted throttle pot ELECTRICAL TABLE 2 TROUBLESHOOTING CHART continued LED PROGRAMMER LCD EXPLANATION POSSIBLE CAUSE CODE DISPLAY THROTTLE FAULT 2 Pot low broken or 1 Pot low wire open shorted 2 Pot low wire shorted 3 Wrong throttle type selected 3 1 CONT DRVR OC Driver output 1 Direction contactor coil overcurrent shorted 2 Shunt field shorted DIR CONT WELDED Welded direction 1 Direction cont
80. bolt down far enough to slip the the belt off the cogged pulley 7200 330045 10 99 4 37 ELECTRICAL 8 Remove the two screws holding the brush motor to the pivot bracket Remove the brush motor from the machine 9 Loosen the set screws holding the cogged pulley to the brush motor shaft 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 the cogged pulley 4 38 7200 330045 10 99 ELECTRICAL 13 Align the top pulley with the bottom drive plug Make sure the belt is in the center of the top pulley Tighten the set screws tight NOTE Use loctite 242 blue on the threads 14 Use the hex screw under the brush motor to tension the belt Apply 2 5 2 7 Ibs 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 Ib Re check the belt tension 16 Reconnect the brush motor into the main harness NOTE See schematic in this section 7200 330045 10 99 4 39 ELECTRICAL 17 Reinstall the belt cover Tighten the scr
81. button and Squeegee button e ES and Squeegee LED s off ES PUMP OPERATION ES PUMP ENABLED BY INDICATOR e ES button e ES LED on e ES float covered or ES 30 second timer running The ES 30 second timer starts when the ES pump brings the solution level below the ES float ES PUMP INHIBITED BY INDICATOR e More than 30 seconds has passed since the ES float has become uncovered e Solution tank full float covered for more then 5 seconds 7200 330045 10 99 4 79 ELECTRICAL Operating Mode Entry Sequence how to activate Input Display Mode Display the state of floats 1 Push and hold the Scrub button limit switches and sensors In this mode the 2 Turn on the key pressure led 2 will blink 3 Hold the Scrub button for 5 seconds 4 Release the Scrub button 5 Brush pressure LED 2 will begin to blink INPUT DISPLAY MODE The purpose of the Input Display Mode is for the technician to observe the effectiveness of various inputs and sensors on the controller board When in this mode the operator can scrub with the machine as normal and observe the operation of the various inputs When in the Input Display Mode each of the control panel LED s are associated with one board input When the operator activates an input the corresponding LED will become illuminated The operator may activate scrub functions in this mode The LED s on the instrument panel no longer correspond to the cont
82. cables 20 Drive the machine and check for proper operation 7200 330045 10 99 2 39 CHASSIS TO REPLACE FRONT DRIVE ASSEMBLY OUTER WHEEL BEARING 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 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 on the hex sleeve or replace the bearing and sleeve assembly Apply grease to the new bearing 2 40 7200 330045 10 99 CHASSIS 7 Install the new outer bearing and hex sleeve assembly on the wheel shaft this is a left hand thread nut Tighten to at least 100 ft lbs and then back off the hex sleeve to ft Ibs Re torque hex sleeve to 30 ft Ibs 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 Ib 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
83. ctive controller controller or microprocessor fault controller operational no faults 1 1 current sensor error 1 2 hardware failsafe fault 1 3 M fault or motor output short 1 4 static return to off SRO fault throttle wiper fault emergency reverse circuit check fault high pedal disable HPD fault pot low input fault NN BM Us contactor driver overcurrent or field winding short main contactor welded field winding open missing contactor w BU low battery voltage overvoltage thermal cutback due to over under temp anti tiedown fault v ds wapa BRP S9 te NN E ELECTRICAL Step 2 Connect the programmer put it in diagnostic mode and read the display fault information In this example the display shows No Faults Present indicating that the controller has not detected anything out of the norm Step 3 Put the programmer in test mode and observe the status of the inputs and outputs in the forward direction In this example the display shows that the forward switch did not close when forward was selected which means the problem is either in the forward switch or the switch wiring Step 4 Check or replace the forward switch and wiring and repeat the test If the programmer shows the forward switch closing and the vehicle now drives normally the pro
84. d 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 Ib 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 15 20 ft Ib 7200 330045 10 99 2 27 CHASSIS 20 21 2 28 Reinstall the drive assembly in the machine See TO INSTALL FRONT DRIVE ASSEMBLY instructions Operate the machine and check for smooth steering operation Check the brakes for proper operation Adjust if necessary See TO ADJUST SERVICE BRAKES instructions 7200 330045 10 99 TO REPLACE DRIVE ASSEMBLY PIVOT CONE BEARING FOR SAFETY Before Leaving Or Servicing Machine Stop 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 7200 330045 10 99 CHASSIS 2 29 CHASSIS 4 Remove the four hex screws holding the pivot and sprocket assembly to the drive assembly 5 Remove the
85. d is below the minimum level 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 x NOTE There is clear folder at the end of this manual that contains three touch panel overlays Use each of the these overlays in their respective test mode as a technical aide during the diagnostic procedure 7200 330045 10 99 ELECTRICAL 4 81 ELECTRICAL 4 82 7200 330045 10 99 Home fl Find To 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 7200 330045 10 99 ELECTRICAL 4 83 ELECTRICAL POWER UP TESTING OPERATION Key switch to to start position Current flows into key switch terminal 50 Current flows out of key switch terminal 15 turning on M1 contactor and powering up the machine Release key to run position Current flows through closed M1 contacts into key switch pin 30 Current flows out of 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 s
86. e 1 Slide the scrub head under the machine frame with the scrub head link mount holes facing the front 2 Install the ball joint on the 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 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 mechanism 4 Install the clevis pin and cotter pin 5 Reconnect the brush drive motors to the main electrical harness 7200 330045 10 99 SCRUBBING 3 33 SCRUBBING 6 7 3 34 Reconnect the water line to the scrub head 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 7200 330045 10 99 DISC SCRUB HEAD SKIRTS SCRUB HEAD FLOOR SKIRTS The scrub head floor skirts control water spray from the brushes The skirts are located in front and rear of the scrub head Check these skirts for wear and damage after every 50 hours of operation The skirts should clear the floor by O to 0 25 in 0 to 6mm when the scrub head is down Check the floor ski
87. e control panel See TO ACCESS CONTROL PANEL instructions FOR SAFETY Disconnect Battery Connections Before Working On an 2 me li machine 2 Locate the controller box in the center of the control panel 3 Disconnect the wires and power cables leading to the controller 7200 330045 10 99 4 27 ELECTRICAL 4 Remove the three screws and nuts holding the controller to the panel Remove the controller from the machine 5 Position the new controller on the panel Reinstall the screws and nuts Hand tighten 6 Reconnect the power cables and electrical wires to the controller See the schematic in this section 7 Pivot the control panel back in position Reinstall the two screws and tighten to 18 24 Nm 15 20 ft Ib 4 28 7200 330045 10 99 8 Lift the operator seat and reconnect the battery connector at the front of the solution tank 9 Start the machine and check for proper operation of the propelling 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 7200 330045 3 02 ELECTRICAL 4 29 ELECTRICAL ELECTRIC MOTORS The carbon brushes on the vacuum fan motor should be inspected after every 500 hours of machine operation The carbon brushes on the scrub brush motors and
