7200 Service Manual - PSJanitorial.com 7200... · This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT Model 7200 ride on scrubber. The

330045Rev. 02 (3--02)

Service Manual

7200

This service manual is intended to be an aid for the disassembly and reassembly of your TENNANTModel 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, chassislubrication, machine specifications, and machine maintenance chart.

Chassis: Tire/wheel replacement, brake adjustment and replacement, steering adjustment andreplacement.

Scrubbing: Scrub head repair/replacement, brush repair/replacement, skirt/seal repair/replacement,squeegee repair/replacement, solution and recovery tank repair/replacement, and scrubbingtroubleshooting.

Electrical: Battery maintenance and replacement, electric motor removal, electrical schematics,diagnostics, and electrical troubleshooting.

Manual Number -- 330045

Revision: 02

Published: 3--02

Copyright E 1999, 2002 TENNANT, Printed in U.S.A.

GENERAL INFORMATION

1-17200 330045 (3--02)

CONTENTS

PageSAFETY PRECAUTIONS 1-3. . . . . . . . . . . . . .SPECIFICATIONS 1-5. . . . . . . . . . . . . . . . . . . .GENERAL MACHINE

DIMENSIONS/CAPACITIES 1-5. . . . . . . . .GENERAL MACHINE PERFORMANCE 1-5. .POWER TYPE 1-6. . . . . . . . . . . . . . . . . . . . . . . .TIRES 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MACHINE DIMENSIONS 1-7. . . . . . . . . . . . . . .MAINTENANCE 1-8. . . . . . . . . . . . . . . . . . . . . .PUSHING, TOWING, AND TRANSPORTING

THE MACHINE 1-10. . . . . . . . . . . . . . . . . . .PUSHING OR TOWING THE MACHINE 1-10TRANSPORTING THE MACHINE 1-10. . . . . .MACHINE JACKING 1-13. . . . . . . . . . . . . . . . . .TO JACK UP MACHINE 1-13. . . . . . . . . . . . . .STORAGE INFORMATION 1-14. . . . . . . . . . . .FREEZE PROTECTION 1-14. . . . . . . . . . . . . .HARDWARE INFORMATION 1-15. . . . . . . . . .STANDARD BOLT TORQUE CHART 1-15. . .METRIC BOLT TORQUE CHART 1-15. . . . . .BOLT IDENTIFICATION 1-15. . . . . . . . . . . . . . .THREAD SEALANT AND LOCKING

COMPOUNDS 1-15. . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION

1-2 7200 330045 (10--99)

GENERAL INFORMATION

1-37200 330045 (3--02)

SAFETY PRECAUTIONS

The following symbols are used throughout thismanual as indicated in their description:

WARNING: To warn of hazards orunsafe practices that could result insevere personal injury or death.

FOR SAFETY: To identify actions thatmust be followed for safe operation ofequipment.

This machine is designed solely for scrubbing dirtand dust in an indoor environment. Tennant doesnot recommend using this machine in any otherenvironment.

The following information signals potentiallydangerous conditions to the operator orequipment. Read this manual carefully. Knowwhen these conditions can exist. Locate all safetydevices on the machine. Then, take necessarysteps to train machine operating personnel.Report machine damage or faulty operationimmediately. Do not use the machine if it is not inproper operating condition.

WARNING: Batteries emit hydrogen gas.Explosion or fire can result. Keepsparks and open flame away. Keepcovers open when charging.

WARNING: Flammable materials cancause an explosion or fire. Do not useflammable materials in tank(s).

WARNING: Flammable materials orreactive metals can cause an explosionor fire. Do not pickup.

FOR SAFETY:

1. Do not operate machine:-- Unless trained and authorized.-- Unless operation manual is read andunderstood.

-- In flammable or explosive areas unlessdesigned for use in those areas.

2. Before starting machine:-- Make sure all safety devices are inplace and operate properly.

-- Check brakes and steering for properoperation (if so equipped).

3. When using machine:-- Go slow on inclines and slipperysurfaces.

-- Use care when backing machine.-- Follow mixing and handlinginstructions on chemical containers.

4. Before leaving or servicing machine:-- Stop on level surface.-- Set parking brake (if equipped).-- Turn off machine and remove key.

5. When servicing machine:-- Avoid moving parts. Do not wear loosejackets, shirts, or sleeves whenworking on machine.

-- Block machine tires before jackingmachine up.

-- Jack machine up at designatedlocations only. Block machine up withjack stands.

-- Use hoist or jack that will support theweight of the machine.

-- Wear eye and ear protection whenusing pressurized air or water.

-- Disconnect battery connections beforeworking on machine.

-- Avoid contact with battery acid.-- Use Tennant supplied or equivalentreplacement parts.

6. When loading/unloading machineonto/off truck or trailer.-- Turn off machine.-- Use truck or trailer that will supportthe weight of the machine.

-- Use winch. Do not push the machineonto/off the truck or trailer unless theload height is 380 mm (15 in) or lessfrom the ground.

-- Set parking brake after machine isloading (option).

-- Block machine tires.-- Tie machine down to truck or trailer.

GENERAL INFORMATION

1-4 7200 330045 (10--99)

The safety labels appear on the machine in thelocations indicated. If these or any label becomesdamaged or illegible, install a new label in itsplace.BATTERY CHARGING LABEL -- LOCATED ONAND UNDERNEATH THE SEAT SUPPORT.

FLAMMABLE SPILLS LABEL --LOCATED ON THE SEAT SUPPORT.

FOR SAFETY LABEL -- LOCATED ON THESEAT SUPPORT.

FLAMMABLE MATERIALS LABEL -- LOCATEDON THE UNDERSIDE OF THE TANK COVERAND ON THE LEFT SIDE OF THE OPERATORCOMPARTMENT.

350656

GENERAL INFORMATION

1-57200 330045 (3--02)

SPECIFICATIONS

GENERAL MACHINE DIMENSIONS/CAPACITIES

Item Dimension/capacity

Length 1830 mm (72 in)

Length (with Pre--Sweept) 2465 mm (97 in)

Width (less squeegee) 1020 mm (40.25 in)

Width (with squeegee) 1155 mm (45.5 in)

Height 1360 mm (53.5 in)

Height with overhead guard 2032 mm (80 in)

Disk brush diameter for side brush (option) 455 mm (18 in)

Disk brush diameter for Pre--Sweept (option) 380 mm (15 in)

Disk brush diameter for 700 mm (28 in) scrub head 355 mm (14 in)

Disk brush diameter for 900 mm (36 in) scrub head 455 mm (18 in)

Cylindrical sweep brush diameter for Pre--Sweept (option) 150 mm (6 in)

Cylindrical sweep brush length for Pre--Sweept (option) 810 mm (32 in)

Cylindrical scrub brush diameter 150 mm (6 in)

Cylindrical brush length for 700 mm (28 in) scrub head 700 mm (28 in)

Cylindrical brush length for 900 mm (36 in) scrub head 900 mm (36 in)

Squeegee width for 700 mm (28 in) scrub head 950 mm (37.5 in)

Squeegee width for 900 mm (36 in) scrub head 1155 mm (45.5 in)

Scrubbing path width for 700 mm (28 in) scrub head 700 mm (28 in)

Scrubbing path width for 900 mm (36 in) scrub head 900 mm (36 in)

Solution tank capacity 130 L (35 gallons)

Recovery tank capacity 210 L (55 gallons)

GVWR 1134 Kg (2500 lbs)

GENERAL MACHINE PERFORMANCE

Item Measure

Aisle turnaround width 2080 mm (82 in)

Aisle turnaround width (with Pre--Sweept) 2770 mm (109 in)

Travel Speed 9.6 Km (6 mph)

Maximum rated climb and descent angle for transport 8_@ gross weight

Maximum rated climb and descent angle for scrubbing 4_

Maximum rated climb and descent angle for trailering 11_

GENERAL INFORMATION

1-6 7200 330045 (3--02)

POWER TYPE

Type Quantity Volts Ah Rating Weight

Batteries 6 6 235 @ 20 hr rate 30 kg (67 lb)

6 6 335 @ 20 hr rate 47 kg (104 lb)

Type Use VDC kW (hp)

Electric Motors Pre--Sweept brush (disk) 36 0.20 (0.25)

Pre--Sweept brush (cyl) 36 0.45 (0.60)

Scrub brush (disk) 36 0 56 (0 75)Scrub brush (disk) 36 0.56 (0.75)

Scrub brush (cyl) 36 0.56 (0.75)

Vacuum fan 36 0 6 (0 8)Vacuum fan 36 0.6 (0.8)

Propelling 36 1 1 (1 5)Propelling 36 1.1 (1.5)

Type VDC amp Hz Phase VAC

Chargers (Smart) 36 20 60 1 120

36 20 50 1 230

36 20 50 1 245

36 30 60 1 120

36 30 50 1 230

36 30 50 1 245

TIRES

Location Type Size

Front (1) Solid 100 mm wide x 305 mm OD (4 in wide x 12 in OD)

Rear (2) Solid 90 mm wide x 305 mm OD (3.5 in wide x 12 in OD)

GENERAL INFORMATION

1-77200 330045 (3--02)

TOP VIEW

SIDE VIEW

2032 mm(80.0 in)

1360 mm(53.5 in)

+

--

921 mm(36.25 in)

1155 mm(45.5 in)

1092 mm(43.0 in)1830 mm(72.0 in)

1020 mm(40.25 in)

1025 mm(40.35 in)

405 mm(16.0 in)

810 mm(32.0 in)

FRONT VIEW

915 mm(36.0 in)

350790

MACHINE DIMENSIONS

GENERAL INFORMATION

1-8 7200 330045 (3--02)

MAINTENANCE

1

2

23

4

1

1 5

5

6

7

8

9

10

10

11

13

1214

350790

GENERAL INFORMATION

1-97200 330045 (3--02)

MAINTENANCE CHART

Interval Key Description ProcedureLubricant/

Fluid

No. ofServicePoints

Daily 1 Side and rear squeegees Check for damage and wear -- 3y2 Scrub brushes Check for damage, wear, debris -- 28 Recovery tank Clean tank -- 18 Recovery tank, ESt mode Clean ESt filter -- 17 Solution tank, ESt mode Clean solution supply filter -- 19 Vacuum fan inlet filter Clean -- 1-- Machine Check for leaks -- 311 Cylindrical brushes only:

debris troughClean -- 1

12 Pre--Sweept brushes Check for damage and wear -- 212 Pre--Sweept debris hop-

perClean -- 1

50 Hours 15 Pre--Sweept cylindricalbrushes

Check taper -- 1

5 Cylindrical scrub brushes Check taper and rotate front torear

-- 2

10 Squeegee caster wheelsand pivot points

Lubricate SPL 4

4 Battery cells Check electrolyte level DW 31 Side and rear squeegees Check deflection and leveling -- 614 Pre--Sweept skirts

and sealsCheck for damage and wear -- 4

100 Hours 5 Cylindrical scrub brushdrive belts

Check tension and wear -- 2

13 Pre--Sweeptbrush drive belts

Check tension and wear -- 2

3 Steering caster pivot bear-ing

Lubricate SPL 1

200 Hours 4 Battery terminals andcables

HCheck and clean -- 12

6 Steering gear chain Lubricate GL 1500 Hours 9 Vacuum fan motor(s) Check motor brushes -- 1

Steering gear chain HCheck deflection -- 11000 5 Brush drive motors Check motor brushes -- 2 (4)Hours 6 Propelling motor Check motor brushes -- 1

6 Rear wheel nuts Torque wheel nuts -- 3

LUBRICANT/FLUID

DW Distilled water. . . .SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1). . .GL SAE 90 weight gear lubricant. . . .

NOTE: Also check procedures indicated (H) after the first 50 hours of operation.

GENERAL INFORMATION

1-10 7200 330045 (3--02)

PUSHING, TOWING, AND TRANSPORTINGTHE MACHINE

PUSHING OR TOWING THE MACHINE

If the machine becomes disabled, it can bepushed or towed from the front or rear.

Only push or tow the machine for a very shortdistance and do not exceed 3.2 kp/h (2 mph). It isNOT intended to be pushed or towed for a longdistance or at a high speed.

ATTENTION! Do not push or towmachine for a long distance or damagemay occur to the propelling system.

TRANSPORTING THE MACHINE

1. Position the rear of the machine at theloading edge of the truck or trailer.

FOR SAFETY: Use truck or trailer thatwill support the weight of the machine.

NOTE: Empty the recovery and solution tanksbefore transporting the machine.

GENERAL INFORMATION

1-117200 330045 (3--02)

2. If the loading surface is not horizontal or ishigher than 380 mm (15 in) from the ground,use a winch to load machine.If the loading surface is horizontal AND is380 mm (15 in) or less from the ground, themachine may be driven onto the truck ortrailer.

3. To winch the machine onto the truck ortrailer, attach the winching chains to the reartie down locations. The rear tie-downlocations are the holes in the sides of themachine frame near the rear bumper.

FOR SAFETY: When loading machineonto truck or trailer, use winch. Do notdrive the machine onto the truck ortrailer unless the loading surface ishorizontal AND is 380 mm (15 in) or lessfrom the ground.

4. Position the machine onto the truck or traileras far as possible. If the machine starts toveer off the centerline of the truck or trailer,stop and turn the steering wheel to centerthe machine.

5. Set the parking brake, lower the scrub headand block the machine tires. Tie down themachine to the truck or trailer beforetransporting.

The front tie-down locations are the holes inthe front side of the machine frame.

GENERAL INFORMATION

1-12 7200 330045 (3--02)

The rear tie-down locations are the holes inthe sides of the machine frame near the rearbumper.

6. If the loading surface is not horizontal or ishigher than 380 mm (15 in) from the ground,use a winch to unload machine.

If the loading surface is horizontal AND is380 mm (15 in) or less from the ground, themachine may be driven off the truck ortrailer.

FOR SAFETY: When unloading machineoff truck or trailer, use winch. Do notdrive the machine off the truck or trailerunless the loading surface is horizontalAND 380 mm (15 in) or less from theground.

GENERAL INFORMATION

1-137200 330045 (10--99)

MACHINE JACKING

TO JACK UP MACHINE

FOR SAFETY: Before Leaving OrServicing Machine; Stop On LevelSurface, Set Parking Brake.

The model 7200 can be jacked up from any of thefour corners. Always empty the solution andrecovery tanks before jacking.

FOR SAFETY: When servicing machine,block machine tires before jackingmachine up.

FOR SAFETY: When servicing machine,jack machine up at designated locationsonly. Block machine up with jackstands.

7. TO JACK UP THE FRONT: Place blocksbehind the rear tires when jacking up thefront of the machine. Place jack standsunder the machine frame after the machineis at the desired level.

8. TO JACK UP THE REAR: The front of themachine must be placed on jack standsbefore the rear of the machine can bejacked up. If this is not done the machine willtip or rock on the jack because of the singlefront tire. Place jack stands under the rear ofthe machine after lifting.

GENERAL INFORMATION

1-14 7200 330045 (10--99)

STORAGE INFORMATION

The following steps should be taken when storingthe machine for extended periods of time.

1. Drain and clean the solution and recoverytanks.

ESt machines: Run clean water throughthe solution system and the ESt solutionpump.

2. Park the machine in a cool, dry area.

3. Remove the batteries, or charge them everythree months.

FREEZE PROTECTION

1. Be sure the solution tank is empty.

2. Pour 3.8 L (1 gal) of pre-mixedautomotive-type windshield washer solutioninto the solution tank.

3. Turn the machine power on.

4. Start the solution flow. Start the power wandsolution system and ESt system tocirculate the washer solution through thecomponents.

5. The washer solution does not need to bedrained from the solution tank.

GENERAL INFORMATION

1-157200 330045 (10--99)

HARDWARE INFORMATION

The following charts state standard platedhardware tightening ranges for normal assemblyapplications. Decrease the specified torque by20% when using a thread lubricant. Do notsubstitute lower grade hardware for higher gradehardware. If higher grade hardware than specifiedis substituted, tighten only to the specifiedhardware torque value to avoid damaging thethreads of the part being threaded into, as whenthreading into speed nuts or weldments.

STANDARD BOLT TORQUE CHART

ThreadSize

SAE Grade 5Torque ft lb

(Nm)

SAE Grade 8Torque ft lb

(Nm)

0.25 in 7--10 (9--14) 10--13 (14--38)

0.31 in 15--20 (20--27) 20--26 (27--35)

0.38 in 27--35 (37--47) 36--47 (49--64)

0.44 in 43--56 (58--76) 53--76 (72--103)

0.50 in 65--85 (88--115) 89--116(121--157)

0.62 in 130--170(176--231)

117--265(159--359)

0.75 in 215--280(291--380)

313--407(424--552)

1.00 in 500--650(678--881)

757--984(1026--1334)

NOTE: Decrease torque by 20% when using athread lubricant.