88. e the end of the squeegee blade is to the wall The squeegee blade end should be further away from the wall when the floor curves up into the wall 7200 330045 10 99 Ce SCRUBBING 3 63 SCRUBBING REAR SQUEEGEE BLADES The rear squeegee has two squeegee blades the front and rear Each blade has four wiping edges To use them all start with one wiping edge To use the next wiping edge rotate the blade end for end To use the next wiping edge rotate the top edges down bottom edges up To use the last edge rotate the blade end for end 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 Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 3 64 7200 330045 10 99 SCRUBBING 3 Loosen the two retainer knobs one at each 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 7200 330045 10 99 3 65 SCRUBBING TO REPLACE OR ROTATE REAR SQUEEGEE FRONT BLADE 1 Make
89. e the plastic fittings from the old pump and install in the new pump in the same orientation 4 54 ELECTRICAL 9 Install the new ES pump on the mount bracket Reinstall the large worm drive clamp and hand tighten 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 ES pump for proper operation 7200 330045 10 99 4 55 ELECTRICAL SOLUTION SOLENOID VALVE The solution solenoid valve is used to start and stop the flow of water to the scrub head when the machine is either propelling forward or in neutral This valve is used along with the manual valve which controls the amount of water that flows to the scrub head TO REPLACE SOLUTION SOLENOID VALVE 1 Drain the solution 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 4 56 7200 330045 10 99 ELECTRICAL 3 Go under the machine on the left side 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 clamp
90. e 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 7200 330045 10 99 ELECTRICAL ELECTRICAL 9 Position the new actuator on the spring mount bracket Install the clevis and cotter pins 10 Position the new actuator and spring mount bracket in the machine Slide the assembly down the into the mount 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 four screws to 18 24 Nm 15 20 ft Ib 4 44 7200 330045 10 99 ELECTRICAL 13 Reinstall the prop rod in the bracket and on the bottom of the seat support Snug the screws and nut so 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
91. el 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 enough to remove the slack in the pedal movement 6 Re tighten the two jam nuts firmly Operate the machine and check the brake pedal for a shorter stroke 7200 330045 10 99 TO REPLACE DRIVE ASSEMBLY BRAKE SHOES The front brake shoes should be replaced when the machine no longer stops easily or the adjustment in the brake cable has been used up FOR SAFETY Before Leaving Or Servicing Machine 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 out of the drive wheel and away from the drive assembly 7200 330045 10 99 CHASSIS CHASSIS 6 Go to the other side of the drive assembly and remove the hub cap This will expose the outer bearing hex sleeve and lock bolt 7 Remove the lock bolt this is a right hand thread screw 8 Remove the hex
92. eone toggled the scrub or squeegee buttons If the operator presses the squeegee button squeegee and vacuum fan operation will resume ALL FOUR BRUSH PRESSURE LED S will begin to blink alerting the operator to the open breaker condition 7200 330045 10 99 4 73 ELECTRICAL Operating Mode Entry Sequence how to activate Self Test Mode Test controller output 1 Push and hold the Squeegee button transistors actuators and scrub brush motor 2 Turn on the key operation In this mode the battery 3 Hold the Squeegee button for 5 seconds LED 4 LED will blink 4 Release the Squeegee button 5 Battery 4 LED will begin to blink SELF TEST MODE The purpose of the Self Test Mode is to test the operation of the control board and to exercise all of its outputs When this mode is engaged various motors and accessories will be engaged at full power as part of the test Extreme care must be taken to be sure that technicians and bystanders are not injured as a result of this test e TO PREVENT INJURY ALWAYS TURN THE MACHINE OFF AFTER THE DIAGNOSTIC MESSAGES HAVE BEEN DISPLAYED e IF THE DIAGNOSTIC MESSAGES DO NOT APPEAR DO NOT ATTEMPT TO SERVICE THIS MACHINE WITHOUT FIRST TURNING IT OFF AND RETURNING TO ANOTHER MODE The Self Test Mode tests each of the following controller board functions 1 Squeegee actuator 2 Scrub head actuator 3 Scrub brush motor current 4 Hour meter output 5 Water valve outp
93. ews to 11 14 Nm 7 10 ft Ib 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 4 40 7200 330045 10 99 ELECTRICAL 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 7200 330045 10 99 4 41 ELECTRICAL TO REPLACE SCRUB HEAD LIFT ACTUATOR 1 Start the machine and lower the scrub head to the floor Shut off the machine FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 2 Go in on top of the scrub head and remove the cotter pin and clevis pin from the bottom of the scrub head lift actuator tube 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 Before Working On machine 5 Tie the seat up Remove the screw holding the seat prop rod to the bottom of the seat support Remove the prop rod from the lock slot 6 Locate the lift actuator spring mount bracket Remove th
94. ews and tighten to 64 83 Nm 47 61 ft Ib 7 Reinstall the steering chain and master link Adjust the steering chain See TO ADJUST STEERING CHAIN instructions 8 Reinstall the brake cable on the wheel support Tighten the jam nut on the brake cable where it attaches to the wheel support 2 22 7200 330045 10 99 CHASSIS 9 Reinstall the cotter pin and clevis pin in the end of the brake cable where it attaches to the lever on the wheel support 10 Turn the steering wheel all the way to the right 11 Locate the area where the brake cable attaches to the drive support 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 proper operation Adjust if necessary See TO ADJUST SERVICE BRAKES instructions 7200 330045 10 99 2 23 CHASSIS TO REPLACE DRIVE ASSEMBLY CASTER BEARING AND THRUST WASHERS FOR SAFETY Before Leaving Or Servicing Machine Stop 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 pla
95. he 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 7200 330045 10 99 SCRUBBING 3 53 SCRUBBING 3 Go under the machine on the left side 4 Locate the manual solution valve above the scrub head 5 Remove the cotter pin from the control lever rod where it attaches to the valve Pop the rod out of the mount hole 6 Loosen the worm drive clamps holding the two solution hoses to the valve fittings Pull the hoses off the fittings 7 Remove the two screws holding the valve to the machine frame Remove the manual valve from the machine 3 54 7200 330045 10 99 8 Remove the fittings from the old valve and 9 10 11 12 13 7200 330045 10 99 install in the new valve in the same orientation Remove the lever from the old valve and install it on the new valve in the same orientation Install the new valve on the machine Hand tighten the screws Reconnect the two solution hoses Hand tighten the worm drive clamps Place the control lever rod in the mount hole and install the cotter pin Operator the machine and check the water valve for proper operation SCRUBBING 3 55 SCRUBBING
96. heck the batteries and charge if necessary See TO CHARGE BATTERIES instructions Reconnect the battery connector at the front of the solution tank Lower the seat support and operate the machine Check for proper operation ELECTRICAL FRONT OF MACHINE ELECTRICAL INSTRUMENT PANEL The instrument panel consists of a touch panel circuit board switches and circuit breakers The touch panel controls various machine functions The indicator 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 control panel 7200 330045 10 99 ELECTRICAL 3 Remove the six nuts holding 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 7200 330045 10 99 ELECTRICAL 7 Pull the touch panel bezel up and remove from the machine 8 Remove the touch panel from the machine NOTE Be careful when removing the ribbon c