METRIC BOLT TORQUE CHART

ThreadSize

Class 8.8Torque ft lb

_Nm)

Class 10.9Torque ft lb

(Nm)

M4 2 (3) 3 (4)

M5 4 (5) 6 (8)

M6 7 (9) 10 (14)

M8 18 (24) 25 (34)

M10 32 (43) 47 (64)

M12 58 (79) 83 (112)

M14 94 (127) 133 (180)

M16 144 (195) 196 (265)

M20 260 (352) 336 (455)

M24 470 (637) 664 (900)

NOTE: Decrease torque by 20% when using athread lubricant.

Exceptions to the above chart:

Check the machine for exceptions!

BOLT IDENTIFICATION

IdentificationGrade Marking

Specification andGrade

SAE--Grade 5

SAE--Grade 8

ISO--Grade 8.8

ISO--Grade 10.9

01395

THREAD SEALANT AND LOCKINGCOMPOUNDS

Thread sealants and locking compounds may beused on this machine. They include the following:

Locktite 515 sealant -- gasket formingmaterial. TENNANT Part No. 75567,15 oz(440 ml) cartridge.

Locktite 242 blue -- medium strength threadlocking compound. TENNANT Part No.32676, 0.5 ml tube.

Locktite 271 red -- high strength threadlocking compound. TENNANT Part No.19857, 0.5 ml tube.

GENERAL INFORMATION

1-16 7200 330045 (3--02)

CHASSIS

2-17200 330045 (10--99)

CONTENTS

Page

INTRODUCTION 2--3. . . . . . . . . . . . . . . . . . . . . .SEAT 2--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATOR SEAT 2--4. . . . . . . . . . . . . . . . .TO REMOVE SEAT ASSEMBLY 2--4. .TO INSTALL SEAT ASSEMBLY 2--6. . .TO ADJUST SEAT POSITION 2--7. . . .

STATIC DRAG CHAIN 2--7. . . . . . . . . . . . . . . . .BRAKES AND TIRES 2--8. . . . . . . . . . . . . . . . . .

SERVICE BRAKES 2--8. . . . . . . . . . . . . . . . .PARKING BRAKE 2--8. . . . . . . . . . . . . . . . . .

TO ADJUST SERVICE BRAKES 2--9. .TO ADJUST PARKING BRAKE 2--10. .TO REPLACE DRIVE ASSEMBLY

BRAKE SHOES 2--11. . . . . . . . . . . . .REAR TIRES AND WHEELS 2--15. . . . . . . . . .

TO REMOVE REAR TIRE 2--15. . . . . . . . . .TO INSTALL REAR TIRE 2--16. . . . . . . . . . .TO REPLACE REAR WHEEL

BEARINGS 2--17. . . . . . . . . . . . . . . . . . . .FRONT TIRE AND WHEEL, AND WHEEL

DRIVE SUPPORT 2--19. . . . . . . . . . . . . . . . .FRONT WHEEL SUPPORT CASTER

BEARING ASSEMBLY 2--19. . . . . . . . . .TO REMOVE FRONT DRIVE

ASSEMBLY 2--20. . . . . . . . . . . . . . . . . . . .TO INSTALL FRONT DRIVE

ASSEMBLY 2--22. . . . . . . . . . . . . . . . . . . .TO REPLACE DRIVE ASSEMBLY

CASTER BEARING ANDTHRUST WASHERS 2--24. . . . . . . . .

TO REPLACE DRIVE ASSEMBLYPIVOT CONE BEARING 2--29. . . . . . . .

Page

PLANETARY GEAR BOX 2--32. . . . . . . . . . . . .TO REMOVE PLANETARY GEAR

BOX 2--32. . . . . . . . . . . . . . . . . . . . . . . . . .TO INSTALL PLANETARY GEAR

BOX 2--34. . . . . . . . . . . . . . . . . . . . . . . . . .TO REPLACE FRONT TIRE AND

WHEEL ASSEMBLY 2--36. . . . . . . . . . . .TO REPLACE FRONT DRIVE

ASSEMBLY OUTER WHEELBEARING 2--40. . . . . . . . . . . . . . . . . .

TO REPLACE FRONT DRIVEASSEMBLY INNER WHEEL

BEARING 2--42. . . . . . . . . . . . . . . . . .STEERING 2--46. . . . . . . . . . . . . . . . . . . . . . . . . .

TO ADJUST STEERING CHAIN 2--46. . . .TO REPLACE STEERING CHAIN 2--47. . .TO REPLACE LARGE STEERING

SPROCKET 2--48. . . . . . . . . . . . . . . . . . .TO REPLACE SMALL STEERING

SPROCKET 2--50. . . . . . . . . . . . . . . . . . .TO REPLACE STEERING HOUSING

BEARINGS 2--52. . . . . . . . . . . . . . . . . . . .TO REPLACE STEERING U--JOINT 2--56.

CHASSIS

2-2 7200 330045 (10--99)

CHASSIS

2-37200 330045 (10--99)

INTRODUCTION

This section includes information on the mainchassis related components for example the seat,steering, front drive assembly, brakes and tires.

CHASSIS

2-4 7200 330045 (10--99)

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 thatprevents the machine from propelling unlesssomeone is sitting on it.

TO REMOVE SEAT ASSEMBLY


1. Lift the seat assembly until the prop rod isengaged.

2. Unplug the seat switch wire harness plugfrom the main harness.

CHASSIS

2-57200 330045 (10--99)

3. Lift the seat assembly slightly and removethe prop rod from the slot in the prop rodbracket.

4. Slide the seat assembly to the right until isoff the two mount pins. Remove the seatassembly from the machine.

CHASSIS

2-6 7200 330045 (10--99)

TO INSTALL SEAT ASSEMBLY


1. Position the seat assembly in the operatorscompartment.

2. Line up the two hinge pins on the seatassembly and seat support. Slide the seatassembly all the way on the pins.

3. Install the prop rod in the bracket slot.

4. Route the seat switch harness through thehole in the seat support plate.

5. Plug the seat switch harness into the mainharness plug.

6. Disengage the prop rod and lower the seatassembly.

CHASSIS

2-77200 330045 (10--99)

TO ADJUST SEAT POSITION


1. Sit down on the seat in the operatorscompartment.

2. Grasp the adjustment lever in the frontcenter of the seat.

3. Push the adjustment lever to the left.

4. Move the seat forward or backward until thedesired position is achieved.

5. Release the adjustment lever. The seat willnow be locked in the new position.

STATIC DRAG CHAIN

The static drag chain prevents the buildup ofstatic electricity in the machine. It is attached thethe rear squeegee mount frame. Make sure thechain is in contact with the floor at all times.

CHASSIS

2-8 7200 330045 (10--99)

BRAKES AND TIRES

SERVICE BRAKES

The service brake is located on the front wheelassembly. It is actuated with a foot brake pedal inthe operators compartment.

PARKING BRAKE

The parking brake is located on the front wheelassembly. It is actuated with a smaller toe leveron the top of the foot brake pedal in the operatorscompartment. It is deactivated by simply pushingon the foot brake pedal.

CHASSIS

2-97200 330045 (10--99)

TO ADJUST SERVICE BRAKES

The service brakes should be adjusted when anexcessive amount of brake pedal stroke is neededto stop the machine.

FOR SAFETY: Before Leaving OrServicing Machine; Stop On LevelSurface, Block Rear Wheels.

1. Go under the machine in the front rightcorner.

2. Locate the area where the brake cableattaches to the drive support. The beginningadjustment should be 1.375 in. of conduitshowing on the cable end.

3. Turn the steering wheel all the way to theright.

NOTE: Spin the tire/wheel assembly to make surethe brakes are not dragging with the brake pedalNOT engaged.

4. Loosen the two jam nuts on the brake cable,where it attaches to the drive supportcasting.

5. Move the cable away from the brake leverfar enough to remove the slack in the pedalmovement.

6. Re--tighten the two jam nuts firmly. Operatethe machine and check the brake pedal for ashorter stroke.

CHASSIS

2-10 7200 330045 (10--99)

TO ADJUST PARKING BRAKE

The parking brake should be adjusted when anexcessive amount of brake pedal stroke is neededto hold the machine.


1. Go under the machine in the front rightcorner.




4. Loosen the two jam nuts on the brake cable,where it attaches to the drive supportcasting.

5. Move the cable away from the brake leverfar enough to remove the slack in the pedalmovement.

6. Re--tighten the two jam nuts firmly. Operatethe machine and check the brake pedal for ashorter stroke.

CHASSIS

2-117200 330045 (10--99)

TO REPLACE DRIVE ASSEMBLY BRAKESHOES

The front brake shoes should be replaced whenthe machine no longer stops easily or theadjustment in the brake cable has been used up.


1. Raise the seat support and unplug thebattery connectors.

2. Raise the front of the machine and placejack stands under the frame.

3. Mark and remove the electrical cablesleading to the drive motor.

4. Remove the four hex screws holding theouter plate, motor, and planetary gear box tothe main drive assembly.

5. Pull the planetary gear box, outer plate, andmotor out of the drive wheel and away fromthe drive assembly.

CHASSIS

2-12 7200 330045 (10--99)

6. Go to the other side of the drive assemblyand remove the hub cap. This will exposethe outer bearing, hex sleeve, and lock bolt.

7. Remove the lock bolt.(this is a right--hand thread screw).

8. Remove the hex sleeve and outer bearingcone assembly.(this is a left hand thread nut).

9. The axle/tire/wheel assembly can now beremoved from the drive assembly. This willexpose the brake shoes.

10. Loosen the two jam nuts on the brake cable,where it attaches to the drive supportcasting. Pull the brake cable off the driveassembly.

11. Remove the large ”C” spring holding the twobrake shoes together. Remove the brakeshoes.

NOTE: There is a great deal of tension on the ”C”spring. Care must be used when spreading thespring for removal or installation.

12. Install the new brake shoes on the driveassembly in the same orientation as the oldones were removed.

13. Reinstall the ”C” spring on the new brakeshoes.

CHASSIS

2-137200 330045 (10--99)

14. Reinstall the axle/tire/wheel assembly intothe drive assembly. Make sure the inner andouter wheel bearings are completelygreased when re--assembling.

15. Reinstall the outer bearing and hex sleeveassembly (this is a left hand threadnut).Tighten to at least 100 ft lbs and thenback off the hex sleeve to 0 ft lbs. Re--torquehex sleeve to 30 ft lbs.

16. Install the lock bolt in the end of the hexsleeve. Tighten the lock bolt to 200 Nm(150 ft lb) while holding the hex sleeve fromturning.

17. Reinstall the hub cap in the drive assembly.

CHASSIS

2-14 7200 330045 (10--99)




20. Go to the other side of the drive assemblyand install the planetary gear box, outerplate, and motor assembly into the wheelassembly and onto the pins of the driveassembly.

21. Install the 4 hex screws and washers.Tighten to 18 -- 24 Nm (15 -- 20 ft lb).

22. Reconnect the electrical cables to the drivemotor.

23. Remove the jack stands and lower themachine.

24. Reconnect the battery cables.

25. Drive the machine and check the brakes forproper operation. Adjust if necessary.

CHASSIS

2-157200 330045 (10--99)

REAR TIRES AND WHEELS

The rear tires on the model 7200 aresemi--pneumatic. The rear tire and wheelassemblies are idler wheels only, they have nobraking capabilities.

TO REMOVE REAR TIRE


1. Jack up the rear corner of the machinewhere the tire needs to be removed.

NOTE: Do not raise both rear wheels off the floorat the same time. The machine will becomeunstable because of the single front tire.

2. Go under the machine in the area of the reartire. Locate the lock nut holding the axleshaft to the machine frame. Remove thelock nut and washer.

3. Support the tire while you pull the axle out ofthe wheel assembly. Drop the wheelassembly out of the machine.

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TO INSTALL REAR TIRE


1. Position the wheel assembly in the machine.(short side of hub toward outside) Raise thetire up and align the hole in the wheelbearing with the axle hole in the frame.

NOTE: The lug nuts must face the outside of themachine.

2. Install the axle shaft in the machine from theoutside of the frame.

NOTE: The axle has a flat portion that must lineup with the flat in the axle mount hole.

3. Install the washer and nut on the axle.Tighten to 68 -- 81 Nm (50 -- 60 ft lb).


5. Drive the machine and check for properoperation.

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TO REPLACE REAR WHEEL BEARINGS


1. Remove the rear wheel assembly. See TOREMOVE REAR TIRE instructions.

2. Remove the three lug nuts holding thebearing housing to the wheel assembly.Remove the bearing housing.

3. Use a press to remove the wheel bearingsfrom the housing.

4. Press the new wheel bearings into thehousing. Press the bearing in until the flangeis seated on the housing.

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5. Reinstall the wheel on the bearing housing.(coining on wheel facing lug nuts) Tightenthe three lug nuts to 58 -- 76 Nm(43 -- 56 ft lb).

NOTE: The lug nuts must face the outside of themachine.

6. Reinstall the rear wheel assembly in themachine. See TO INSTALL REAR TIREinstructions.

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FRONT TIRE AND WHEEL, AND WHEELDRIVE SUPPORT

The front drive assembly controls the forward andreverse movement of the machine along with thebraking and steering. The brakes are actuatedwith a cable and uses a sprocket and chainassembly for the steering. Forward and reverse isaccomplished with an electric motor and planetarygearbox.

FRONT WHEEL SUPPORT CASTER BEARINGASSEMBLY

The front wheel support caster bearing is locatedbetween the bottom swivel plate and the upperswivel plate weldment. The bearing is a flatneedle bearing style.

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TO REMOVE FRONT DRIVE ASSEMBLY





4. Go in operators compartment and loosenthe lower steering shaft mount screws.

5. Pull the mount back to give the steeringchain slack. Locate and remove the masterlink and steering chain.

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6. Remove the cotter pin and clevis pin fromthe end of the brake cable where it attachesto the lever on the wheel support.

7. Loosen the jam nut on the brake cable wereit attaches to the wheel support. Remove thebrake cable from the wheel support.

8. Position a floor jack or transmission jackunder the drive wheel. This will support thedrive assembly when the hardware isremoved.

9. Go to the operators compartment and locatethe 4 button head screws holding the driveassembly to the floor plate. Remove the 4screws while supporting the drive assembly.

10. Remove the drive assembly from themachine.

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TO INSTALL FRONT DRIVE ASSEMBLY




3. Place the front drive assembly on a floorjack or transmission jack. This will supportthe drive assembly when installing it in themachine.

4. Position the drive assembly under themachine in front.

5. Raise the drive assembly up until the mountholes in the floor plate are aligned with themount holes in the upper swivel plateweldment on top of the drive assembly.

NOTE: Make sure to position the grease zerk inthe access hole in the machine floor plate.

6. Install the four button head screws andtighten to 64 -- 83 Nm (47 -- 61 ft lb).

7. Reinstall the steering chain and master link.Adjust the steering chain. See TO ADJUSTSTEERING CHAIN instructions.

8. Reinstall the brake cable on the wheelsupport. Tighten the jam nut on the brakecable where it attaches to the wheel support.

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9. Reinstall the cotter pin and clevis pin in theend of the brake cable where it attaches tothe lever on the wheel support.




12. Reinstall the electrical cables on the drivemotor.



15. Operate the machine and check for properoperation. Check the brakes for properoperation. Adjust if necessary. See TOADJUST SERVICE BRAKES instructions.

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TO REPLACE DRIVE ASSEMBLY CASTERBEARING AND THRUST WASHERS


1. Remove the drive assembly from themachine. See TO REMOVE FRONT DRIVEASSEMBLY instructions.



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4. Remove the four hex screws holding thepivot and sprocket assembly to the driveassembly.

5. Remove the sprocket from the pivotassembly.

6. Remove the cotter pin and castle nut fromthe upper swivel plate weldment.

7. Remove the flat washer and cone bearingfrom the bottom swivel plate.

8. Lift the bottom swivel plate off the upperswivel plate weldment.

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9. Remove and discard both thrust washersand the caster bearing from the upper swivelplate weldment.

10. Apply grease on both sides of the newcaster bearing.

11. Position the new caster bearing on top of thenew lower thrust washer.

12. Reinstall the second new thrust washer ontop of the new caster bearing.

13. Reinstall the bottom swivel plate on theupper swivel plate weldment. Make sure thegrease seal is in place on the upper swivelplate weldment.

14. Reinstall the bearing cone and flat washeron the bottom swivel plate. Make sure thebearing cone is greased.

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15. Reinstall the castle nut and tighten to(125 ft lbs). Then back off to the nextnearest hole and install the cotter pin. Checkto make sure the caster bearing can beturned by hand. Reduce torque if necessary.

16. Reinstall the sprocket on the front driveassembly.

17. Reinstall the pivot and sprocket assembly onthe drive assembly. Reinstall the four screwsand tighten to 68 -- 81 Nm (50 -- 60 ft lb).

18. Install the planetary gear box, outer plate,and motor assembly into the wheelassembly and onto the pins of the driveassembly.


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20. Reinstall the drive assembly in the machine.See TO INSTALL FRONT DRIVEASSEMBLY instructions.

21. Operate the machine and check for smoothsteering operation. Check the brakes forproper operation. Adjust if necessary. SeeTO ADJUST SERVICE BRAKESinstructions.

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TO REPLACE DRIVE ASSEMBLY PIVOT CONEBEARING





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5. Remove the sprocket from the pivotassembly.

6. Remove the cotter pin and castle nut fromthe upper swivel plate weldment.

7. Remove the flat washer and old conebearing from the bottom swivel plate.

8. Install the new cone bearing and flat washeron the bottom swivel plate. Make sure thenew cone bearing is greased.

9. Reinstall the castle nut and tighten to200 Nm (150 ft lbs). Then tighten to the nextnearest hole and install the cotter pin.

10. Reinstall the sprocket on the pivot assembly.

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12. Install the planetary gear box, outer plate,and motor assembly into the wheelassembly and onto the pins of the driveassembly.



15. Operate the machine and check for smoothsteering operation. Check the brakes forproper operation. Adjust if necessary. SeeTO ADJUST SERVICE BRAKESinstructions.

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PLANETARY GEAR BOX

The model 7200 front drive system includes a selfcontained planetary gearbox. The electric drivemotor provides power to the planetary gearboxwhich, through a gear reduction, spins the fronttire.

TO REMOVE PLANETARY GEAR BOX





4. Remove the 4 hex screws holding theelectric drive motor to the drive assemblyouter plate. Remove the drive motor.

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5. Remove the four hex screws holding theouter plate to the main drive assembly.

6. Remove the 6 socket screws holding theouter plate to the planetary gear box.Remove the outer plate.

7. Pull the old planetary gear box out of thedrive wheel. Remove the old planetary gearbox from the machine.

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TO INSTALL PLANETARY GEAR BOX


1. Install the new planetary gearbox on theouter motor mount plate. Install the 6 socketscrews into the planetary gear box. Torquethe 6 screws to 193 -- 250 Ncm(17--22 in. lbs.).

NOTE: Do not tighten this hardware above agrade 2 torque. The planetary gearbox is madefrom a softer grade of cast iron and the threadscould strip out.

2. Reinstall the outer motor mount plate andgear box on the drive assembly. Tighten thefour screws to 18 -- 24 Nm (15 -- 20 ft lb).

NOTE: When installing the motor on the driveassembly, make sure the terminals are pointing upand slightly forward for proper electrical cableinstallation.

3. Reinstall the electric motor on the driveassembly. Make sure to line up the splineson the motor shaft with the splines of theplanetary gear box. Tighten the 4 hexscrews to 18 -- 24 Nm (15 -- 20 ft lb).

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7. Operate the machine and check the newgearbox for proper operation.

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TO REPLACE FRONT TIRE AND WHEELASSEMBLY








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9. The inner bearing, axle shaft, and tire/wheelassembly can now be removed from thedrive assembly. Use a press to remove theinner bearing from the existing tire/wheelassembly.

10. Install the inner bearing on the newtire/wheel assembly.

11. Reinstall the new tire/wheel assembly in thedrive assembly. Make sure the inner andouter wheel bearings are completelygreased when re--assembling.

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12. Reinstall the outer bearing and hex sleeveassembly. (this is a left hand thread nut)Tighten to at least 100 ft lbs and then backoff the hex sleeve to 0 ft lbs. Re--torque hexsleeve to 30 ft lbs.



15. Go to the other side of the drive assembly.Install the planetary gear box, outer plate,and motor assembly into the wheelassembly and onto the pins of the driveassembly.

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TO REPLACE FRONT DRIVE ASSEMBLYOUTER WHEEL BEARING




3. Go to the side of the drive assemblyopposite the drive motor and remove thehub cap. This will expose the outer bearing,hex sleeve, and lock bolt.



6. Use a press to remove the old outer bearingcone from the hex sleeve. Install a newouter bearing on the hex sleeve or replacethe bearing and sleeve assembly. Applygrease to the new bearing.

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7. Install the new outer bearing and hex sleeveassembly on the wheel shaft. (this is a lefthand thread nut). Tighten to at least 100 ftlbs and then back off the hex sleeve to0 ft lbs. Re--torque hex sleeve to 30 ft lbs.

8. Install the lock bolt (this is a right--handthread screw) in the end of the hex sleeve.Tighten the lock bolt to 200 Nm (150 ft lb)while holding the hex sleeve from turning.





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TO REPLACE FRONT DRIVE ASSEMBLYINNER WHEEL BEARING








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9. The inner bearing, axle shaft, and tire/wheelassembly can now be removed from thedrive assembly. Use a press to remove theinner bearing from the existing tire/wheelassembly. Discard the old wheel bearing.

10. Press a new inner wheel bearing on thewheel shaft. Apply grease to the newbearing.

11. Reinstall the tire/wheel assembly in the driveassembly. Make sure the inner and outerwheel bearings are completely greasedwhen re--assembling.

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12. Reinstall the outer bearing and hex sleeveassembly. (this is a left hand thread nut)Tighten to at least 100 ft lbs and then backoff the hex sleeve to 0 ft lbs. Re--torque hexsleeve to 30 ft lbs.



15. Go to the other side of the drive assembly.Install the planetary gear box, outer plate,and motor assembly into the wheelassembly and onto the pins of the driveassembly.

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STEERING

The steering on the model 7200 is controlled withtwo sprockets and one chain. A large diametersprocket is mounted on the top of the front driveassembly and a small diameter sprocket ismounted on the bottom of the steering shaft. Thesteering chain runs around both of thesesprockets.

After extended use, the steering chain maystretch slightly. Any slack in the chain can beremoved by following the adjustment procedurelisted below.

TO ADJUST STEERING CHAIN


1. Go into the operators compartment andlocate the two hex screws holding the lowersteering shaft bearing assembly to the floorplate. Loosen these two hex screws.

2. Push the lower steering shaft assemblyforward until the slack has been removedfrom the steering chain. Tighten the two hexscrews to 18 -- 24 Nm (15 -- 20 ft lb).

3. Operate the machine and check the steeringfor proper operation.

NOTE: There is also a half link that can beremoved for more adjustment.

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TO REPLACE STEERING CHAIN




3. Go under the machine and locate thesteering chain.

4. Rotate the steering wheel until the masterlink on the chain is accessible.

5. Remove the chain master link. Remove thesteering chain from both sprockets.

6. Remove and discard the steering chain fromthe machine.

7. Route the new chain around both steeringsprockets. Install the master link.



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TO REPLACE LARGE STEERING SPROCKET




3. Remove the old sprocket from the pivotassembly.

4. Install the new sprocket on the pivotassembly.

NOTE: Make sure the roll pin in the top of thedrive assembly lines up with the hole in thesprocket.

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7. Operate the machine and check for smoothsteering operation.

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TO REPLACE SMALL STEERING SPROCKET




3. Go into the operators compartment andlocate the lower steering shaft mountassembly. Loosen the two screws and pullthe mount back to give the steering chainslack.

4. Go under the machine and locate thesteering chain.

5. Rotate the steering wheel until the masterlink on the chain is accessible.

6. Remove the chain master link. Remove thesteering chain from both sprockets.

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7. Loosen the set screws holding the smallsprocket to the lower shaft. Slip the smallsprocket off the shaft.

8. Install the new small sprocket on the lowersteering shaft. Firmly tighten the set screws.

9. Route the steering chain around bothsteering sprockets. Install the master link.

10. Adjust the steering chain. See TO ADJUSTSTEERING CHAIN instructions.



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2-52 7200 330045 (10--99)

TO REPLACE STEERING HOUSINGBEARINGS


1. Jack up the front of the machine at the jackpoint. Install jack stands under the machineframe.

2. Turn the steering wheel all the way to theleft.

3. Go to the operators compartment and locatethe steering U--joint. Loosen the two setscrews on the top of the steering U--joint.

4. Pull the steering wheel and long steeringshaft up and out of the top of the steeringU--joint.

5. Remove the two hex screws holding thesteering bearing housing to the machineframe. Push the bearing housing back in theslots.

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6. Go under the machine and locate the smallsteering chain sprocket.

7. Locate the master link on the steering chain.Remove the master link and steering chainfrom the small steering sprocket.

8. Remove the steering housing from themachine.

9. Loosen the two set screws holding theU--joint to the top of the short steering shaft.Remove and retain the U--joint and squarekey.

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10. Loosen the set screw holding the smallsteering sprocket to the bottom of the shortsteering shaft. Remove and retain smallsprocket and woodruff key.

11. Use an arbor press to press the shortsteering shaft and two bearings out of thehousing. Discard the bearings. Retain theshort shaft.

NOTE: Note the orientation of the shaft in thehousing.

12. Use the arbor press to install the newbearings into the steering housing.

13. Use the arbor press to install the shortsteering shaft into the new bearings.

14. Reinstall the small steering sprocket andwoodruff key on the bottom of the steeringhousing. Tighten the set screws tight.

15. Reinstall the U--joint and square key on thetop of the steering housing. Tighten the setscrews tight.

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16. Reinstall the steering housing in themachine. Reinstall the two hex screws.Leave loose for now.

17. Position the long steering shaft and steeringwheel into the top of the steering U--joint.Tighten the set screws tight.

18. Go under the machine and reinstall thesteering chain around the small steeringsprocket. Reinstall the master link.

19. Turn the steering wheel all the way to the leftand then to the right. Find the point in therotation where the steering chain is the mosttight.

20. Push the bearing housing forward in theslots. This will remove any excess slack inthe steering chain. Tighten the two hexscrews to 37 -- 48 Nm (26 -- 34 ft lb).

21. Remove the jack stands and lower themachine to the floor. Operate the machineand check the steering chain for properoperation.

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2-56 7200 330045 (10--99)

TO REPLACE STEERING U--JOINT


1. Jack up the front of the machine at the jackpoint. Install jack stands under the machineframe.

2. Go to the operators compartment and locatethe steering U--joint. Loosen the two setscrews on the top of the steering U--joint.

3. Pull the steering wheel and long steeringshaft up and out of the top of the steeringU--joint.

4. Loosen the two set screws holding theU--joint to the top of the short steering shaft.Remove and discard the U--joint and squarekey.

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5. Install the new U--joint and square key onthe top of the steering housing. Tighten theset screws tight.

6. Position the long steering shaft and steeringwheel into the top of the steering U--joint.Tighten the set screws tight.

7. Operate the machine and check the steeringU--joint for proper operation.

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2-58 7200 330045 (10--99)

SCRUBBING

3-17200 330045 (10--99)

CONTENTS

PageINTRODUCTION 3--3. . . . . . . . . . . . . . . . . . . . . .SOLUTION TANK 3--4. . . . . . . . . . . . . . . . . . . . .

TO DRAIN AND CLEAN SOLUTIONTANK WITH ESt 3--5. . . . . . . . . . . . . . .

TO REMOVE SOLUTION TANK 3--7. . . . . .TO INSTALL SOLUTION TANK 3--11. . . . .

RECOVERY TANK 3--15. . . . . . . . . . . . . . . . . . .TO DRAIN AND CLEAN RECOVERY

TANK 3--15. . . . . . . . . . . . . . . . . . . . . . . . .TO REMOVE RECOVERY TANK 3--18. . . .TO INSTALL RECOVERY TANK 3--22. . . .

SCRUB HEAD 3--25. . . . . . . . . . . . . . . . . . . . . . .SCRUB HEAD LINKS 3--25. . . . . . . . . . . . . . . . .

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 3--31. . . . . . . . . . . . . . . . . . . . . . . . .TO INSTALL CYLINDRICAL SCRUB

HEAD 3--33. . . . . . . . . . . . . . . . . . . . . . . . .DISC SCRUB HEAD SKIRTS 3--35. . . . . . . . . .SCRUB HEAD FLOOR SKIRTS 3--35. . . . . . . .

TO ADJUST DISC SCRUB HEADSKIRTS 3--35. . . . . . . . . . . . . . . . . . . . . . .

TO REPLACE DISC SCRUB HEADSKIRTS 3--36. . . . . . . . . . . . . . . . . . . . . . .

CYLINDRICAL BRUSH HEAD DEBRISTRAY 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 SCRUBBRUSHES 3--41. . . . . . . . . . . . . . . . . . . . .

CYLINDRICAL SCRUB BRUSHES 3--43. . . . .TO REPLACE CYLINDRICAL SCRUB

BRUSHES 3--43. . . . . . . . . . . . . . . . . . . . .TO CHECK AND ADJUST

CYLINDRICAL BRUSH PATTERN 3--46CYLINDRICAL BRUSH DRIVE BELT 3--49. . .

TO REPLACE BRUSH DRIVE BELT 3--49.MANUAL SOLUTION VALVE 3--53. . . . . . . . . .

TO REPLACE SOLUTION VALVE 3--53. . .

PageSQUEEGEES 3--56. . . . . . . . . . . . . . . . . . . . . . .

TO REMOVE REAR SQUEEGEEASSEMBLY 3--56. . . . . . . . . . . . . . . . . . . .

TO INSTALL REAR SQUEEGEEASSEMBLY 3--58. . . . . . . . . . . . . . . . . . . .

TO LEVEL REAR SQUEEGEE 3--59. . . . . .TO ADJUST REAR SQUEEGEE

BLADE DEFLECTION 3--61. . . . . . . . . . .REAR SQUEEGEE CASTERS 3--63. . . . . . . . .

TO ADJUST REAR SQUEEGEEGUIDE ROLLER 3--63. . . . . . . . . . . . . . .

REAR SQUEEGEE BLADES 3--64. . . . . . . . . .TO REPLACE OR ROTATE REAR

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 SQUEEGEELIFT CABLE 3--70. . . . . . . . . . . . . . . . . . .

SIDE SQUEEGEE BLADES 3--73. . . . . . . . . . .TO REPLACE SIDE SQUEEGEE

BLADES 3--74. . . . . . . . . . . . . . . . . . . . . .VACUUM FAN 3--75. . . . . . . . . . . . . . . . . . . . . . .

TO REMOVE VACUUM FANASSEMBLY 3--75. . . . . . . . . . . . . . . . . . . .

TO INSTALL VACUUM FANASSEMBLY 3--77. . . . . . . . . . . . . . . . . . . .

SCRUBBING TROUBLESHOOTING 3--79. . .

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SCRUBBING

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INTRODUCTION

When scrubbing, the water flows from the solutiontank, through the solution valve, and down to thescrub brushes. The brushes rotate to scrub thefloor. As the machine moves forward the rearsqueegee wipes the dirty solution off the floor,which is then picked up and drawn into therecovery tank by the vacuum fan.

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3-4 7200 330045 (10--99)

SOLUTION TANK

The solution tank supplies the brushes with awater and detergent solution. The solution tank islocated to the right of the recovery tank andbehind the operators seat.

Access to the solution tank is through the openingat the top of the tank, reached by lifting up thetank cover.

The solution tank requires no regularmaintenance. If detergent cakes on the bottom ofthe tank, remove the deposits with a strong blastof warm water. Do not use water hotter than 130_F (54_ C) or use steam to clean the tank becausedamage may occur. A tank drain hose has beenprovided to allow the tank to be drained forcleaning.

The solution tanks with ESt should be drainedand cleaned after every work shift.

ESt

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TO DRAIN AND CLEAN SOLUTION TANKWITH ESt

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 parkingbrake.


5. Remove the drain hose cap from the accesscaps at the rear of the solution tank.

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3-6 7200 330045 (10--99)

6. Pull the tank drain hoses out and place themover the floor drain. Remove the drain capfrom the end of the hose. Drain the tanks.

7. Open the tank cover.

8. Spray the inside of the solution and recoverytanks with a strong blast of warm water. Donot use water hotter than 130_ F (54_ C) oruse steam to clean the tank becausedamage may occur. Remove the EStoutlet filter, clean, reinstall.

9. Check the vacuum fan filter on top of therecovery tank. Clean or replace if necessary.

10. Close the tank cover.

11. Replace the drain hoses in the tanks.

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TO REMOVE SOLUTION TANK


1. In order to remove the solution tank, therecovery tank must be removed first. SeeTO REMOVE RECOVERY TANKinstructions.

2. Remove the seat assembly. See TOREMOVE SEAT ASSEMBLY instructions inCHASSIS section.

3. Disconnect the battery plug from thebatteries. Remove the two screws holdingthe battery connector bracket to the front ofthe solution tank.