97. ht hand thread screw 8 Remove the hex sleeve and outer bearing cone assembly this is a left hand thread nut 9 The 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 7200 330045 10 99 CHASSIS 2 37 CHASSIS 12 13 Reinstall the outer bearing and hex sleeve assembly this is a left hand thread nut Tighten to at least 100 ft Ibs and then back off the hex sleeve to 0 ft Ibs Re torque hex sleeve to 30 ft Ibs Install the lock bolt in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft Ib 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 2 38 Install the planetary gear box outer plate and motor assembly into the wheel assembly and onto the pins of the drive assembly 7200 330045 10 99 CHASSIS 16 Install the 4 hex screws and washers Tighten to 18 24 Nm 15 20 ft Ib 17 Reconnect the electrical cables to the drive motor 18 Remove the jack stands and lower the machine 19 Reconnect the battery
98. in the debris tray located behind the rear scrub brush The debris tray can be easily removed and emptied TO REMOVE DEBRIS TRAY 1 Start the machine and touch the scrub button Shut off the key when the scrub head is near the floor 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 the squeegee lock pin 3 Pivot the side squeegee out away from the scrub head 7200 330045 10 99 3 37 SCRUBBING 4 3 38 Grasp the plastic debris tray and pivot the bottom up away from the back of the scrub head Pivot the debris tray far enough to allow the rubber skirt to clear the scrub head Pull the debris tray straight out to the right until it is free of the scrub head lip Empty the debris tray 7200 330045 10 99 TO INSTALL DEBRIS TRAY 1 Lower the scrub head to the floor FOR SAFETY Before Leaving Or Servicing Machine Stop On Level 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 7200 33004
99. ine and check the steering for proper operation AT II E RE 7200 330045 10 99 2 47 CHASSIS TO REPLACE LARGE STEERING SPROCKET FOR SAFETY Before Leaving Or Servicing Machine Stop 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 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 CHASSIS 5 Reinstall the pivot and sprocket assembly on the drive assembly Reinstall the four screws and tighten to 68 81 Nm 50 60 ft Ib 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 7200 330045 10 99 2 49 CHASSIS TO REPLACE SMALL STEERING SPROCKET 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 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 ch
100. ire 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 assembly outer plate Remove the drive motor 2 32 7200 330045 10 99 CHASSIS 5 Remove the four hex screws 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 7200 330045 10 99 2 33 CHASSIS TO INSTALL PLANETARY GEAR BOX FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Install the new planetary gearbox on the outer motor mount plate Install the 6 socket screws into the planetary gear box Torque the 6 screws to 193 250 Ncm 17 22 in Ibs NOTE Do not tighten this hardware above a grade 2 torque 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 Ib
101. l Surface Set Parking Brake 1 Position the solution tank on the right side edge of the machine 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 loose for now 7200 330045 10 99 SCRUBBING 6 Install the two screws holding the front of the solution tank to the 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 Ib 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 7200 330045 10 99 SCRUBBING 10 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 7200 330045 10 99 SCRUBBING 14 Reinstall the battery in the right rear corner of the battery compartment 15 Reinstall the bat
102. lastic 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 the old fan 4 60 7200 330045 10 99 4 Reinstall the three screws and brackets Tighten the 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 7200 330045 10 99 ELECTRICAL 4 61 ELECTRICAL ELECTRICAL SCHEMATIC 000000 008237 vos BATTERIES 36VDC 2 GROUND f M M2 CB 7 VDC evoe evoc IA RED 2 0RA 3 GRY 3A env k ISAF BLK 47 amps PER 20A OR 40A Ue VAC FANS ev 13A8 8LK M OTOR ons 62 BLU Alo gt 3B 6RY lt 7 gAG BLK 22 ee 4 YEL 62A BLU G2D BLU Let 62B BLU 66A GRN I3DD BLK 25A A RIGHT BRUSH MOTOR 9 4A YEL s G4A PUR G4D PUR g G4B PUR 66B GRN Sek PER n 25A B I3EE BLK DN 64C PUR 62C BLU LEFT BRUSH MOTOR PRESS Bal ES 2B Es 7 T 4 47 NES ex Er d d 5 w 64 PUR Y Y I3AC BLK
103. ll S 4 is closed the overflow system will shut off the scrub and vacuum up system If the overflow float switch becomes continuously active about 3 seconds the overflow light will turn on and latch If the Scrub or squeegee functions are active they will become deactivated and the vacuum fan will turn off after a slight delay If the operator presses the squeegee button the squeegee will drop and the vacuum fan will run for about 30 seconds to pick up any excess water The overflow indicator will not turn off by simply emptying the recovery tank The overflow indicator will remain illuminated until at least one of the following action occur 1 The overflow float switch becomes inactive S 4 is open and the scrub button is pushed Continued on next page 7200 330045 10 99 ELECTRICAL 4 71 ELECTRICAL 2 The overflow float switch becomes inactive and the squeegee button is pushed 3 The overflow float switch becomes inactive and an on off on button cycle is performed BATTERY GAUGE The battery gauge displays the state of charge of the batteries with a 4 segment LED display When the last segment is blinking the battery voltage is about 31 1 2 volts 8096 discharge and the batteries need charging The scrub and squeegee functions will shut off if the operator is scrubbing at this point If the user selects the squeegee button squeegee will lower and the vacuum fan will run for about 30 seconds to all
104. lution tank 13 Close the seat support Start the machine and check for proper operation 7200 330045 10 99 4 23 ELECTRICAL FUSES The fuse is a one time protection device designed to stop the flow of current in the event of a circuit overload NOTE Always replace the fuse with a fuse of the same amperage The fuse is located behind the operator console Access the fuse by lowering the operator console FU 1 80A 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 bottom left side of the control panel 4 24 7200 330045 10 99 ELECTRICAL 3 Loosen both bolts holding the two power cables to the top and bottom of the fuse and red stand offs 4 The fuse has slots on the top and bottom Slide the fuse up and to the side 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 Ib 7 Lift the operator seat and reconnect the battery connector at the front of the solution tank 8 Start the machine and check for proper o
105. more than a few seconds The ES Air flush valve will cycle on and off every 5 seconds Continued on next page 7200 330045 10 99 4 77 ELECTRICAL INTERLOCKS The operator can start and stop the various functions of the 7200 scrubber using a variety of closures and interlocks What follows are two tables for each of the three basic scrubbing functions Scrub brushes Squeegee and vacuum fan and ES pump One table lists the actions required for the basic function to be running The other table lists the actions that would prevent the operation from running If the operator satisfies all of the requirements from the first table and none of the situations of the second table exist the operator could expect the function to operate SCRUB BRUSH OPERATION SCRUB BRUSH OPERATION ENABLED BY INDICATOR e Forward or reverse propel e Forward or reverse contactors engaged SCRUB BRUSH OPERATION INHIBITED BY INDICATOR SQUEEGEE AND VACUUM FAN OPERATION SQUEEGEE FUNCTION ENABLED BY INDICATOR e Scrub button or squeegee button e Squeegee LED on Reverse contactor disengaged 4 78 7200 330045 10 99 ELECTRICAL ES AIR FLUSH OPERATION ES AIR FLUSH VALVE ENABLED BY INDICATOR e ES button and Squeegee button e ES and Squeegee LED s on e ES Air flush valve will open for a 5 second period at a 45 second interval if both ES and Squeegee are enabled ES AIR FLUSH VALVE INHIBITED BY INDICATOR e ES