4. Remove the battery nearest the right, rearcorner of the battery compartment.

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5. Remove the two screws holding the front ofthe solution tank to the seat support.

6. If the machine is equipped with an overheadguard----it must be removed.

7. Make sure the solution tank is drained andthe tank clean out caps removed.

8. Remove the four hex screws holding theplastic, rear drain splash tray. Let it dropdown for access to the solution tankhardware.

9. Remove the screw on the right side of thesolution tank drain cap.

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10. Open the tank cover. Remove the hardwareholding the top of the prop arm to the tankcover.

11. Remove the plastic tank cover hinge rod.Remove the tank cover from the machine.

12. Remove the hardware holding the air flushvalve and bracket to the solution tank.

13. Disconnect the clear water hose from thetop, front corner of the solution tank.

14. Disconnect the float switch electrical plugfrom the main harness.

NOTE: Make sure to note the orientation of theelectrical harness before removing the solutiontank. It is very important to position the harness inthe same location when installing a new tank.

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15. Lift the solution tank up far enough toaccess the clamp on the hose running fromthe bottom of the solution tank to the watervalve. Loosen this clamp and remove thehose from the solution tank.

16. The solution tank can now be removed fromthe machine.

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TO INSTALL SOLUTION TANK


1. Position the solution tank on the right sideedge of the machine frame.

2. Connect the hose coming from the watervalve to the nipple on the bottom of thesolution tank. Tighten the worm drive clamp.

3. Drop the solution tank down in place. Becareful to route the electrical harnessproperly.

4. Move the tank around until all the mountholes in the tank are lined up with the holesin the frame.

5. Install the hex screw in the area to the rightof the tank drain cap. Leave loose for now.

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6. Install the two screws holding the front of thesolution tank to the seat support. Leaveloose for now.

7. Install the air flush valve mount bracket onthe side of the solution tank. Tighten all fourscrews to 18 -- 24 Nm (15 -- 20 ft lb).

8. Connect the water hose to the top, frontnipple on the solution tank. Tighten theworm drive clamp.

9. Connect the float switch to the mainharness.

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10. Reinstall the tank cover and plastic hingerod.

11. Reconnect the top of the prop arm to thetank cover.

12. Reinstall the plastic, rear drain splash trayover the tank drains. Tighten the fourscrews.

13. Reinstall the tank drain hose and caps.

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14. Reinstall the battery in the right, rear cornerof the battery compartment.

15. Reinstall the battery connector mountbracket on the front of the solution tank.Tighten the two screws to 18 -- 24 Nm(15 -- 20 ft lb).

16. Reinstall the overhead guard if it wasremoved earlier.

17. Operate the machine and check the solutiontank for any leaks and for proper operationof the float switch.

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RECOVERY TANK

The recovery tank stores the water solutionpicked up by the squeegees and vacuum fan. Therecovery tank is located at the left, rear corner ofthe machine, on the left of the solution tank.

The recovery tank should be drained and cleanedafter the solution tank is empty and whenever thefloat switch stops the vacuum fan or the recoveryfull 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 parkingbrake.


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5. Remove the drain hose cap from the accesscaps at the rear of the recovery tank.

6. Pull the tank drain hoses out and place themover the floor drain. Remove the drain capfrom the end of the hose. Drain the tanks.

7. Open the tank cover.

8. Spray the inside of the solution and recoverytanks with a strong blast of warm water. Donot use water hotter than 130_ F (54_ C) oruse steam to clean the tank becausedamage may occur. Remove the EStoutlet filter, clean, reinstall.

9. Check the vacuum fan filter on top of therecovery tank. Clean or replace if necessary.

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10. Close the tank cover.

11. Replace the drain hoses in the tanks.

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TO REMOVE RECOVERY TANK


1. In order to remove the recovery tank, thesolution tank hardware must be loosened orremoved first. See TO REMOVESOLUTION TANK instructions.

2. Tilt the seat support until the prop rod isengaged.

3. If the machine is equipped with an overheadguard----it must be removed.

4. Make sure the recovery tank is drained andthe tank clean out caps removed.

5. Remove the four hex screws holding theplastic, rear drain splash tray. Let it dropdown for access to the recovery tankhardware.

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6. Remove the screw on the left side of thesolution tank drain cap.

7. Open the tank cover. Remove the hardwareholding the top of the prop arm to the tankcover.

8. Pull the vacuum hose out of the hole in therecovery tank.

9. Remove the plastic tank cover hinge rod.Remove the tank cover from the machine.

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10. Remove the two screws holding the vacuumfan to the top of the recovery tank. Pull thevacuum fan up and disconnect the electricalplug. Remove the vacuum fan from themachine.

11. Remove the hardware holding the air flushvalve and bracket to the recovery tank.

12. Go in the operators compartment andremove the screw from the left, front cornerof the recovery tank.

13. Pull the recovery tank up far enough toaccess the ESt hose on the inside wall.Remove the hose from the recovery tank.

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14. Disconnect the float switch electrical plugfrom the main harness.

NOTE: Make sure to note the orientation of theelectrical harness before removing the solutiontank. It is very important to position the harness inthe same location when installing a new tank.

15. The recovery tank can now be removedfrom the machine.

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TO INSTALL RECOVERY TANK


1. Position the recovery tank on the left sideedge of the machine frame.

2. Connect the hose coming from the EStpump to the nipple on the side of therecovery tank. Tighten the worm driveclamp.

3. Drop the recovery tank down in place. Becareful to route the electrical harnessproperly.

4. Move the tank around until the front andback mount holes in are lined up with theholes in the frame.

5. Install the hex screw in the area to the left ofthe tank drain cap. Leave loose for now.

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6. Install the screw holding the left front of therecovery tank to the frame in the area of theoperators compartment. Leave loose fornow.

7. Install the air flush valve mount bracket onthe front of the recovery tank. Tighten allthree screws to 18 -- 24 Nm (15 -- 20 ft lb).

8. Reinstall the vacuum fan on the recoverytank. Reconnect the vacuum fan to the mainelectrical harness. Tighten the hardware to18 -- 24 Nm (15 -- 20 ft lb).

9. Reinstall the tank cover and plastic hingerod.

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10. Reconnect the top of the prop arm to thetank cover.

11. Reinstall the plastic, rear drain splash trayover the tank drains. Tighten the fourscrews.

12. Reinstall the tank drain hose and caps.

13. Reinstall the overhead guard if it wasremoved earlier.

14. Operate the machine and check therecovery tank for any leaks and for properoperation of the float switch.

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SCRUB HEAD

The model 7200 can be equipped with eithera cylindrical or a disc style scrub head. The scrubhead houses the scrub brushes and their drivemechanisms.

The scrub head adjustments are factory set andshould not be changed unless scrub head partsare damaged or replaced.

The scrub head also includes floor skirts tocontrol water spray. These skirts can be adjustedand need to be replaced if worn or damaged.

SCRUB HEAD LINKS

The scrub head links attach the scrub headframe to the machine frame. The two scrub headlinks allow the scrub head to follow the contour ofthe floor. The links have a pivot point on each endand no regular lubrication.

CYLINDRICAL

DISC

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TO REPLACE SCRUB HEAD LINKS

1. Start the machine and lower the scrub headto the floor. Shut off the key.


2. Go under the machine on each side andremove the nyloc nut holding the scrub headlinks to the machine frame and scrub headframe. Remove the scrub head links fromthe machine.

NOTE: The measurement for the new scrub headlinks should be 16 inches from the center of thefront ball joint to the center of the rear balljoint.

3. Install the new scrub head links on themachine with the ball joints facing the insideof the machine frame. Firmly tighten the fournyloc nuts.

NOTE: Use the front frame hole for thecylindrical scrub head and the rear framemount hole for the disc scrub head.

4. Start the machine and raise the scrub head.Check the scrub head links for properoperation.

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TO REMOVE DISC SCRUB HEAD



2. Disconnect the water line leading from theshut--off valve to the scrub head.

3. Disconnect the two scrub brush motors fromthe main electrical harness.

NOTE: Mark the connectors for properre--assembly.

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4. Remove the cotter pin and clevis pin fromthe scrub head lift mechanism where itattaches to the frame and actuator.

5. Remove the nyloc nut holding the ball jointto the mount bracket on the scrub head. Dothis on both sides of the scrub head.

6. Jack up the front of the machine far enoughto slide the scrub head out. Install jackstands under the machine frame.

7. The scrub head can now be pulled out fromunder the machine frame.

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TO INSTALL DISC SCRUB HEAD


1. Slide the scrub head under the machineframe with the scrub head link mount holesfacing the front.

2. Install the ball joint on the end of the scrubhead link into the mount hole on the scrubhead. The ball joint should be positioned soit is facing the inside of the machine frame.Do this on both sides of the machine.

3. Position the scrub head as close as possibleto the center. Remove the jack stands andlower the machine until the clevis pins canbe reinstalled in the front of the scrub headlift bracket and the bottom of the lift actuator.

4. Reconnect the brush drive motors to themain electrical harness.

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5. Reconnect the water line to the scrub head

6. Start the machine and raise the scrub head.Operate the machine and check the scrubhead for proper operation. Check the scrubbrushes for proper rotation.

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TO REMOVE CYLINDRICAL SCRUB HEAD



2. Disconnect the water line leading from theshut off valve to the scrub head.

3. Disconnect the two scrub brush motors fromthe main electrical harness. Mark theconnectors for proper re--assembly.

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4. Remove the cotter pin and clevis pin fromthe scrub head lift mechanism where itattaches to the scrub head.

5. Remove the nyloc nut holding the ball jointto the mount bracket on the scrub head. Dothis on both sides of the machine.

6. Turn on the machine and raise the scrubhead lift actuator. Turn off the machine.

NOTE: This will allow more clearance for thescrub head to slide out.

7. The scrub head can now be pulled out fromunder the machine frame.

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TO INSTALL CYLINDRICAL SCRUB HEAD


1. Slide the scrub head under the machineframe with the scrub head link mount holesfacing the front.

2. Install the ball joint on the end of the scrubhead link into the mount hole on the scrubhead. The ball joint should be positioned soit is facing the inside of the machine frame.Do this on both sides of the machine.

3. Position the scrub head as close as possibleto the center. Turn on the machine and lowerthe scrub head lift actuator.

NOTE: Do this in small increments until themount hole in the scrub head lines up with themount hole in the lift mechanism.

4. Install the clevis pin and cotter pin.

5. Reconnect the brush drive motors to themain electrical harness.

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6. Reconnect the water line to the scrub head

7. Start the machine and raise the scrub head.Operate the machine and check the scrubhead for proper operation. Check the scrubbrushes for pattern and proper rotation. SeeTO CHECK AND ADJUST CYLINDRICALBRUSH PATTERN instructions.

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DISC SCRUB HEAD SKIRTS

SCRUB HEAD FLOOR SKIRTS

The scrub head floor skirts control water sprayfrom the brushes. The skirts are located in frontand rear of the scrub head. Check these skirts forwear and damage after every 50 hours ofoperation.

The skirts should clear the floor by 0 to 0.25 in.(0 to 6mm) when the scrub head is down. Checkthe floor skirt adjustment after every 50 hours ofoperation.

TO ADJUST DISC SCRUB HEAD SKIRTS



2. Loosen the screws holding the retainer andskirt to the scrub head frame.

3. Position the up or down as needed toachieve 1/8 to 1/4 inch clearance from thebottom of the skirt to the floor.

4. Re--tighten the retainer screws. Operate themachine and check the scrub head skirts forproper water spray control.

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TO REPLACE DISC SCRUB HEAD SKIRTS



2. Remove the screws holding the retainer andskirt to the scrub head frame. Remove anddiscard the skirt.

3. Position the new skirt and existing retaineron the scrub head. Adjust the skirt andtighten the retainer screws. See TOADJUST DISC SCRUB HEAD SKIRTSinstructions.

4. Operate the machine and check the scrubhead skirts for proper water spray control.

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CYLINDRICAL BRUSH HEAD DEBRIS TRAY

The cylindrical style scrub head is equippedwith a rear mounted debris tray. Small debris ispicked up by the two cylindrical scrub brushes anddeposited in the debris tray located behind therear scrub brush. The debris tray can be easilyremoved and emptied.

TO REMOVE DEBRIS TRAY

1. Start the machine and touch the scrubbutton. Shut off the key when the scrubhead is near the floor.

NOTE: Do not touch the directional pedal.


2. Go to the right side of the machine. Locatethe scrub head side squeegee. Pull the hairpin out of the squeegee lock pin.

3. Pivot the side squeegee out, away from thescrub head.

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4. Grasp the plastic debris tray and pivot thebottom up, away from the back of the scrubhead. Pivot the debris tray far enough toallow the rubber skirt to clear the scrubhead.

5. Pull the debris tray straight out to the rightuntil it is free of the scrub head lip. Emptythe debris tray,

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TO INSTALL DEBRIS TRAY

1. Lower the scrub head to the floor.


2. Position the debris tray, opening facingforward, on the lip on the back of the scrubhead. Push the debris tray in until is stops.

3. Swing the right hand side squeegee back tothe side of the scrub head. Make sure thelock pin is positioned in the mount hole.Reinstall the hair pin.

4. Start the machine and raise the scrub head.

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TO REPLACE DEBRIS TRAY SKIRT

1. Remove the debris tray. See TO REMOVEDEBRIS TRAY instructions.


2. Remove the six screws, washers, and nutsholding the debris tray skirt and retainer tothe top lip of the tray. Remove the retainerand skirt. Discard the skirt.

3. Position the new debris tray skirt andexisting retainer on the top lip of the tray.

4. Reinstall the hardware and hand tightenlightly.

5. Reinstall the debris tray in the machine. SeeTO INSTALL DEBRIS TRAY instructions.

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SCRUB BRUSHES

The machine can be equipped with either disk orcylindrical scrub brushes. Check scrub brushesdaily for wire or string tangled around the brush orbrush drive hub. Also check for brush damageand wear.

DISC SCRUB BRUSHES

The disk brushes should be replaced if a largenumber of bristles are missing or if bristle length isless than 10 mm (0.38 in).

NOTE: Replace worn brushes in pairs. Scrubbingwith brushes of unequal bristle length will result indiminished scrubbing performance.

TO REPLACE DISC SCRUB BRUSHES

1. Raise the scrub head.

2. Turn the machine power off and set theparking brake.


3. Turn the brush until you can see the brushspring clip.

4. Press the brush spring clip together withyour thumb and index finger. The brush willdrop off of the brush drive hub. Pull thebrush out from under the scrub head.

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5. Place the new scrub brush on the floor infront of the scrub head. Push the brushunder the scrub head.

6. Line up the brush drive socket with the driveplug.

7. While pressing the brush spring clip togetherwith your thumb and index finger, lift thescrub brush onto the drive plug.

8. Check to make sure the brush is securelymounted on the brush drive hub.

9. Repeat for the other brush.

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CYLINDRICAL SCRUB BRUSHES

Check the brush taper and rotate the brushesfrom front-to-rear every 50 hours of machineoperation for maximum brush life and bestscrubbing performance.

The cylindrical brushes should be replaced if largeamounts of bristles are missing, or if theremaining bristle length is less than 10 mm(0.38 in).

NOTE: Replace worn brushes in pairs. Scrubbingwith brushes of unequal bristle length will result indiminished scrubbing performance.

NOTE: Fill the solution tank before checking oradjusting the brush pattern.

TO REPLACE CYLINDRICAL SCRUBBRUSHES

1. Press the scrubbing switch. When the scrubhead is approximately 25 mm (1 in) from thefloor, turn the machine power off.

2. Set the parking brake.


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3. Remove the cotter pin that holds the sidesqueegee in place. Swing the squeegeeaway from the scrub head.

4. Push downward on the mounting spring andidler door until the top of the door releasesfrom the scrub head. Pull the bottom of thedoor outward, then pull the idler door andidler plug off of the brush.

5. Pull the old brush out of the scrub head.

6. Position the brush with the double row endtowards you. Guide the new brush onto thedrive hub.

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7. Insert the Idler plug (on the inside of the idlerdoor), into the brush.

8. Push down on the door to catch the door inthe scrub head, then pull up on the door tolatch it into the spring.

9. Repeat for the other brush on the other sideof the scrub head.

NOTE: Each side of the scrub head is stampedwith a letter. The idler door of that side of thescrub head is stamped with the same letter. Makesure the letter on the door matches the letter onthe scrub head when replacing the doors.

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TO CHECK AND ADJUST CYLINDRICALBRUSH PATTERN

1. Apply chalk (or another material that will noteasily blow away), to a smooth, level sectionof the floor.

2. Set the parking brake.

3. Lower the scrub head in the chalked area.Allow the machine to scrub in the sameplace for 15 to 20 seconds.

NOTE: If chalk or other material is not available,allow the brushes to spin on the floor for twominutes. A polish mark will remain on the floor.

4. Raise the scrub head and move the machineaway from the chalked area. Turn themachine power off.

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5. Observe the shape of the brush patterns. Ifthe brush patterns have parallel sides, thebrushes do not need adjustment.

If one, or both of the brush patterns aretapered, the brushes need adjustment tostraighten the brush pattern.

1. To adjust brush taper, push downwardon the mounting spring and idler dooruntil the top of the door releases fromthe scrub head. Pull the bottom of thedoor outward, then pull the idler doorand idler plug off of the brush.

2. While holding the flat end of the idlershaft with a wrench, loosen themounting screw on the outside of theidler door.

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3. Turn the idler shaft to raise or lower theend of the brush as needed tostraighten the brush pattern. Tightenthe mounting screw.

4. Check the brush patterns again andreadjust as necessary until bothpatterns 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 headlinks. Both scrub head links should be adjustedequally.

Check the brush patterns again and readjust asnecessary until both patterns are the same.

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CYLINDRICAL BRUSH DRIVE BELT

The two brush drive belts are located onthe cylindrical brush scrub head. The belts drivethe cylindrical brushes. Proper belt tension is a3 mm (0.1 in) deflection from a force of1.1 to 1.2 kg (2.5 to 2.7 lb) at the belt midpoint.

Check and adjust the belt tension every 100 hoursof operation.

TO REPLACE BRUSH DRIVE BELT

1. Start the machine and lower the scrub headnear the floor. Shut off the key.


2. Remove the scrub brushes. See TOREPLACE CYLINDRICAL SCRUBBRUSHES instructions.

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3. Remove the two screws holding the beltcover to the scrub brush motor. Remove thebelt cover from the scrub head.

4. Loosen the two pivot bolts on the bottom ofthe brush motor.

5. Loosen the belt tension bolt under the brushmotor. Turn the bolt down far enough toallow the belt to be slipped off the motorpulley. Push the drive belt down toward thelower brush drive plug.

NOTE: Make sure the scrub head is slightly offthe floor before attempting to remove the driveplug rubber seal.

6. Cut the RTV sealant around the rubber seal.Use a needle nose pliers to remove it fromthe brush drive plug. Note the orientation ofthe seal. Remove the drive plug.

7. Remove the brush drive belt from themachine.

NOTE: It is a tight fit for the belt in the area of thelower belt cover and bottom drive plug. Carefullywork the belt past the lower cover----DO NOTremove the lower cover.

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8. Slip the new drive belt into position. Pushthe rest of the drive belt up toward the motorbelt pulley. Slip the drive belt over the motorbelt pulley.

9. Reinstall the brush drive plug. Install thedrive belt over the drive plug.

10. Reinstall the rubber seal on the drive plug.Note the orientation of the seal. UseRTV--Blue sealant all around the seal wheninstalling.

11. Use the tension bolt under the drive motor totighten the drive belt. Apply 2.5 -- 2.7 lbs offorce to the drive belt in the middle of thespan. The belt should deflect 0.10 inch.

12. Tighten the drive motor pivot bolts to18 -- 24 Nm (15 -- 20 ft lb). Re--checkthe belt tension.

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13. Reinstall the belt cover. Tighten the screwsto 11 -- 14 Nm (7 -- 10 ft lb).

14. Reinstall the scrub brushes. See TOREPLACE CYLINDRICAL SCRUBBRUSHES instructions.

15. Operate the machine and check the scrubbrushes for proper operation.

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MANUAL SOLUTION VALVE

The manual solution valve is located under thefloor plate on the left side of the machine. Thisvalve controls the amount of water being sent tothe scrub brushes. The control lever is located inthe operators compartment, next to the operatorsleft leg.

TO REPLACE SOLUTION VALVE

1. Drain the solution tank.

2. Lower the scrub head to the floor.


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3. Go under the machine on the left side.

4. Locate the manual solution valve above thescrub head.

5. Remove the cotter pin from the control leverrod where it attaches to the valve. Pop therod out of the mount hole.

6. Loosen the worm drive clamps holding thetwo solution hoses to the valve fittings. Pullthe hoses off the fittings.

7. Remove the two screws holding the valve tothe machine frame. Remove the manualvalve from the machine.

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8. Remove the fittings from the old valve andinstall in the new valve in the sameorientation.

9. Remove the lever from the old valve andinstall it on the new valve in the sameorientation.

10. Install the new valve on the machine. Handtighten the screws.

11. Reconnect the two solution hoses. Handtighten the worm drive clamps.

12. Place the control lever rod in the mount holeand install the cotter pin.

13. Operator the machine and check the watervalve for proper operation.

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SQUEEGEES

The rear squeegee assembly channels water intothe vacuum fan suction. The front blade channelsthe water, and the rear blade wipes the floor.

Check the squeegee blades for damage and weardaily. Rotate or replace either of the squeegeeblades if the leading edge is torn or worn half-waythrough the thickness of the blade.

The squeegee can be adjusted for leveling anddeflection. The deflection and leveling of thesqueegee blades should be checked daily, orwhen scrubbing a different type of floor.

The squeegee assembly can be removed fromthe squeegee pivot to prevent damage duringtransport of the machine.

TO REMOVE REAR SQUEEGEE ASSEMBLY

1. Lower the squeegee to approximately25 mm (1 in.) from the floor.



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3. Remove the squeegee suction hose fromthe squeegee.

4. Remove both squeegee mounting knobs.

5. Pull the squeegee off the machine.

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TO INSTALL REAR SQUEEGEE ASSEMBLY

1. Make sure the squeegee pivot is lowered.


2. Place the squeegee under the squeegeepivot.

3. Push the squeegee frame onto thesqueegee pivot.

4. Tighten the mounting knobs.

5. Push the squeegee suction hose onto thesqueegee fitting.

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TO LEVEL REAR SQUEEGEE

Leveling of the squeegee assures even contactfor the length of the squeegee blade with thesurface being scrubbed. Make sure thisadjustment is done on an even, level floor.


2. Lower the squeegee.

3. Drive the machine forward a few feet, thenset the parking brake.


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4. Look at the deflection of the squeegee overthe full length of the squeegee blade.

5. If the deflection is not the same over the fulllength of the blade, turn the squeegeeleveling knob to make adjustments.

The squeegee leveling knob is locateddirectly behind the squeegee suction hose.DO NOT disconnect the suction hose fromthe squeegee frame when levelingsqueegee.

--Turn the squeegee leveling knobcounter-clockwise to increase thedeflection at the ends of the squeegee.

--Turn the squeegee leveling knobclockwise to decrease the deflection atthe ends of the squeegee blade.

6. Drive the machine forward with thesqueegee down to check the squeegeeblade deflection.

7. Readjust the squeegee blade deflection ifnecessary.

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TO ADJUST REAR SQUEEGEE BLADEDEFLECTION

Deflection is the amount of curl the squeegeeblade has when the machine moves forward whilethe squeegee lowered to the floor. The bestdeflection is when the squeegee wipes the floorjust dry with a minimum amount of deflection.


2. Lower the squeegee.

3. Drive the machine forward, and look at thedeflection of the squeegee blade. Thecorrect amount of deflection is 12 mm(0.50in) for scrubbing smooth floors and 15 mm(0.62 in) for rough floors.

03719

12 mm(0.50 in)

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4. Turn the machine power off.

5. To adjust the amount of deflection, turn thesqueegee deflection cams clockwise todecrease the blade deflection.

NOTE: Turn the squeegee deflection camscounter--clockwise to increase blade deflection.

6. Drive the machine forward again to checkthe squeegee blade deflection.

7. Readjust the squeegee blade deflection ifnecessary.

03719

12 mm(0.50 in)

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REAR SQUEEGEE CASTERS

The rear squeegee casters each have two greasefittings. Lubricate the pivot point and casterbearing on each squeegee caster with LubriplateEMB grease (TENNANT part no. 01433--1) every50 hours.

TO ADJUST REAR SQUEEGEE GUIDEROLLER

On the left end of the squeegee is a guide rollerthat guides the squeegee blade end along a wall.Loosen the nut at the top of the guide roller andmove the roller in or out to adjust how close theend of the squeegee blade is to the wall. Thesqueegee blade end should be further away fromthe wall when the floor curves up into the wall.

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REAR SQUEEGEE BLADES

The rear squeegee has two squeegee blades, thefront and rear. Each blade has four wiping edges.To use them all, start with one wiping edge. Touse the next wiping edge, rotate the bladeend-for-end. To use the next wiping edge, rotatethe top edges down, bottom edges up. To use thelast edge, rotate the blade end-for-end. Rotatesqueegee blades when they become wornhalf--way through the thickness of the blade.

Replace damaged squeegee blades.

TO REPLACE OR ROTATE REARSQUEEGEE (REAR) BLADE

1. Make sure the squeegee is raised off thefloor.



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3. Loosen the two retainer knobs, one at eachend of the squeegee.

4. Pull off the rear retaining band.

5. Pull off the rear squeegee blade.

6. Insert the rotated or new squeegee bladeand then insert the retainer band.

7. Tighten the two retainer knobs until the endsof the front and rear squeegee blades touch.Do not over--tighten.

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TO REPLACE OR ROTATE REAR SQUEEGEE(FRONT) BLADE

1. Make sure the squeegee is raised off thefloor.

2. Turn the machine power off and set theparking brake if your machine has thisoption.


3. Remove the squeegee from the machine.See TO REMOVE SQUEEGEE ASSEMBLYinstructions.

4. Remove the rear squeegee blade andretainer. See TO REPLACE OR ROTATEREAR SQUEEGEE (REAR) BLADE.

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5. Loosen the two remaining knobs on top ofthe squeegee assembly.

6. Pull the retainer plate back and pull out thefront squeegee blade of the squeegeeframe.

7. Insert the rotated or new squeegee blade inthe squeegee frame, lining up the slots inthe blade with the tabs on the retainer plate.

8. Push the retainer plate forward. Tighten thetwo outside knobs on top of the squeegeeassembly.

9. Insert the rear squeegee blade and retainer.Tighten the two rear blade retainer knobsuntil the ends of the front and rear squeegeeblades touch. Do not over--tighten.

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10. Install the squeegee assembly on thesqueegee pivot. See TO INSTALLSQUEEGEE ASSEMBLY instructions.

11. Adjust the squeegee blade leveling anddeflection as stated in TO LEVELSQUEEGEE and ADJUST SQUEEGEEBLADE DEFLECTION instructions.

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REAR SQUEEGEE WHEEL CAMS

The squeegee wheel cams adjust the squeegeedeflection along the entire length of the squeegee.There is a wheel cams at either end of thesqueegee.

Increase deflection: Turn the camscounter-clockwise.

Decrease deflection: Turn the cams clockwise.

REAR SQUEEGEE LEVELING KNOB

The squeegee leveling knob adjusts the deflectionat the ends of the squeegee.

The squeegee leveling knob is located directlybehind the squeegee suction hose.

NOTE: DO NOT disconnect the suction hose fromthe squeegee frame when leveling squeegee.

Increase end deflection: Turn the squeegeeleveling knob counter-clockwise to increase thedeflection at the end of the squeegees.

Decrease end deflection: Turn the squeegeeleveling knob clockwise to decrease the deflectionat the end of the squeegees.

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TO REPLACE REAR SQUEEGEE LIFT CABLE

1. Lower the squeegee to the floor.

2. Make sure the solution tank is drained andthe tank clean out caps removed.


3. Remove the four hex screws holding theplastic, rear drain splash tray. Let it dropdown for access to the rear squeegee liftcable.

4. Locate the rear squeegee lift cable. Removethe cotter pin and clevis pin from the end ofthe lift cable where it attaches to the lift pivotbracket.

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5. Remove the cotter pin and long clevis pinfrom just behind the lift cable drum.

6. Remove the cotter pin and clevis pin fromthe end of the lift cable where it attaches tothe squeegee frame. Remove the cable fromthe machine.

7. Position the new cable in the machine. Startby attaching one end of the cable tosqueegee frame. Reinstall the clevis pin andcotter pin.

8. Attach the other end of the new lift cable tothe lift pivot bracket. Reinstall the clevis pinand cotter pin.

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9. Reinstall the long clevis pin and cotter pin inthe mount hole just behind the lift cabledrum.

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 rearsqueegee. Check the new cable for properoperation.

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SIDE SQUEEGEE BLADES

The side squeegees control water spray andchannel water into the path of the rear squeegee.Check the side squeegees for damage and weardaily.

Replace the side squeegee blades if they becomedamaged or lose their shape. Replace thesqueegee deflectors if they become worn.

CYLINDRICAL SCRUB HEAD

DISC SCRUB HEAD

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TO REPLACE SIDE SQUEEGEE BLADES

1. Raise the scrub head.



3. Remove the cotter pin, clevis pin, deflectorand the retainer bracket from the sidesqueegee.

4. Pull the squeegee out of the squeegeeframe.

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 otherside of the scrub head.

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VACUUM FAN

The vacuum fan, when activated, creates air flowin the recovery tank. With the recovery tank coverclosed, the air flow from the vacuum fan createsvacuum at the squeegee vacuum hose. Thisvacuum pulls water from the lowered squeegeeinto the recovery tank. The vacuum fan isequipped with a easily serviceable air filter.

TO REMOVE VACUUM FAN ASSEMBLY


1. Open the recovery/solution tank cover.

2. Locate the vacuum fan on the left, front ofthe recovery tank.

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3. Remove the two screws holding the vacuumfan to the top of the tank. Pull the vacuumfan assembly out of the top of the tank. Let itrest on the edge of the tank.

4. Disconnect the vacuum fan motor from themain electrical harness.

5. Remove the vacuum fan assembly from themachine. Be careful not to loose the rubberseal on the outlet of the vacuum housing.

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TO INSTALL VACUUM FAN ASSEMBLY


1. Open the recovery/solution tank cover.

2. Position the vacuum fan assembly on theedge of the recovery tank.

3. Connect the plug from the vacuum fan motorto the main electrical harness. Seeschematic in the ELECTRICAL section.

4. Drop the vacuum fan assembly straightdown into the tank mounting area. Makesure the rubber seal is in place on the outletof the vacuum housing.

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5. Install the two screws and tighten to18 -- 24 Nm (15 -- 20 ft lb).

6. Close the tank cover and operate themachine. Check the vacuum fan for properoperation.

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SCRUBBING TROUBLESHOOTING

Problem Cause RemedyTrailing water -- poor or no waterpickup

Worn squeegee blades Rotate or replace squeegeeblades

Squeegee out of adjustment Adjust squeegeeVacuum hose clogged Flush vacuum hosesVacuum fan inlet filter dirty Clean inlet filterDebris caught on squeegee Remove debrisVacuum hose to squeegee orrecovery tank disconnected ordamaged

Reconnect or replace vacuumhose

Tank cover not completely closed Check for obstructionsTank cover not completely closed Check for obstructionsTank cover not completely closed Check for obstructionsTorn seals on recovery tank Replace seals

Vacuum fan will not turn on Recovery tank full Drain recovery tankFoam filling recovery tank Empty recovery tankg y

Use less or change detergentUse a de--foamer

Vacuum fan circuit breakertripped

Reset circuit breaker

Little or no solution flow to thefloor

Solution tank empty Fill solution tank

Solution control rod broken or outof adjustment

Replace and/or adjust rod

Solution flow turned off Turn solution flow onSolution supply lines plugged Flush solution supply linesSolution solenoid clogged orstuck

Clean or replace

ESt mode (option): ESt switchoff

Turn ESt switch on

Poor scrubbing performance Debris caught on scrub brushes Remove debrisImproper detergent or brushused

Check with TENNANTrepresentative for advice

Worn scrub brush(es) Replace scrub brush(es)Scrub brush motor circuitbreaker(s) tripped

Reset circuit breaker(s)

Reduce scrub brush downpressureUneven brush pressure, levelscrub headBroken brush drive belts oncylindrical scrub head, replacebeltCheck with TENNANTrepresentative for advice

Low battery charge Charge batteries until the chargerautomatically turns off

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ELECTRICAL

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CONTENTS

PageINTRODUCTION 4-3. . . . . . . . . . . . . . . . . . . . . .

BATTERIES 4-4. . . . . . . . . . . . . . . . . . . . . . .CHARGING THE BATTERIES 4-5. . . .TO REPLACE BATTERIES 4-8. . . . . . .