106. n off and the scrub head will start to raise 2 The machine will delay a few seconds and the squeegee will start to raise 3 The vacuum fan will turn off after a slight delay 4 70 7200 330045 10 99 SQUEEGEE BUTTON Pressing the squeegee button will start or stop the water pickup operation If the operator presses the squeegee button while the squeegee LED is currently not illuminated will cause the following actions 1 The squeegee LED will be illuminated 2 If the machine is not in reverse the squeegee will drop and the vacuum fan will turn on If the machine goes into reverse while the squeegee is active the squeegee will rise If the machine remains in reverse long enough the vacuum fan will shut off Pressing the squeegee button while the squeegee LED is on will cause the following actions 1 The squeegee LED will turn off 2 The squeegee will raise 3 The vacuum fan will turn off after a slight delay ES BUTTON Pressing the ES button will enable or disable the ES system The ES system will draw water from the recovery tank through a filter and pump it into the solution tank If the operator has turned on the ES system the recovery tank 1 2 full float is closed and the solution tank full float S 9 is open the ES pump will begin to run The ES pump will continue to run for about 30 seconds after the ES float becomes uncovered OVERFLOW FLOAT If the recovery tank becomes fu
107. nd drive plug on the brush motor shaft Install the screw and washer in the center of the drive plug Tighten to 18 24 Nm 15 20 ft Ib 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 7200 330045 10 99 4 35 ELECTRICAL TO REPLACE CYLINDRICAL SCRUB HEAD BRUSH MOTOR FOR SAFETY Before Leaving Or Servicing 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 4 36 7200 330045 10 99 ELECTRICAL 4 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 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
108. nect 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 7200 330045 10 99 SCRUBBING 3 27 SCRUBBING 4 Remove the cotter pin and clevis pin from the scrub head lift mechanism where it attaches to the 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 3 28 7200 330045 10 99 SCRUBBING TO INSTALL DISC SCRUB HEAD FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Slide the scrub head under the machine frame with the scrub head link mount holes facing the front 2 Install the ball joint on the 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 lift actuator 4 Reconnect the b
109. ng the water flows 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 7200 330045 10 99 3 3 SCRUBBING SOLUTION TANK The solution tank supplies the brushes with a water and detergent solution The solution tank is located to the right of the recovery tank and behind the operators seat Access to the solution tank is through the opening at the top of the tank reached by lifting up the tank cover The solution tank requires no regular maintenance If detergent cakes on the bottom of the tank remove the deposits with a strong blast of warm water Do not use water hotter than 130 F 54 C or use steam to clean the tank because damage may occur A tank drain hose has been provided to allow the tank to be drained for cleaning The solution tanks with ES should be drained and cleaned after every work shift 3 4 7200 330045 10 99 TO DRAIN AND CLEAN SOLUTION TANK WITH ES 1 Close the solution tank water valve 2 Raise the scrub head and rear squeegee 3 Stop the machine next to a floor drain 4 Shut off the machine and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 5 Remove the drain hose
110. ng housing back in the slots 2 52 7200 330045 10 99 CHASSIS 6 Go under the machine and locate the small steering chain sprocket 7 Locate the master link on the steering chain Remove the master link and steering chain from the small steering sprocket 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 7200 330045 10 99 CHASSIS 10 Loosen the set screw holding the small steering sprocket to the bottom of the short steering shaft Remove and retain small sprocket and woodruff key 11 Use an arbor press to press the short steering shaft and two bearings out of the housing Discard the bearings Retain the short shaft NOTE 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 joint and square key on the top of the steering housing Tighten the set Screws tight 2 54 CHASSIS 16 Reinstall the steering housing in the machine Reinstall the two hex screws Leave loose for now 17 Position the long steering shaft and steering 18
111. ning on wheel facing lug nuts Tighten the three lug nuts to 58 76 Nm 43 56 ft Ib 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 7200 330045 10 99 FRONT TIRE AND WHEEL AND WHEEL DRIVE SUPPORT The front drive assembly controls the forward and reverse movement of the machine along with the braking and 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 7200 330045 10 99 CHASSIS CHASSIS TO REMOVE FRONT DRIVE ASSEMBLY 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 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 2 20 CHASSIS 6 Remove the cot
112. ny slack in the chain can be removed 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 been removed from the steering chain Tighten the two hex screws to 18 24 Nm 15 20 ft Ib 3 Operate the machine and check the steering for proper operation NOTE There is also a half link that can be removed for more adjustment 2 46 7200 330045 10 99 CHASSIS TO REPLACE STEERING CHAIN 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 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 Sy A NC LL 7 Route the new chain around both steering sprockets Install the master link 8 Remove the jack stands and lower the machine 9 Operate the mach
113. ons are the holes in the sides of the machine frame near the rear bumper If the loading surface is not horizontal or is higher than 380 mm 15 in from the ground use a winch to unload machine If the loading surface is horizontal AND is 380 mm 15 in or less from the ground the machine may be 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 7200 330045 3 02 GENERAL INFORMATION MACHINE JACKING TO JACK UP MACHINE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake The model 7200 can be jacked up from any of the four corners Always empty the solution and recovery tanks before jacking FOR SAFETY When servicing machine block machine tires before jacking machine up FOR SAFETY When servicing machine jack machine up at designated locations only Block machine up with 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 can be jacked up If this is not done the machine will tip or rock on the jack because of the single f
114. ore Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 7200 330045 10 99 3 43 SCRUBBING 3 Remove the cotter pin that holds the side squeegee in place Swing the squeegee away from the scrub head 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 3 44 7200 330045 10 99 7 Insert the Idler plug on the inside of the idler door into the brush 8 Push down on the door to catch the door in the scrub 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 7200 330045 10 99 SCRUBBING 3 45 SCRUBBING TO CHECK AND ADJUST CYLINDRICAL BRUSH PATTERN 1 Apply chalk or another material that will not easily blow away to a smooth level section of the floor 2 Set the parking brake 3 Lower the scrub head in the chalked area Allow the machine to scrub in the