INSTRUMENT PANEL 4-10. . . . . . . . . . . . .TO REPLACE TOUCH PANEL 4-10. . .

CONTROL PANEL 4-15. . . . . . . . . . . . . . . .TO ACCESS CONTROL PANEL 4-15.TO REPLACE CIRCUIT BOARD 4-17.

CIRCUIT BREAKERS 4-20. . . . . . . . . . . . . .RESETABLE CIRCUIT

BREAKERS 4-20. . . . . . . . . . . . . . . . .TO REPLACE CIRCUIT

BREAKER 4-21. . . . . . . . . . . . . . . . . .FUSES 4-24. . . . . . . . . . . . . . . . . . . . . . . .TO REPLACE FUSE 4-24. . . . . . . . . . . .

DIRECTIONAL CONTROL PEDAL 4-26. .TO REPLACE MOTOR

CONTROLLER 4-27. . . . . . . . . . . . . .TO REPLACE TAILLIGHT BULB 4-29. . . .ELECTRIC MOTORS 4-30. . . . . . . . . . . . . .

TO REPLACE DRIVE MOTOR 4-30. . .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 LIFTACTUATOR 4-42. . . . . . . . . . . . . . . . .

TO REPLACE REAR SQUEEGEELIFT ACTUATOR 4-46. . . . . . . . . . .

ESt PUMP 4-49. . . . . . . . . . . . . . . . . . . . . .TO REPLACE ESt PUMP

(early machines) 4-49. . . . . . . . . . . . .TO REPLACE ESt PUMP

(later machines) 4-53. . . . . . . . . . . . .SOLUTION SOLENOID VALVE 4-56. . . . .

TO REPLACE SOLUTIONSOLENOID 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. . . . . . . . . . . . . . .

PageOPERATING MODES 4-69. . . . . . . . . . . . . .

NORMAL MODE 4-70. . . . . . . . . . . . . . .SCRUB BUTTON 4-70. . . . . . . . . . . .SQUEEGEE BUTTON 4-71. . . . . . .ESt BUTTON 4-71. . . . . . . . . . . . . .OVERFLOW FLOAT 4-71. . . . . . . . .BATTERY GAUGE 4-72. . . . . . . . . . .HOUR METER 4-72. . . . . . . . . . . . . .

INTERLOCKS 4-72. . . . . . . . . . . . . . . . . .SELF TEST MODE 4-74. . . . . . . . . . . .SELF TEST ERROR CODES 4-76. . . .ACTUATOR GROUP, SQUEEGEE

BUTTON PRESSED 4-76. . . . . . . . .BRUSH MOTOR GROUP, SCRUB

BUTTON PRESSED 4-76. . . . . . . . .ACCESSORY OUTPUT GROUP

ESt BUTTON PRESSED 4-76. . . .MANUAL MODE 4-77. . . . . . . . . . . . . . .

SCRUB BUTTON 4-77. . . . . . . . . . . .SQUEEGEE BUTTON 4-77. . . . . . .ESt BUTTON 4-77. . . . . . . . . . . . . .

INTERLOCKS 4-78. . . . . . . . . . . . . . . . . .SCRUB BRUSH OPERATION 4-78. . . .SQUEEGEE AND VACUUM FAN

OPERATION 4-78. . . . . . . . . . . . . . . .ESt AIR FLUSH OPERATION 4-79. . .ESt PUMP OPERATION 4-79. . . . . . .INPUT DISPLAY MODE 4-80. . . . . . . . .TROUBLESHOOTING 4-83. . . . . . . . . .

POWER UP TESTING 4-84. . . . . . . . . . . . .PROPEL 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 LEDDIAGNOSTICS 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. . . . . . . . . . . . . . . .ESt SYSTEM 4-106. . . . . . . . . . . . . . . . . . .ESt FILTER FLUSH SYSTEM 4-109. . . .

ELECTRICAL

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ELECTRICAL

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INTRODUCTION

The machines electrical system consists of thebatteries, instrument panel, drive motor,actuators, switches, relays, and circuit breakers.

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BATTERIES

The batteries are designed to hold their power forlong periods of time. The lifetime of the batteriesis limited to number of charges the batteriesreceive. To get the most life from the batteries,recharge them immediately when the batterydischarge indicator begins to blink.

After every 200 hours of use check for loosebattery connections and clean the surface of thebatteries, 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 thebatteries. Use a wire brush to clean the terminalposts and the cable connectors. Wipe off allcleaning solution residue. After cleaning, apply acoating of clear battery post protectant to theterminals and the cable connectors. Keep the topsof the batteries clean and dry.

Objects made of metal can potentially short circuitthe batteries. Keep all metallic objects off thebatteries. Replace any worn or damaged wires.

Check the electrolyte level in each battery cellbefore and after charging, and after every 50hours of operation. Do not charge the batteriesunless the fluid is slightly above the battery plates.If needed, add just enough distilled water to coverthe plates. Never add acid to the batteries. Do notoverfill. Always keep the battery caps on, exceptwhen adding water or taking hydrometer readings.

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Using a hydrometer, measure the specific gravityto determine the charge level and condition of thebatteries. If one or more of the battery cells testlower than the other battery cells (0.050 or more),the cell is damaged, shorted, or is near failure.Completely recharge the batteries, then retestthem.

NOTE: Do not take readings immediately afteradding distilled water. If the water and acid are notthoroughly mixed, the readings may not beaccurate. Check the hydrometer readings againstthe following chart to determine the remainingbattery charge level:

SPECIFIC GRAVITY BATTERYat 27_ C (80_F) CHARGE

1.265 100% Charged

1.223 75% Charged

1.185 50% Charged

1.148 25% Charged

1.110 Discharged

NOTE: If the readings are taken when the batteryelectrolyte is any temperature other than 27 C (80F), the reading must be temperature corrected.Add or subtract to the specific gravity reading0.004, 4 points, for each 6 C (10 F) above orbelow 27 C (80 F).

CHARGING THE BATTERIES

1. Drive the machine to a flat, dry surface.

NOTE: Make sure the area is well ventilated.


FOR SAFETY: Before leaving orservicing machine, stop on levelsurface, set parking brake, turn offmachine, and remove key.

3. Lift the operator seat to access the batteries.The support arm automatically engageswhen the seat is lifted all the way up.

4. Check the water level in all battery cells.

04380

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If the level is low, add just enough distilledwater to cover the plates. DO NOTOVERFILL. The batteries can overflowduring charging due to expansion.

NOTE: Make sure the battery caps are in placewhile charging.

FOR SAFETY: When maintaining orservicing machine, avoid contact withbattery acid.

5. Unplug the machine connector from thebatteries.

6. Plug the charger connector into the batteryconnector.

WARNING: Batteries emit hydrogengas. Explosion or fire can result. Keepsparks and open flame away. Keepcovers open when charging.

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7. Plug the battery charger into the wall outlet.

NOTE: If the red “ABNORMAL CYCLE” lamplights when the TENNANT charger is plugged intoa wall outlet, the charger cannot charge thebattery and there is something wrong with thebattery.

8. The TENNANT charger will startautomatically. When the batteries are fullycharged, the TENNANT charger willautomatically turn off.

9. After the charger has turned off, unplug thecharger from the wall outlet.

10. Unplug the charger connector from thebattery connector on the machine.

FOR SAFETY: When maintaining orservicing machine, avoid contact withbattery acid.

11. Connect the battery connector to themachine connector.

12. Check the electrolyte level in each batterycell after charging. If needed, add distilledwater to raise the electrolyte level to about12 mm (0.4 in) below the bottom of the sighttubes.

13. Lower the seat support by slightly raising itwhile pushing the support arm inward.

07224

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TO REPLACE BATTERIES

1. Drive the machine to a flat, dry surface.

NOTE: Make sure the area is well ventilated.




4. Un--plug the battery connector from in frontof the solution tank.

FOR SAFETY: Disconnect BatteryConnections Before Working Onmachine.

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5. Pull the rubber battery cable boots back toaccess the cable end nuts.

6. Remove all of the battery cables.

7. Use the built--in straps to lift and removeeach battery.

8. Use a solution of baking soda and water toclean the battery compartment area.

9. Install the new batteries in the sameorientation as the old batteries.

10. Reconnect all of the battery cables.

11. Check the batteries and charge if necessary.See TO CHARGE BATTERIES instructions.

12. Reconnect the battery connector at the frontof the solution tank.

13. Lower the seat support and operate themachine. Check for proper operation.

--

+

-- +

--+

--

+

--

+

--+

FRONT OFMACHINE

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INSTRUMENT PANEL

The instrument panel consists of a touch panel,circuit board, switches, and circuit breakers. Thetouch panel controls various machine functions.The indicator lights keep the operator informed onmachine performance.

TO REPLACE TOUCH PANEL


1. Open the control panel. See TO ACCESSCONTROL PANEL instructions.


2. Locate the circuit board cover on the inside,front wall of the steering support, behind thecontrol panel.

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3. Remove the six nuts holding the circuitboard cover onto the frame.

4. Pull the circuit board cover back to accessthe circuit board.

5. Un--plug the two ribbon cables from thecircuit board.

6. Locate the four touch panel lock clips on theunder side of the dash panel. Remove thelock clips.

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7. Pull the touch panel bezel up and removefrom the machine.

8. Remove the touch panel from the machine.

NOTE: Be careful when removing the ribboncables from the slot in the dash panel.

9. Position the new touch panel on themachine. Route the ribbon cable through theslot in the dash panel.

10. Place the touch panel bezel over the touchpanel. Line up the posts on the bezel withthe mount holes in the dash panel.

11. Install the four lock clips on the bezel posts.

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12. Connect the ribbon cables to the circuitboard.

13. Position the circuit board cover back up tothe inside, front wall of the steering support,behind the control panel.

14. Reinstall the six nuts on the circuit breakercover. Hand tighten lightly.

15. Pivot the control panel back in position.Reinstall the two screws and tighten to18 -- 24 Nm (15 -- 20 ft lb).

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16. Lift the operator seat and reconnect thebattery connector at the front of the solutiontank.

17. Close the seat support. Start the machineand check for proper operation.

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CONTROL PANEL

The control panel houses the directionalcontroller, relays, contactors, and fuses. Thesecomponents can be accessed by pivoting thecontrol panel mount plate down against the seatsupport.

TO ACCESS CONTROL PANEL



2. Un--plug the battery connector from in frontof the solution tank.


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3. Lower the seat support.

4. Remove the two screws at the top of thecontrol panel mount plate.

5. Pivot the mount plate down until it is restingagainst the seat support.

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TO REPLACE CIRCUIT BOARD




2. Locate the circuit board cover on the inside,front wall of the steering support, behind thecontrol panel.

3. Remove the six nuts holding the circuitboard cover on the frame.

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4. Pull the circuit board cover back to accessthe circuit board.

5. Un--plug the two ribbon cables from thecircuit board.

6. Un--plug the three wire connectors from thecircuit board.

7. Pop the circuit board off the six plasticstand--offs. Remove the circuit board fromthe machine. Note the orientation of thecircuit board.

8. Position the new circuit board on the sixplastic stand--offs. Gently push the boarddown until the stand--off snaps in place.

9. Reconnect the three wire connectors andtwo ribbon cables to the new circuit board.See schematic in this section.

10. Position the circuit board cover back up tothe inside, front wall of the steering support,behind the control panel.

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11. Reinstall the six nuts on the circuit boardcover. Hand tighten lightly.




ELECTRICAL

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CIRCUIT BREAKERS

RESETABLE CIRCUIT BREAKERS

Circuit breakers are resetable electrical circuitprotection devices designed to stop the flow ofcurrent in the event of a circuit overload. Once acircuit breaker is tripped, reset it manually bypressing the reset button after the breaker hascooled down.

If the overload that caused the circuit breaker totrip is still present, the circuit breaker will continueto stop current flow until the problem is corrected.

The circuit breakers are located on the operatorconsole.

The chart below shows the circuit breakers andthe electrical components they protect.

CircuitBreaker Rating Circuit Protected

CB1 10 A Machine power

CB2 10 A Battery dischargeindicator

CB3 15 A Head lights

CB4 10 A Power wand

CB5 10 A Horn

CB6 10 A Instrument panel

CB7 20 A Vacuum Fan

CB7 40 A Heavy duty vacuum fan

CB8 25 A Scrub brush motor

CB9 25 A Scrub brush motor

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TO REPLACE CIRCUIT BREAKER




2. Locate the circuit breakers on the upperedge of the control panel.

3. Locate the circuit breaker that needschanging.

4. Disconnect the wires from the back of circuitbreaker.

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5. Remove the metal lock ring from the circuitbreaker. The lock ring may have to be cut toremove, or, remove the two screws holdingthe CB to the panel.

6. Push the circuit breaker out of the mounthole, or, remove the CB from the back ofpanel.

7. Remove the rubber boot from the old circuitbreaker and install it on the new circuitbreaker. (lower amp only)

8. Position the new circuit breaker in the mounthole. Note that the circuit breaker and mounthole are ”D” shaped. The circuit breaker canonly be installed one way. (lower amp only)

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9. Install the new lock ring on the new circuitbreaker, or, reinstall the two screws. Handtighten.

10. Reconnect the wires to the back of the newcircuit breaker. See the schematic in thissection.




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FUSES

The fuse is a one-time protection device designedto stop the flow of current in the event of a circuitoverload.

NOTE: Always replace the fuse with a fuse of thesame amperage.

The fuse is located behind the operator console.Access the fuse by lowering the operator console.

Fuse Rating Circuit Protected

FU-1 80 A Propelling

TO REPLACE FUSE




2. Locate the electrical fuse on the bottom, leftside of the control panel.

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3. Loosen both bolts holding the two powercables to the top and bottom of the fuse andred stand--offs.

4. The fuse has slots on the top and bottom.Slide the fuse up and to the side andremove.

5. Position the new fuse on the two redstand--offs, under the two bolts and powercables. Hand tighten the hardware. See theschematic in this section.



8. Start the machine and check for properoperation.

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DIRECTIONAL CONTROL PEDAL

The directional pedal controls the machine’sdirection of travel and propelling speed. Themachine’s speed is controlled by the amount ofpressure placed on the pedal; the farther thepedal is pressed, the faster the machine willtravel.

When the machine is moving forward and thedirectional pedal is reversed, the machine willcoast for a short distance before changingdirection. Use the brake pedal to stop themachine.

Forward: Press the top of the directionalpedal with the upper part of your foot.

NOTE: A machine power shut--off switch islocated under the operator seat. If there is noweight on the operator seat, the machine WILLNOT propel in any direction.

Reverse: Press the bottom of thedirectional pedal with the heel of your foot.

NOTE: When the directional pedal is placed intothe reverse position, the rear squeegee willautomatically raise. After a short delay, thevacuum will stop.

Neutral: The machine will automaticallyreturn to the Neutral position when you takeyour foot off of the directional pedal.

NOTE: When the directional pedal returns to theneutral position the scrub head will stop. After ashort delay, the scrub head will also raise.

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TO REPLACE MOTOR CONTROLLER




2. Locate the controller box in the center of thecontrol panel.

3. Disconnect the wires and power cablesleading to the controller.

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4. Remove the three screws and nuts holdingthe controller to the panel. Remove thecontroller from the machine.

5. Position the new controller on the panel.Reinstall the screws and nuts. Hand tighten.

6. Reconnect the power cables and electricalwires to the controller. See the schematic inthis section.


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9. Start the machine and check for properoperation of the propelling.

TO REPLACE TAILLIGHT BULB

1. Drain the tanks, then remove tank draincaps.

2. Loosen the bottom screws holding the driptray.

3. Rotate the tray outward from the bottom.This allows access to the taillight assembly.

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ELECTRIC MOTORS

The carbon brushes on the vacuum fan motorshould be inspected after every 500 hours ofmachine operation. The carbon brushes on thescrub brush motors and propelling motor shouldbe inspected after every 1000 hours of machineoperation.

TO REPLACE DRIVE MOTOR





3. Mark and remove the four electrical cablesleading to the drive motor.

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4. Remove the 4 hex screws holding theelectric drive motor to the drive assemblyouter plate. Remove the drive motor.

NOTE: When installing the motor on the driveassembly, make sure the terminals are pointing upand slightly forward for proper electrical cableinstallation.

5. Install the new electric motor on the driveassembly.

NOTE: Make sure to line up the splines on themotor shaft with the splines of the planetary gearbox.