115. out of the wheel assembly Drop the wheel assembly out of the machine 7200 330045 10 99 CHASSIS CHASSIS TO INSTALL REAR TIRE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Position the wheel assembly in the machine short side of hub toward outside Raise the tire up and align 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 Ib 4 Remove the jack stands and lower the machine 5 Drive the machine and check for proper operation 7200 330045 10 99 TO REPLACE REAR WHEEL BEARINGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 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 7200 330045 10 99 CHASSIS CHASSIS 5 Reinstall the wheel on the bearing housing coi
116. ow the operator to pick up any excess water The squeegee will then lift and the vacuum fan will shut off after a slight delay HOUR METER The hour meter logs hours if the machine is in one of the following modes 1 Propelling 2 Vacuum fans running INTERLOCKS The 7200 has several interlocks which can inhibit or cancel machine functions e REVERSE When the operator engages the reverse contactor the following function will become inhibited SQUEEGEE will rise When the operator disengages the reverse contactor the squeegee function will resume VACUUM FAN will turn off after a time delay When the operator disengages the reverse contactor the vacuum fan operation will resume e NEUTRAL When the operator disengages the forward contactors the machine will detect neutral and inhibit the following functions When the machine detects the forward switch the functions will resume WATER VALVE will turn off 5 SECOND delay If the machine is still in neutral after the 5 second delay SCRUB BRUSHES will turn off SCRUB HEAD will raise slightly Continued on next page 4 72 7200 330045 10 99 ELECTRICAL LOW BATTERY The machine will cancel the following functions when the last battery LED is blinking about 31 5 volts SCRUB FUNCTION The scrub function will cancel as if someone toggled the scrub button The operator cannot restart the scrub functions until the meter is reset
117. peration 7200 330045 10 99 4 25 ELECTRICAL DIRECTIONAL CONTROL PEDAL The directional pedal controls the machine s direction of travel and propelling speed The machine s speed is controlled by the amount of pressure placed on the pedal the farther the pedal is pressed the faster the machine will travel When the machine is moving forward and the directional pedal is reversed the machine will coast for a short distance before changing direction Use the brake pedal to stop the machine Forward Press the top of the 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 raise After a short delay the vacuum Will stop Neutral The machine will automatically return to the Neutral position when you take your foot off of the directional pedal NOTE When the directional pedal returns to the neutral position the scrub head will stop After a short delay the scrub head will also raise 4 26 7200 330045 10 99 ELECTRICAL TO REPLACE MOTOR CONTROLLER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Open th
118. propelling motor should be 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 cables leading to the drive motor 4 30 4 Remove the 4 hex screws holding the electric drive motor to the drive assembly outer plate Remove the drive motor NOTE When installing the motor on the drive assembly make sure the terminals are pointing up and slightly forward for proper 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 Ib 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 cables 10 Drive the machine and check the new drive motor for proper operation 7200 330045 10 99 ELECTRICAL 4 31 ELECTRICAL TO REPLACE DISC SCRUB HEAD BRUSH MOTOR FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake
119. readjust as necessary until both patterns are the same 3 48 7200 330045 10 99 CYLINDRICAL BRUSH DRIVE BELT The two brush drive belts are located on the cylindrical brush scrub head The belts drive the cylindrical brushes Proper belt tension is a 3 mm 0 1 in deflection from a force of 1 1 to 1 2 kg 2 5 to 2 7 Ib 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 instructions 7200 330045 10 99 SCRUBBING 3 49 SCRUBBING 3 Remove the two screws holding the belt cover to the scrub brush motor Remove the belt cover from the scrub head 4 Loosen the two pivot bolts on the bottom of the brush motor 5 Loosen the belt tension bolt under the brush motor Turn the bolt down far enough to allow the belt to be slipped off the motor pulley Push the drive belt down toward the lower brush drive plug 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
120. rol 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 LED may not turn on The controller will temporarily display scrub pressure when the operator presses and holds the scrub button If the operator holds the scrub button long enough the machine will scroll slowly through the down pressures The assignments of LED s to inputs are as follows Battery 1 When the least significant battery LED is blinking the battery voltage is below 31 5V and the batteries are in need of a charge Battery 2 When the battery 2 LED is on the reverse contactor is active Battery 3 When the battery 3 LED is on the forward contactor is active Battery 4 When the battery 4 LED is on there is power sensed on the outputs of both brush motor circuit breakers Continued on next page 4 80 7200 330045 10 99 Squeegee When the squeegee LED is on the solution tank full float is active Overflow When the overflow LED is on the recovery tank full float is active ES When the ES LED is on the ES float is active Pressure 1 When the pressure 1 LED is on the scrub is active and the brush current detecte
121. ront tire Place jack stands under the rear of the machine after lifting 7200 330045 10 99 GENERAL INFORMATION STORAGE INFORMATION The following steps should be taken when storing the machine for extended periods of time 1 Drain and clean the solution and recovery tanks ES machines Run clean water through the solution system and the ES solution pump Park the machine in a cool dry area Remove the batteries or charge them every three months FREEZE PROTECTION 1 2 Be sure the solution tank is empty Pour 3 8 L 1 gal of pre mixed automotive type windshield washer solution into the solution tank Turn the machine power on Start the solution flow Start the power wand solution system and ES system to circulate the washer solution through the components The washer solution does not need to be drained from the solution tank 7200 330045 10 99 GENERAL INFORMATION HARDWARE INFORMATION The following charts state standard plated hardware tightening ranges for normal assembly applications Decrease the specified torque by 2096 when using a thread lubricant Do not substitute lower grade hardware for higher grade hardware If higher grade hardware than specified is substituted tighten only to the specified hardware torque value to avoid damaging the threads of the part being threaded into as when threading into speed nuts or weldments STANDARD BOLT TORQUE
122. rt 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 clearance from the bottom of the skirt to the floor 4 Re tighten the retainer screws Operate the machine and check the scrub head skirts for proper water spray control 7200 330045 10 99 SCRUBBING 3 35 SCRUBBING TO REPLACE 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 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 3 36 7200 330045 10 99 SCRUBBING CYLINDRICAL BRUSH HEAD DEBRIS TRAY The cylindrical style scrub head is equipped with a rear mounted debris tray Small debris is picked up by the two cylindrical scrub brushes and deposited
123. rts Operating Modes ELECTRICAL Entry Sequence how to activate Normal Mode Normal operation Default when key is turned on More info pages 4 66 thru 4 69 Self Test Mode Test controller actuators and scrub brush motor operation In this mode the battery LED 4 will blink More info pages 4 70 thru 4 72 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 Input Display Mode Display the state of floats limit switches and sensors In this mode pressure LED 2 will blink More info pages 4 76 and 4 77 NOTE There is a clear folder at the end of this manual that contains three touch panel overlays Use each of the these overlays in their respective test mode as a technical aide during the diagnostic procedure 7200 330045 10 99 Push and hold the Squeegee button Turn on the key Hold the Squeegee button for 5 seconds Release the Squeegee button Push and hold the ES button Turn on the key Hold the ES button for 5 seconds Release the ES button Push and hold the Scrub button Turn on the key Hold the Scrub button for 5 seconds Release the Scrub button 4 69 ELECTRICAL Operating Mode Entry Sequence how to activate Normal Mode Normal operation Default when key is turned on NORMAL MODE The purpose of the normal mode is for the general
124. rush drive motors to the main electrical harness 7200 330045 10 99 3 29 SCRUBBING 5 6 3 30 Reconnect the water line to the scrub head 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 7200 330045 10 99 TO REMOVE CYLINDRICAL SCRUB HEAD 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 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 7200 330045 10 99 SCRUBBING 3 31 SCRUBBING 4 Remove the cotter pin and clevis pin from the scrub head lift mechanism where it attaches to the scrub head 5 Remove the nyloc nut holding the ball joint to the mount bracket on the scrub head Do this on both sides of the machine 6 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 3 32 7200 330045 10 99 TO INSTALL CYLINDRICAL SCRUB HEAD FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brak
125. ry tank Use less 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 replace ES mode option ES switch off Turn ES switch on Poor scrubbing performance Debris caught on scrub brushes Remove debris Improper detergent or brush used Check with TENNANT representative for advice Worn scrub brush es Replace scrub brush es Scrub brush motor circuit breaker s tripped Reset circuit breaker s Reduce scrub brush down pressure Uneven brush pressure level scrub head Broken brush drive belts on cylindrical scrub head replace belt Check with TENNANT representative for advice Low battery charge Charge batteries until the charger automatically turns off 7200 330045 10 99 3 79 SCRUBBING 3 80 7200 330045 10 99 Home fl Find To 7200 330045 3 02 TO REPLACE DISC SCRUB HEAD BRUSH MOTOR 4 32 TO REPLACE CYLINDRICAL SCRUB HEAD BRUSH MOTOR 4 36 LIFT ACTUATORS 4 41 TO REPLACE SCRUB HEAD LIFT
126. s holding the water hoses to the valve Mark the hoses and pull them off the fittings 7200 330045 10 99 4 57 ELECTRICAL 7 Remove the two screws holding the valve to the machine frame Remove the valve from the machine 8 Position 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 4 58 7200 330045 10 99 ELECTRICAL VACUUM FAN The vacuum fan when activated creates 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 7200 330045 10 99 4 59 ELECTRICAL TO REPLACE VACUUM FAN FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Remove the vacuum fan assembly from the machine See TO REMOVE VACUUM FAN ASSEMBLY instructions in the SCRUBBING section NOTE Make sure to note the position of the vacuum fan exhaust outlet when removing the fan from the housing 2 Remove the three screws and brackets holding the vacuum fan to the p
127. se steam to clean the tank because damage may occur Remove the ES outlet filter clean reinstall 9 Check the vacuum fan filter on top of the recovery tank Clean or replace if necessary 7200 330045 10 99 SCRUBBING 10 Close the tank cover 11 Replace the drain hoses in the tanks 7200 330045 10 99 SCRUBBING TO REMOVE RECOVERY TANK FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 In order to remove the recovery tank the solution tank hardware 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 hardware 3 18 7200 330045 10 99 SCRUBBING 6 Remove the screw on the left side 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 7200 330045 10 99 SCRUBBING 10 Remove the two screws holding the vacuum fan to the top of the recovery
128. sleeve and outer bearing cone assembly this is a left hand thread nut 9 The axle tire wheel assembly can now be removed from 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 installation 12 Install the new brake shoes on the drive assembly in the same orientation as the old ones were removed 13 Reinstall the C spring on the new brake shoes 7200 330045 10 99 CHASSIS 14 Reinstall the axle tire wheel assembly into the drive assembly Make sure the inner and outer wheel bearings are completely greased when re assembling 15 Reinstall the outer bearing and hex sleeve assembly this is a left hand thread nut Tighten to at least 100 ft Ibs and then back off the hex sleeve to 0 ft Ibs Re torque hex sleeve to 30 ft Ibs 16 Install the lock bolt in the end of the hex sleeve Tighten the lock bolt to 200 Nm 150 ft Ib while holding the hex sleeve from turning 17 Reinstall the hub cap in the drive assembly 7200 330045 10 99 CHASSIS 18 Locate the area where the brake cable attaches to the drive support The beginning adjus
129. 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 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 Ibs Then tighten to the next nearest hole and install the cotter pin 10 Reinstall the sprocket on the pivot assembly 2 30 7200 330045 10 99 CHASSIS 11 Reinstall the pivot and sprocket assembly on the drive assembly Reinstall the four screws and tighten to 68 81 Nm 50 60 ft Ib 12 Install the planetary gear box outer plate and 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 Ib 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 instructions 7200 330045 10 99 2 31 CHASSIS PLANETARY GEAR BOX The model 7200 front drive system includes a self contained planetary gearbox The electric drive motor provides power to the planetary gearbox which through a gear reduction spins the front t
130. strument panel We have associated a group of error codes to each button on the instrument panel If the operator presses the button assigned to a group that has sensed an error the controller will display the error code using the brush pressure LED s If the operator presses a button assigned to a group that has not sensed an error the controller will display no error code on the brush pressure LED s The error code assignments are as follows ACTUATOR GROUP SQUEEGEE BUTTON PRESSED PRESSUREO 0 PRESSURE2 PRESSURE3 ERROR No squeegee actuator zero current Low Do Early squeegee stall eo eee 3 E CELLS T TON BRUSH MOTOR GROUP SCRUB BUTTON PRESSED PRESSURE PRESGURET PRESSUREZ PRESSURES ERROR PON E rs motorcar caren ero motorcar tewinehmatersurent ACCESSORY OUTPUT GROUP ES BUTTON PRESSED ES LED SQUEEGEE ee poe LED ae Flush valve output a S Hour meter output ON ES pump output ON Fan contactor output ON Brush contactor output 7200 330045 10 99 4 76 ELECTRICAL Operating Mode Entry Sequence how to activate Manual Mode Manually operate discrete 1 Push and hold the ES button functions without interlocks In this mode the 2 Turn on the key battery 3 LED will blink 3 Hold the ES button for 5 seconds 4 Release the ES
131. tank Pull the vacuum fan up and disconnect the electrical 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 ES hose on the inside wall Remove the hose from the recovery tank 3 20 7200 330045 10 99 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 installing a new tank 15 The recovery tank can now be removed from the machine 7200 330045 10 99 SCRUBBING 3 21 SCRUBBING TO INSTALL RECOVERY TANK FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Position the recovery tank on the left side edge of the machine frame 2 Connect the hose coming from the ES 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