6. Tighten the 4 hex screws to 18 -- 24 Nm(15 -- 20 ft lb).

7. Reconnect the electrical cables to the drivemotor. See the schematic in this section.



10. Drive the machine and check the new drivemotor for proper operation.

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TO REPLACE DISC SCRUB HEAD BRUSHMOTOR


1. Remove the side squeegees. See TOREPLACE SIDE SQUEEGEE BLADESinstructions in the SCRUBBING section.

2. Remove the scrub brushes. See TOREPLACE DISC SCRUB BRUSHESinstructions in the SCRUBBING section.

3. Go in under the scrub head and remove thescrew and washer from the center of thebrush drive plug.

4. Drop the drive plug down off the motor shaft.Make sure to retain the square key.

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5. Remove the four screws holding the brushmotor 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 anddisconnect the scrub brush motor from themain harness. Note the orientation of wire tomotor.

8. Lift the brush motor off the deck of the scrubhead and remove it from the machine. Notethe orientation of the brush motor powercable. The new motor must be orientatedthe same direction.

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9. Position the new motor on the scrub head.

10. Reconnect the motor wires to the mainelectrical harness. See schematic in thissection.

11. Start the machine and raise the scrub head.Shut off the key.

12. Rotate the brush motor until it is orientatedproperly and the mount holes line up withthe holes in the deck of the scrub head.Install the four screws and tighten to11 -- 14 Nm (7 -- 10 ft lb).

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4-357200 330045 (10--99)

13. Install the square key and drive plug on thebrush motor shaft. Install the screw andwasher in the center of the drive plug.Tighten to 18 -- 24 Nm (15 -- 20 ft lb).

14. Reinstall the scrub brush. See TOREPLACE DISC SCRUB BRUSHESinstructions in the SCRUBBING section.

15. Reinstall the side squeegees. See TOREPLACE SIDE SQUEEGEE BLADESinstructions in the SCRUBBING section.

16. Start the machine and operate the scrubbingfunction. Check for proper operation androtation of the new motor.

FRONT OF MACHINE

SCRUB BRUSH ROTATION

ELECTRICAL

4-36 7200 330045 (10--99)

TO REPLACE CYLINDRICAL SCRUB HEADBRUSH MOTOR


1. Remove the side squeegees. See TOREPLACE SIDE SQUEEGEE BLADESinstructions in the SCRUBBING section.

2. Remove the scrub brushes. See TOREPLACE DISC SCRUB BRUSHESinstructions in the SCRUBBING section.

3. Start the machine and lower the scrub head.Shut off the key.

ELECTRICAL

4-377200 330045 (10--99)

4. Go in on top of the scrub head anddisconnect the scrub brush motor from themain harness. Note the orientation of wire tomotor.

5. Loosen the front and rear pivot mount boltson the brush motor.

6. Remove the two screws holding the brushmotor belt cover to the brush motor.Remove the belt cover from the scrub head.

7. Loosen the jam nut on the belt tension boltunder the brush motor. Turn the tension boltdown far enough to slip the the belt off thecogged pulley.

ELECTRICAL

4-38 7200 330045 (10--99)

8. Remove the two screws holding the brushmotor to the pivot bracket. Remove thebrush motor from the machine.

9. Loosen the set screws holding the coggedpulley to the brush motor shaft. Slide thepulley off the shaft.

NOTE: Do not loose the square key.

10. Install the cogged pulley and square keyonto the shaft of the new brush motor.

NOTE: Leave the set screws loose for now.

11. Position the new brush motor on the scrubhead. Align the mounting holes on the motorwith the holes in the pivot mount bracket.Install the two screws. Snug the hardwarefor now.

12. Slip the brush belt over the cogged pulley.

ELECTRICAL

4-397200 330045 (10--99)

13. Align the top pulley with the bottom driveplug. Make sure the belt is in the center ofthe top pulley. Tighten the set screws tight.

NOTE: Use loctite 242 blue on the threads.

14. Use the hex screw under the brush motor totension the belt. Apply 2.5--2.7 lbs. of forceat the middle of the span that is oppositebelt travel.

NOTE: There should be 0.10 inch of deflection.

15. Tighten the two motor pivot screws to18 -- 24 Nm (15 -- 20 ft lb). Re--check thebelt tension.

16. Reconnect the brush motor into the mainharness.

NOTE: See schematic in this section.

ELECTRICAL

4-40 7200 330045 (10--99)

17. Reinstall the belt cover. Tighten the screwsto 11 -- 14 Nm (7 -- 10 ft lb). Apply a smallamount of RTV sealant on the flange of thebelt cover to keep dust out of the cogs of thebelt.

18. Reinstall the scrub brushes. See TOREPLACE CYLINDRICAL SCRUBBRUSHES instructions in the SCRUBBINGsection.

19. Operate the machine and check the scrubbrush motor for proper operation.

ELECTRICAL

4-417200 330045 (10--99)

LIFT ACTUATORS

The lift actuators are electric devices that, with apush of a switch, raise and lower either the scrubhead or the rear squeegee.

ELECTRICAL

4-42 7200 330045 (10--99)

TO REPLACE SCRUB HEAD LIFT ACTUATOR

1. Start the machine and lower the scrub headto the floor. Shut off the machine.


2. Go in on top of the scrub head and removethe cotter pin and clevis pin from the bottomof the scrub head lift actuator tube.

3. Go into the operators compartment andlocate the two screws holding the liftactuator mount bracket to the front of theseat support. Remove the two screws.

4. Raise the seat support and unplug thebattery connector.


ELECTRICAL

4-437200 330045 (10--99)

5. Tie the seat up. Remove the screw holdingthe seat prop rod to the bottom of the seatsupport. Remove the prop rod from the lockslot.

6. Locate the lift actuator spring mount bracket.Remove the two screws holding the mountbracket to the actuator mount assembly.

7. Lift the actuator and spring mount bracketout of the assembly and remove from themachine.

8. Remove the cotter pin and clevis pin holdingthe actuator to the bottom of the springmount bracket. Remove the actuator. Notethe orientation of the actuator on thebracket.

ELECTRICAL

4-44 7200 330045 (10--99)

9. Position the new actuator on the springmount bracket. Install the clevis and cotterpins.

10. Position the new actuator and spring mountbracket in the machine. Slide the assemblydown the into the mount bracket. Route thewires and plug in the connector. Make surethe wires are located in the slot on the of theactuator bracket before installing the springmount bracket.

11. Reinstall the two screws in the spring mountbracket. Leave loose for now.

12. Go around to the front of the seat supportand install the two screws that hold the frontof the spring mount bracket to the seatsupport. Tighten all four screws to18 -- 24 Nm (15 -- 20 ft lb).

ELECTRICAL

4-457200 330045 (10--99)

13. Reinstall the prop rod in the bracket and onthe bottom of the seat support. Snug thescrews and nut so the rod can still pivot.

14. Go in on top of the scrub head and installthe clevis and cotter pin in the bottom of thescrub head lift actuator tube and scrub headlift bracket.

15. Raise the seat support and plug in thebattery connector. Lower the seat assembly.

16. Operate the machine and check the scrubhead lift actuator for proper operation.

ELECTRICAL

4-46 7200 330045 (10--99)

TO REPLACE REAR SQUEEGEE LIFTACTUATOR

1. Start the machine and lower the rearsqueegee. Shut off the machine.


2. Disconnect the squeegee lift actuator fromthe main electrical harness.

3. Locate the four screws holding thesqueegee mount channel to the back of themachine.

4. Remove the four screws. Let the squeegeemount channel and squeegee assemblydrop down to access the lift actuator.

5. Remove the long hex screw and nyloc nutfrom the motor end of the lift actuator.

ELECTRICAL

4-477200 330045 (10--99)

6. Remove the cotter pin and clevis from thetube end of the lift actuator.

7. Remove the actuator from the machine.

8. Position the new actuator on the squeegeeweldment and the tube end into the pivotweldment.

9. Reinstall the hex screw and nut in the motorend of the lift actuator.

10. Reinstall the cotter pin and clevis in the tubeend of the lift actuator.

ELECTRICAL

4-48 7200 330045 (10--99)

11. Position the squeegee mount channel andsqueegee assembly back into position onthe back of the machine frame. Reinstall thefour screws. Tighten to 37 -- 48 Nm(26 -- 34 ft lb).

12. Reconnect the squeegee lift actuator to themain electrical harness. See schematic inthis section.

13. Start the machine and check the rearsqueegee actuator for proper operation.

ELECTRICAL

4-497200 330045 (10--99)

ESt PUMP

The ESt pump is used to transfer filtered waterfrom the recovery tank to the solution tank. Withthe ESt system activated, float switches inthe recovery tank and solution tank are used toturn the pump on and off automatically.

TO REPLACE ESt PUMP(early machines)


1. Make sure the solution and recovery tanksare empty.

2. Remove the vacuum fan assembly. See TOREMOVE VACUUM FAN ASSEMBLYinstructions.

ELECTRICAL

4-50 7200 330045 (10--99)

3. Locate the ESt pump under the vacuumfan.

4. Remove the two screws holding the EStpump mount plate to the recovery tank. Pullthe pump and plate assembly up far enoughto access the hoses and wires.

5. Disconnect the ESt pump from the mainelectrical harness.

6. Loosen the worm drive clamps holding thesolution hoses to the ESt pump. Pull thehoses off the pump fittings.

7. Pull the ESt pump assembly out of themachine.

ELECTRICAL

4-517200 330045 (10--99)

8. Remove the three screws holding the EStpump to the mount plate. Remove the pump.

9. Remove the plastic fittings from the oldpump and install in the new pump in thesame orientation.

10. Install the new ESt pump on the mountplate. Hand tighten the hardware.

11. Position the pump assembly in the tankarea. Place both solution hoses on the pumpfittings. Hand tighten the worm drive clamps.

12. Reconnect the pump to the main electricalharness. See schematic in this section.

ELECTRICAL

4-52 7200 330045 (10--99)

13. Line up the mount plate with the holes in therecovery tank. Reinstall the hardware andtighten to 18 -- 24 Nm (15 -- 20 ft lb).

14. Reinstall the vacuum fan assembly. See TOINSTALL VACUUM FAN ASSEMBLYinstructions.

15. Operate the machine and check the EStpump for proper operation.

ELECTRICAL

4-537200 330045 (10--99)

TO REPLACE ESt PUMP(later machines)


1. Make sure the solution and recovery tanksare empty.

2. Remove the vacuum fan assembly. See TOREMOVE VACUUM FAN ASSEMBLYinstructions.

3. Locate the ESt pump under thesolution/recovery tanks, behind the rearsqueegee mount frame.

ELECTRICAL

4-54 7200 330045 (10--99)

4. Disconnect the ESt pump from the mainelectrical harness.

5. Loosen the worm drive clamps holding thesolution hoses to the ESt pump. Pull thehoses off the pump fittings.

6. Loosen the large worm drive clamp holdingthe pump to the bracket.

7. Pull the ESt pump assembly out of themachine.

8. Remove the plastic fittings from the oldpump and install in the new pump in thesame orientation.

ELECTRICAL

4-557200 330045 (10--99)

9. Install the new ESt pump on the mountbracket. Reinstall the large worm driveclamp and hand tighten tight.

10. Place both solution hoses onto the pumpfittings. Hand tighten the worm drive clamps.

11. Reconnect the pump to the main electricalharness. See schematic in this section.

12. Reinstall the vacuum fan assembly. See TOINSTALL VACUUM FAN ASSEMBLYinstructions.

13. Operate the machine and check the EStpump for proper operation.

ELECTRICAL

4-56 7200 330045 (10--99)

SOLUTION SOLENOID VALVE

The solution solenoid valve is used to start andstop the flow of water to the scrub head when themachine is either propelling forward or in neutral.This valve is used along with the manual valve,which controls the amount of water that flows tothe 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.


ELECTRICAL

4-577200 330045 (10--99)

3. Go under the machine on the left side, infront of the rear tire.

4. Locate the solution solenoid valve in thearea of the manual valve.

5. Mark and disconnect the wires leading to thesolenoid valve.

6. Loosen the two worm drive clamps holdingthe water hoses to the valve. Mark thehoses and pull them off the fittings.

ELECTRICAL

4-58 7200 330045 (10--99)

7. Remove the two screws holding the valve tothe machine frame. Remove the valve fromthe machine.

8. Position the new solenoid valve in themachine. Reinstall the hardware and lightlyhand tighten.

9. Re--connect the two water hoses to the newvalve. Hand tighten the two worm driveclamps.

10. Re--connect the wires to the new solenoidvalve. See schematic in the section.

11. Start the machine and operate. Check thenew valve for proper operation.

ELECTRICAL

4-597200 330045 (10--99)

VACUUM FAN

The vacuum fan, when activated, creates air flowin the recovery tank. With the recovery tankclosed, the air flow from the vacuum fan createsvacuum at the squeegee vacuum hose. Thisvacuum pulls water from the lowered squeegeeinto the recovery tank.

The vacuum fan is equipped with a easilyserviceable air filter.

ELECTRICAL

4-60 7200 330045 (10--99)

TO REPLACE VACUUM FAN


1. Remove the vacuum fan assembly from themachine. See TO REMOVE VACUUM FANASSEMBLY instructions in the SCRUBBINGsection.

NOTE: Make sure to note the position of thevacuum fan exhaust outlet when removing the fanfrom the housing.

2. Remove the three screws and bracketsholding the vacuum fan to the plastichousing. Remove the vacuum fan.

NOTE: Make sure to install a gasket on thebottom of the new fan.

3. Position the new fan on the housing in thesame orientation as the old fan.

ELECTRICAL

4-617200 330045 (10--99)

4. Reinstall the three screws and brackets.Tighten the hardware only until the gasketstarts to compress.

NOTE: On a machine equipped with the HDvacuum fan option, there is two fans and threeadded brackets and screws.

5. Reinstall the vacuum fan assembly in themachine. See TO INSTALL VACUUM FANASSEMBLY instructions in the SCRUBBINGsection.

ELECTRICAL

4-62 7200 330045 (3--02)

ELECTRICAL SCHEMATIC (000000--008237)

1 2 73 4 5 6 8350764 -- ALL

ELECTRICAL

4-637200 330045 (3--02)

ELECTRICAL SCHEMATIC (000000--008237)1 2 3 4 5 6 7 8

350764 -- ALL

ELECTRICAL

4-64 7200 330045 (3--02)

ELECTRICAL SCHEMATIC (008238-- )

BATTERIES

62D/BLU

64B/PUR

62B/BLU

66B/GRN

66A/GRN

13AH/BLK

13AJ/BLK

64/PUR

15--20AMPS

PERMOTORDN.

PRESS.#4

13DD/BLK

13EE/BLK

64D/PUR

62A/BLU

64A/PUR

4/YEL

4A/YEL

64C/PUR

62C/BLU

27D/GRN

27/GRN

27E/GRN

13AK/BLK

13D/BLK

88/BLK 87/CLR

13AA/SHIELD

27A/GRN29/GRY

28/BRN

13M/BLK

13AV/BLK

31/YEL

27B/GRN

6/BLU 35/GRN

5/BRN

8/BLU 25/GRY

26/ORA

27C/GRN

11/BRN

22A/BRN

22A/BRN

22/BRN

BRUSHMOTOR

FAULTSENSE

LINE

BRUSHMOTOR

FAULTSENSE

LINE

13A/BLK

13B/BLK

13C/BLK

13S/BLK

13R/BLK

13Q/BLK

14/GRY

23/GRN

24/GRY

6B/BL U

13M/BLK

7/PUR1B/RED

1A/RED

2/ORA

3/GRY

3A/GRY

3B/GRY

13AG/BLK

13AF/BLK

13AB/BLK

13AC/BLK

+36VDC

GROUND

17AMPS

PER

MOTOR SHUNT HARNESS

FOR OPT. DISK BR. HEAD

CLOSED

=VAC/SQGE

DISABLED

(ESOPTION)

CLOSED

=ES

ENABLED

(ESOPTION)

CLOSED

=ES

OFF

SHUNTASSEMBLY222835

50A/TANGND’D

=SW

EEPER

ENABLED--

DISK

SCRUBBER

MACHINE

OPTIONONLY

12/GRN

32C/ORA

27F/GRN

WHT

BLK

42/BRN

93A/ORA

28B/BRN

29A/GRY

28A/BR N

43/ORA

50A/TAN

13T/BLK

10C/YEL

10F/YE L10B/YEL

10D/YEL

25A/GRY

10A/YEL

6A/BL U

43/ORA

GND’D

=SW

EEPER

ENABLED--

DISK

SCRUBBER

MACHINE

OPTIONONLY

DISK

SCRUBBER

MACHINE

OPTIONONLY

M2B

CB--7

20/40A

M3B

FU--1

80A(100Aw/SWEEPER

UNIT)

M1B

MAIN

S--3

SEAT SWITCH

S--2

EMERGENCYSW

.

x=CLOSED

CONTACT

START

RUN

OFF

XXX

X

X

S--1

KEYSW

50 83 15 75

30

CB--1

10A

D--1

CB--2

10A

M2A

VACFAN

+--

CB--9

25A

MTR

MTR

LEFTBRUSHMOTOR

A(B)

B(A)

0--5VDC

BLK

POTLOWORA

GROUND

W/BRN

+36V

=FW

DWHT

+36V

=REVB/WHT

+36VDC

GRN

THROTTLE

CURTIS ET--103

ABCFDE

D--8

MTR

RIGHTBRUSHMOTOR

AB

D--6

CN.O.