132. te 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 2 24 CHASSIS 4 Remove the four hex screws holding the pivot and sprocket 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 7200 330045 10 99 2 25 CHASSIS 9 10 11 12 13 14 2 26 Remove and discard both thrust washers and the caster bearing from the upper swivel plate weldment Apply grease on both sides of the new caster bearing Position the new caster bearing on top of the new lower thrust washer Reinstall the second new thrust washer on top of the new caster bearing 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 Reinstall the bearing cone and flat washer on the bottom swivel plate Make sure the bearing cone is greased 7200 330045 10 99 CHASSIS 15 Reinstall the castle nut and tighten to 125 ft Ibs Then back off to the next nearest hole and install the cotter pin Check to make sure the caster bearing can be turned by han
133. ter pin and clevis pin from the end of the brake cable where it attaches 1 to the lever the wheel support a its mu eect pilis rm npe rre m 7 Loosen the jam nut on the brake cable were it attaches to 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 from the machine 7200 330045 10 99 2 21 CHASSIS TO INSTALL FRONT DRIVE ASSEMBLY 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 Place the front drive assembly on a floor jack or transmission jack This will support the drive assembly when installing it in the machine 4 Position 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 scr
134. terlock or direction switch circuit open Sequencing delay too short Throttle input wire open Throttle input wire shorted to B or B Throttle por defective Wrong throttle type selected Emergency reverse wire or check wire open Improper sequence of KSI interlock and throtde inputs Wrong HPD type selected Misadjusted throttle por Sequencing delay too short Throttle pot wire open Throttle pot wire shorted Wrong throttle type selected Main contactor coil shorted Field winding shorted Main contactor stuck closed Main contactor driver shorted Field winding connection open Field winding open Main contactor coil open Main contactor missing Wire to main contactor open Battery voltage undervoltage cutback limit Corroded battery terminal Loose battery or controller terminal 1 Battery voltage gt overvoltage shutdown limit 2 Vehicle operating with charger attached Temperature gt 85 C or lt 25 C Excessive load on vehicle Improper mounting of controller Operation in extreme environments Mode switches shorted to Mode switches ticd down co select Mode 2 or Mode 4 permanently Insert for Table 7 uu 3 2 3 2 3 2 The codes are listed in Table 7 Table 7 STATUS LED FAULT CODES LED CODES EXPLANATION 3 LED off solid on no power or defe
135. tery connector mount bracket on the front of the solution tank Tighten the two screws to 18 24 Nm 15 20 ft Ib 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 7200 330045 10 99 SCRUBBING RECOVERY TANK The recovery tank stores the water solution picked up by the squeegees and vacuum fan The recovery tank is located at the left rear corner of the machine on the left of the solution tank The recovery tank should be drained and cleaned after the solution tank is empty and whenever the float switch stops the vacuum fan or the recovery full light comes on 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 Machine Stop On Level Surface Set Parking Brake 7200 330045 10 99 SCRUBBING 5 Remove the drain hose cap from the access caps at the rear of the recovery tank 6 Pull the tank drain hoses out and place them over the floor drain Remove the drain cap from the end of the hose Drain the tanks 7 Open the tank cover 8 Spray the inside of the solution and recovery tanks with a strong blast of warm water Do not use water hotter than 130 F 54 C or u
136. 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 the recovery and solution tanks before transporting the machine 7200 330045 3 02 GENERAL INFORMATION 2 If the loading surface is not horizontal or is higher than 380 mm 15 in from the ground use a winch to load machine If the loading surface is horizontal AND is 380 mm 15 in or less from the ground the machine may be driven onto the truck or trailer 3 To winch the machine onto the truck or trailer attach the winching chains to the rear tie down locations The rear tie down locations are the holes in the sides 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 steering wheel to center the machine 5 Set the parking brake lower the scrub head and block the machine tires Tie down the machine to the truck or trailer before transporting The front tie down locations are the holes in the front side of the machine frame 7200 330045 3 02 GENERAL INFORMATION 6 The rear tie down locati
137. 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 2 6 7200 330045 10 99 TO ADJUST SEAT POSITION FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Sit down on the seat in the operators compartment 2 Grasp the adjustment lever in the 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 contact with the floor at all times 7200 330045 10 99 CHASSIS 2 7 CHASSIS BRAKES AND TIRES SERVICE BRAKES The service brake is located on the front wheel 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 2 8 7200 33004
138. tment should be 1 375 in of conduit showing on the cable end 19 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 20 Goto 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 Ib 22 Reconnect the electrical cables to the drive motor 23 Remove the jack stands and lower the machine 24 Reconnect the battery cables 25 Drive the machine and check the brakes for proper operation Adjust if necessary 7200 330045 10 99 REAR TIRES AND WHEELS The rear tires on the model 7200 are semi pneumatic The rear tire and wheel assemblies are idler wheels only they have no braking capabilities TO REMOVE REAR TIRE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake 1 Jack up the rear corner of the machine where the tire needs to be removed 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 you pull the axle
139. top switch Machine turns off KEY SWITCH OFF BATTERY VOLTAGE CHECK FOR BATTERY O VOLTAGE VOLTAGE ON 25 GRY AT KEY SWITCH TURN AND HOLD KEY SWITCH 1 RED FU 1 5 BRN TO THE START POSITION CB 2 8 BLU D 2 OR 25 GRY ARE OPEN BATTERY CHECK FOR BATTERY VOLTAGE VOLTAGE ON 27 GRN AT M1 KEY IN START POSITION CHECK FOR VOLTAGE ACROSS M1 COIL 27 GRN TO 13D BLK O VOLTAGE VOLTAGE BATTERY 13D BLK IS OPEN VOLTAGE KEY SWITCH PINS 50 TO 15 26 ORA 5 2 OR 27 GRN ARE OPEN VOLTAGE ON BOTH WIRES 220 O VOLTAGE ON EITHER WIRES 5 BRN AND 6 BLU B ON ONE FU 1 IS OPEN OR SIDE ONLY CABLE OPEN FROM FU 1 TO M1 CONTACTOR REPLACE M1 RELEASE KEY TO START POSITION CHECKFOR O VOLTAGE ON EITHER VOLTAGE AT M1 WIRES 6 BLU AGAIN BATTERY VOLTAGE 6 BLU CB 1 35 GRN D 1 MACHINE IS 7 PUR OR KEY SWITCH PINS 30 POWERED UP TO PIN 15 ARE OPEN 4 84 7200 330045 10 99 ELECTRICAL POWER UP TESTING BATTERIES 36VDC Ej GROUND ll j j j 6VDC 6VDC 6VDC 6VDC 6VDC 6VDC c e 1 5 BRN 5 z o a UJ UJ 2 A 3 so TPE g UJ m c 2 yL Vs 5 5 30 5 1 2 KEY SWITCH OFF RUN START i i e 50 ss 8 27E GRN p g 1 27B GRN 15 26 ORA eo
140. tteries unless the fluid is slightly above the battery plates If needed add just enough distilled water to cover the plates Never add acid to the batteries Do not overfill Always keep the battery caps on except when adding water or taking hydrometer readings 7200 330045 3 02 Using a hydrometer measure the specific gravity to determine the charge level and condition of the batteries If one or more of the battery cells test lower than the other battery cells 0 050 or more the cell is damaged shorted or is near failure Completely recharge the batteries then retest them NOTE Do not take readings immediately after adding distilled water If the water and acid are not thoroughly mixed the readings may not be accurate Check the hydrometer readings against the following chart to determine the remaining battery charge level SPECIFIC GRAVITY BATTERY 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 flat dry surface NOTE Make sure the area is well ventilated 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 turn off machine and remove key
141. tuator to the main electrical harness See schematic in this section 13 Start the machine and check the rear squeegee actuator for proper operation 7200 330045 10 99 4 48 ELECTRICAL ES PUMP The ES pump is used to transfer filtered water from the recovery tank to the solution tank With the ES system activated float switches in the recovery tank and solution tank are used to turn the pump on and off automatically TO REPLACE ES 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 7200 330045 10 99 4 49 ELECTRICAL 3 Locate the ES pump under the vacuum fan 4 Remove the two screws holding the ES pump mount plate to the recovery tank Pull the pump and plate assembly up far enough to access the hoses and wires 5 Disconnect the ES pump from the main electrical harness 6 Loosen the worm drive clamps holding the solution hoses to the ES pump Pull the hoses off the pump fittings 7 Pull the ES pump assembly out of the machine 4 50 7200 330045 10 99 ELECTRICAL 8 Remove the three screws holding the ES pump to the mount plate Remove the pump 9 Remove the plastic fittings from the old pump and install in the new pump in the same orientation
142. unt of curl the squeegee blade has when the machine moves forward while the squeegee lowered to the floor The best deflection is when the squeegee wipes the floor just dry with a minimum amount of deflection 1 Turn the machine power on 2 Lower the squeegee 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 7200 330045 10 99 SCRUBBING 12 mm 0 50 in 03719 3 61 SCRUBBING 4 Turn the machine power off 5 To adjust the amount of deflection turn 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 12 mm 0 50 in 7 Readjust the squeegee blade deflection if necessary 03719 3 62 7200 330045 10 99 REAR SQUEEGEE CASTERS The rear squeegee casters each have two grease fittings Lubricate the pivot point and caster bearing on each squeegee caster with Lubriplate EMB grease TENNANT 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 clos
143. uously until the fault is corrected For example code 3 2 Welded direction contactor appears as 3 2 3 2 3 2 See Insert Table 6 TABLE 1 LED CODES te STATUS EXPLANATION No power or defeCtive controller SOLID ON controller gt SINGLE FLASH Bontrotter operational No faults 1 2 L e Hardware fail safe error 1 3 e M fault or motor output short p 1 4 299000 Sequencing fault SRO d e Emergency reverse circuit check fault A wiring 2253 900 High pedal disable fau MED PABLE 1 continued on the next page 7200 330045 3 02 4 87 ELECTRICAL See Insert Table 7 TABLE 1 LED CODES continued to B or B Q e Contacto t shunt driver overzet rrent GOO ROT elded direction contactor pewered up NOTE Only one fault is indicated at a time and faults are not queued up Operational faults such as a fault in SHO sequencing are cleared by cycling the brake or key switch PROGRAMMER 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 follo
144. ut 6 ES pump output 7 Vacuum fan contactor output 8 Scrub brush contactor output 9 ES Air flush output 4 74 7200 330045 10 99 ELECTRICAL When the operator releases the squeegee button the controller will run the squeegee and the brush head actuators to the up positions It will then run the following procedure 1 Turn on the vacuum fan and lower the squeegee actuator 2 Wait for the actuator to stall flag error for always stalled early stall or never stalled 3 Raise squeegee 4 Drop scrub head about 2 inches 5 Run head actuator up 6 Wait for the actuator to stall flag error for always stalled early stall or never stalled 7 Check brush motor current with brush motors off Flag error for current sensed 8 Turn on the brush motors 9 Flag error for zero current low current or high current 10 Turn off the brush motors 11 Cycle and test the ES pump output 12 Cycle and test the ES air flush output 13 Cycle and test the Vacuum fan output 14 Cycle and test the Scrub brush motor output 15 Cycle and test the Hour meter output 16 Cycle and test the water valve output 17 Blink the squeegee light green for system passed blink the overflow light red for system failed 7200 330045 10 99 4 75 ELECTRICAL SELF TEST ERROR CODES To interrogate the machine to determine the nature of a diagnostic failure the operator must use the buttons on the in
145. wing 4 step process is generally used for diagnosing and troubleshooting an inoperative vehicle 1 Visually inspect the vehicle for obvious problems 2 Diagnose the problem using the programmer 3 Test the circuitry with the programmer 4 Correct the problem Repeat the last three steps as necessary until the vehicle is operational EXAMPLE A vehicle that does not operate in forward is brought in for repair Step 1 Examine the vehicle and its wiring for any obvious problems such as broken wires or loose connections Continued on next page 4 88 7200 330045 3 02 Insert for Table 6 Table6 TROUBLESHOOTING CHART 041 No KNOWN FAULTS LI CURRENT SHUNT FAULT 1 current sensor error i2 mwransatE a hardware failsafe error 1 3 M SHORTEO internal M short to B SRO fault THROTTLE FAULT 1 wiper fault 2 EMR REV WIRING emergency reverse wiring fault cont driver Output overcurrent or field winding shorted 2 4 THROTTLE FAULT 2 pot low broken shorted 3 1 CONT COIL FLO wem 7 3 3 FIELD OPEN motor ficld winding open 1 2 missing contactor low battery voltage over under temp cutback 4 4 ANTI TIEDOWN Mode 2 or Mode 4 selected at startup POSSIBLE CAUSE Controller defective Controller defective Controller defective Improper sequence of KSI interlock and direction inputs Wrong SRO type selected In
146. ws 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 7200 330045 10 99 2 57 CHASSIS 2 58 7200 330045 10 99 Home Go To SCRUBBING CONTENTS Page Page INTRODUCTION 3 3 SQUEEGEES 3 56 SOLUTION TANK 3 4 TO REMOVE REAR SQUEEGEE TO DRAIN AND CLEAN SOLUTION ASSEMBLY 3 56 TANK WITH ES 3 5 TO INSTALL REAR SQUEEGEE TO REMOVE SOLUTION TANK 3 7 ASSEMBLY 3 58 TO INSTALL SOLUTION TANK 3 11 TO LEVEL REAR SQUEEGEE 3 59 RECOVERY TANK 3 15 TO ADJUST REAR SQUEEGEE TO DRAIN AND CLEAN RECOVERY BLADE DEFLECTION 3 61 TANI i aaa ose 3 15 REAR SQUEEGEE CASTERS 3 63 TO REMOVE RECOVERY TANK 3 18 TO ADJUST REAR SQUEEGEE TO INSTALL RECOVERY TANK 3 22 GUIDE ROLLER 3 63 SCRUB HEAD 3 25 REAR SQUEEGEE BLADES 3 64 SCRUB HEAD LINKS 3 25 TO REPLACE OR ROTATE REAR TO REPLACE SCRUB HEAD LINKS 3 26 TO REMOVE DISC SCRUB HEAD 3 27 TO INSTALL DISC SCRUB HEAD 3 29 TO REMOVE CYLINDRICAL SCRUB HEAD RR RR RES 3 31 TO INSTALL CYLINDRICAL SCRUB HEAD 655 Rn 3 33 DISC SCRUB HEAD SKIRTS 3 3
147. ylindrical scrub brushes Check taper and rotate front to rear 10 Squeegee caster wheels Lubricate PL and pivot points Battery cells Check electrolyte level DW 14 Pre Sweep skirts Check for damage and wear and seals 100 Hours 5 Cylindrical scrub brush Check tension and wear drive belts 13 Pre Sweep Check tension and wear brush drive belts ing 200 Hours 4 Battery terminals and and clean cables L Steering gear chain S Side and rear squeegees Check deflection and leveling i S 500 Hours 9 Vacuum fan motor s Check motor brushes N mo 5 Hous e Propelingmotor Check motor brushes 6 Rear wheelnus LUBRICANT FLUID DW Distilled water SPL Special lubricant Lubriplate EMB grease TENNANT part no 01433 1 GL SAE 90 weight gear lubricant N NOTE Also check procedures indicated m after the first 50 hours of operation 7200 330045 3 02 GENERAL INFORMATION PUSHING TOWING AND TRANSPORTING THE MACHINE PUSHING OR TOWING THE MACHINE If the machine becomes disabled it can be pushed or towed from the front or rear Only push or tow the machine for a very short distance and do not 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
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Tennant 7200 Service Manual - Performance Systems Janitorial

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