S--9

SOLUTIONTANK

FULL

AB

BAB A

D--7

VACFANS

MTR

CB--8

25A

D--4

D--3

M1A

MAIN

+--

CN.O.

S--4

REC.TANK

FULL

AB

D--2

CN.O.

S--5

REC.TANK

1/2FULL

AB

M6A

BACK--UPALARM(OPTION)

8586

TRACTIONMOTOR

ARM

A1A2

D--12

D--9

cable--shldCA1

FIELD

TRACTIONMOTOR

F2F1

LOWSPEED

ENABLE

CURTISPMC

1242--4208

PROPELMOTORCONTROLLER

B+

S2

M--

B--

P11

P2

P3

P15

P6

P7

P14

P16

P12

S1

P4

P5

P8

P10

P13

P9

CB--6

15A

SHUNTHIGH

SHUNTLOW

SHIELD

POWER

GND

POWER

GND

CNTRLGND

REC.TANK

FULL

REC.TANK

1/2FULL

SOL.TANK

FULL

VACFAN

+36VDC

--CONTROL

+36VDC

--POWER

BATT.SENSE

BRUSHMTR

FAULT

SENSE

+36VDC

--POWER

PULL--UP

RESISTOR

PULL--DNRESISTOR

REV

SENSE

PULL--DNRESISTOR

FWD

SENSE

CTRL2ELECTRONICCONTROLCIRCUITBOARD

SWEEPSYSTEM

SENSE

P3--2

P3--3

P3--7

P3--8

P3--12

P4--1

P4--2

P4--3

P4--5

P4--6

P4--9

P4--10

P4--11

P5--1

P5--2

P5--3

P4--12

P4--8

P4--76VDC

+----

6VDC

+----

6VDC

+----

6VDC

+----

6VDC

+----

6VDC

+----

A

A

BC

D

E

SENSE

DUST

2

3

1

392180 -- ALL

ELECTRICAL

4-657200 330045 (3--02)

ELECTRICAL SCHEMATIC (008238-- )

2

3

116/YEL

17/GRY

18/BRN

19/GRN

20/GRY

38/ORA

41/BLU

36/GRN

6B/BLU

21/BLU

21/BLU

21A/BLU

13E/BLK

13L/BLK

6D/BLU

40/ORA

40A/ORA

13V/BLK

13G/BLK

13AL/BLK

13CA/BLK

94/ORA

9A/BRN

9/BRN

6C/BLU

37/BLU

81/GRN

81D/GRN

81B/GRN

81E/GRN

81CA/GRN

81C/GRN

81A/GRN

81G/GRN

81F/GRN

LOWBATT.

=31.5VDC

1AMP

2.3AMPS

1.6AMPS

.35AMPS

.35AMPS

1.6AMPS

13AU/BLK

13AP/BLK

13BA/BLK

13BC/BLK

96BB\BLU

48/GRY 50/TAN

97BA/PUR

6E/BLU

96BD/BLU

13AR/BLK

12A/GRN

SWEEPBRUSH

RELAYCOIL&

DUST

CONTROL

PUMP

1Ampmax.

DISK

SCRUBBER

MACHINE

OPTIONONLY:

MAIN

SWEEPING

MOTOR18A

DISK

SCRUBBER

MACHINE

OPTIONONLY:

SIDE

BRUSH

MOTORS

2AEA.

95BA/GRN

49/WHT

49BA/WHT

49BB/WHT

49BA/BB/WHT

93BA/ORA

10BB/YEL

10BC/YEL

96BC\BLU

13BB/BLK

13BC/BLK

13BD/BLK

13BF/BLK

95BC/GRN

96BA/BLU

48BA/GRY

50BA/TAN

10K/YEL

93/ORA

93A/ORA

96/BLU

96A/BLU43A/ORA

13AS/BLK

97/PUR

95BB/GRN

9B/BRN

9C/BRN

13AN/BLK

13AS/BLK

CYLINDRICAL

SCRUBBER

MACHINE

OPTIONONLY

10BC/YEL

CYLINDRICAL

SCRUBBER

MACHINE

OPTION

ONLY

10J/YEL

10BC/YEL

10G/YEL

10E/YEL

10/YEL

10H/YEL

98BA/GRY

98BB/GRY

13BF/BLK

DISK

SCRUBBER

MACHINE

OPTIONONLY:

DISK

SCRUBBER

MACHINE

OPTION

ONLY:

DISK

SCRUBBER

MACHINE

OPTION

ONLY:

DISK

SCRUBBER

MACHINE

OPTION

ONLY:

M3A

+--

SV--1

WATER

SOLENOID

ACT1

AB

MTR

(OPTION)ES

PUMP

SV--2

CB--5

10A

CB--4

10A

M6B


3087


SHROUD

LIGHT

OVER

HEAD

GUARDLIGHT

CB--3

10A

ACT2

AB

S--6

POWER

WANDSW

.

VACWANDPUMP

MTR

HM+

--

S--10A UP DN

86

4 15

2

S--10B

ONE--TOUCH

SWEEPERON

109

S--11B

109

S--11A

ON

OFF

86

41 5

2

LEFT

HEAD

LIGHT

M5B

SWEEPERSYSTEM

MTR

S--8

LIGHT

SW.

RIGHTHEAD

LIGHT

D--11

CB--10

25A

HORN

RIGHTTAILLIGHT

MTR

MAINSW

EEPBRUSHMOTOR

S--7

HORN

BUTTON

RIGHTTAILLIGHT

D--5

5A/10A

D--10

SV--1

EXTEND

LIMITSW

.

RETRACTLIMIT

BLK

RED

BLK

RED

BRUSHLIFT

ACTUATOR

ACT3

B A

MTR

S--12

MTR

D--13

TP1

P2--1

P2--2

P3--1

P1--1

P1--2

P1--4

P1--6

P2--3

P2--4

P2--5

P2--6

P2--7

P2--8

P2--9

P2--10

P2--11

P2--12

LED+5VDC

ESLED

REC.TANK

FULLLED

HOUR

METER

ENABLE

(VAC

OR

PROPEL)

ES

BRDN

PRESS

ESFILTER

FLUSH

ESPUMP

BRUSHHD

ACT.

SQUEEGEE

ACT.

SQUEEGEE

ACT.

WATER

SOL.

MAINBRUSH

BRUSHHD

ACT.

BATT.

LEDS

LED#2

LED#1

BATT.LED

#4

SQ/VAC

LED

SCRUB

DOWN

PRESS.

LEDS

LED#1

LED#2

LED#3

TOUCHPNL

GND.

SQUEEGEE

P3--6

LED#4

LED#3

P4--4

DUST

CONTROL

SWEEPERSYSTEM

P1--1

P1--2

P1--3

P1--6

P2--1

P2--2

P2--3

P2--4

P2--5

P2--6

P2--7

P2--8

P2--9

P2--10

P2--11

P2--12

P3--1

P3--4

P3--5

P3--9

P3--10

P3--11

P3--13

P3--14

P3--15

P2--13

P2--14

P2--15

P2--16

P1--4

P1--5

P3--6

P4--4

M5A

SWEEPERSYSTEM

+--

MTR

B

C

D

E

LEFT

SWEEPBRUSHMOTOR

ONE--TOUCH

SWEEPERON

SQGE

UP/DN

BRSH

HDUP/DN

BRUSH

RIGHTSW

EEPBRUSHMOTOR

RIGHTSW

EEPBRUSHMOTOR

(OPTION)DUST

CONTROLSHUT

OFFVALVE

(OPTION)DUSTCONTROLPUMP

RIGHTSW

EEPBRUSHSW

CN.O.(OPTION)ES

FILTER

FLUSH

CB--11

PANEL SWITCHES

MEMBRANE TOUCH PANEL

PANEL LEDS

DUST

CONTROLON

DUST

CONTROLON

392180 -- ALL

ELECTRICAL

4-66 7200 330045 (3--02)

WIRE HARNESSES GROUP (000000--008237)

1

5

2

3

4

ELECTRICAL

4-677200 330045 (3--02)


1

5

2

3

4

ELECTRICAL

4-68 7200 330045 (3--02)


ELECTRICAL

4-697200 330045 (10--99)

OPERATING MODES

The Model 7200 has 4 different operating modes.The machine operator can access each mode bypressing various buttons on the control panel,holding them, and turning on the key. Thecommon operating modes are detailed in thefollowing charts.

Operating Modes Entry Sequence(how to activate)

Normal Mode; Normal operation.More info pages 4--66 thru 4--69

Default (when key is turned on)

: Self Test Mode; Test controller, actuators, andscrub brush motor operation. In this mode, thebattery LED #4 will blink.More info pages 4--70 thru 4--72

1. Push and hold the Squeegee button2. Turn on the key3. Hold the Squeegee button for 5 seconds4. Release the Squeegee button

: Manual Mode; Manually operate discretefunctions without interlocks. In this mode, thebattery LED #3 will blink.More info pages 4--73 thru 4--75

1. Push and hold the ESt button2. Turn on the key3. Hold the ESt button for 5 seconds4. Release the ESt button

: Input Display Mode; Display the state offloats, limit switches, and sensors. In this mode,pressure LED #2 will blink.More info pages 4--76 and 4--77

1. Push and hold the Scrub button2. Turn on the key3. Hold the Scrub button for 5 seconds4. Release the Scrub button

: NOTE: There is a clear folder at theend of this manual that contains threetouch panel overlays. Use each of thethese overlays in their respective testmode as a technical aide during thediagnostic procedure.

ELECTRICAL

4-70 7200 330045 (10--99)

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 generaloperation of the machine. The machine willnormally start in this mode. What follows is a briefdescription of each of the operations in the normalmode.

SCRUB BUTTON

The purpose of the scrub button is to turn thescrubbing operations on and off and adjust thescrubbing down pressure. Pressing the scrubbutton while the scrubbing operation is currentlyinactive will initiate the following actions:

1. Illuminate the LED’s that indicate the defaultdown pressure. Note: Hold the scrub buttondown to get another down pressure setting.See note 4 below.

2. If the machine is not in reverse, thevacuum fan will turn on, the squeegee willdrop, and the brushes will drop. Putting themachine into reverse will raise the squeegeeand, after a slight delay, turn off the vacuumfan.

3. If the machine is in forward, the brushhead will drop, water valve will turn on, andthe brushes will start turning. Putting themachine into neutral while scrubbing will turnoff the brushes and, after a short delay,slightly raise the scrub head.

4. If the operator holds the scrub button afterthe LED’s become illuminated, the machinewill begin to scroll through the different scrubdown pressures. The controller stores thepressure displayed as the new default afterthe user releases the scrub button.

Pressing and releasing the scrub button while themachine is currently in the scrub mode will initiatethe following actions.

1. The scrub motors will turn off and the scrubhead will start to raise.

2. The machine will delay a few seconds andthe squeegee will start to raise.

3. The vacuum fan will turn off after a slightdelay.

ELECTRICAL

4-717200 330045 (10--99)

SQUEEGEE BUTTONPressing the squeegee button will start or stop thewater pickup operation. If the operator pressesthe squeegee button while the squeegee LED iscurrently not illuminated will cause the followingactions:1. The squeegee LED will be illuminated.

2. If the machine is not in reverse, thesqueegee will drop and the vacuum fan willturn on. If the machine goes into reversewhile the squeegee is active, the squeegeewill rise. If the machine remains in reverselong enough, the vacuum fan will shut off.

Pressing the squeegee button while the squeegeeLED 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 slightdelay.

ESt BUTTON

Pressing the ESt button will enable or disablethe ESt system. The ESt system will drawwater from the recovery tank, through a filter andpump it into the solution tank. If the operator hasturned on the ESt system, the recovery tank 1/2full float is closed, and the solution tank full float(S--9) is open, the ESt pump will begin to run.The ESt pump will continue to run for about 30seconds after the ESt float becomes uncovered.

OVERFLOW FLOAT

If the recovery tank becomes full (S--4 is closed),the overflow system will shut off the scrub andvacuum up system. If the overflow float switchbecomes continuously active (about 3 seconds),the overflow light will turn on and latch. If thescrub or squeegee functions are active, they willbecome deactivated and the vacuum fan will turnoff after a slight delay. If the operator presses thesqueegee button, the squeegee will drop and thevacuum fan will run for about 30 seconds to pickup any excess water. The overflow indicator willnot turn off by simply emptying the recovery tank.The overflow indicator will remain illuminated untilat least one of the following action occur:

1. The overflow float switch becomes inactive(S--4 is open) and the scrub button ispushed.

Continued on next page...

ELECTRICAL

4-72 7200 330045 (10--99)

2. The overflow float switch becomes inactiveand the squeegee button is pushed.

3. The overflow float switch becomes inactiveand an on/off/on button cycle is performed.

BATTERY GAUGE

The battery gauge displays the state of charge ofthe batteries with a 4 segment LED display. Whenthe last segment is blinking, the battery voltage isabout 31--1/2 volts (80% discharge), and thebatteries need charging. The scrub and squeegeefunctions will shut off if the operator is scrubbingat this point. If the user selects the squeegeebutton, squeegee will lower, and the vacuum fanwill run for about 30 seconds to allow the operatorto pick up any excess water. The squeegee willthen lift, and the vacuum fan will shut off after aslight delay.

HOUR METER

The hour meter logs hours if the machine is in oneof the following modes.

1. Propelling

2. Vacuum fans running.

INTERLOCKS

The 7200 has several interlocks which can inhibitor cancel machine functions.

D REVERSE -- When the operator engagesthe reverse contactor, the following functionwill become inhibited:--SQUEEGEE will rise. When the operatordisengages the reverse contactor, thesqueegee function will resume.--VACUUM FAN will turn off after a timedelay. When the operator disengages thereverse contactor, the vacuum fan operationwill resume.

D NEUTRAL -- When the operator disengagesthe forward contactors, the machine willdetect neutral, and inhibit the followingfunctions. When the machine detects theforward switch, the functions will resume.-- WATER VALVE will turn off.-- 5 SECOND delay.If the machine is still in neutral after the 5second delay:-- SCRUB BRUSHES will turn off.-- SCRUB HEAD will raise slightly.


ELECTRICAL

4-737200 330045 (10--99)

D LOW BATTERY -- The machine will cancelthe following functions when the last batteryLED is blinking (about 31.5 volts).--SCRUB FUNCTION-- The scrub functionwill cancel as if someone toggled the scrubbutton. The operator cannot restart thescrub functions until the meter is reset. Theoperator can reset the battery gauge byunplugging the main battery connector.--SQUEEGEE AND VACUUM FAN--Themachine will cancel squeegee operation, asif someone toggled the squeegee button. Ifthe operator presses the squeegee buttonafter being canceled, the squeegee andvacuum fan will resume operation for about30 seconds.

The operator will reset the battery meter eachtime the main battery connector is removed.Each time the operator powers down thecontroller, the machine will store the current stateof battery charge. When the operator powers upthe machine, it will recall the last state of charge,and display it on the touch panel. If the operatordisconnects the main power connector, thecontroller will assume the machine has beencharged. The battery meter will be reset the nexttime the key is turned on.

D FULL RECOVERY TANK -- The 7200 willcancel the following functions if the recoverytank float switch is turned on:THE CONTROLLER will cancel scrub andsqueegee operations, as if someone toggledthe scrub or squeegee buttons.THE TANK FULL LED will start to blink. Thismessage will not turn off by simply emptyingthe recovery tank. The LED will remainblinking until the machine is powered down,or the scrub button is pushed.

D BRUSH MOTOR ERROR -- The controllerwill cancel the following functions if an openbreaker opens during scrub motor operation:THE CONTROLLER will cancel scrub andsqueegee operations, as if someone toggledthe scrub or squeegee buttons. If theoperator presses the squeegee button,squeegee and vacuum fan operation willresume.ALL FOUR BRUSH PRESSURE LED’S willbegin to blink, alerting the operator to theopen breaker condition.

ELECTRICAL

4-74 7200 330045 (10--99)


Self Test Mode; Test controller outputtransistors, actuators, and scrub brush motoroperation. In this mode, the batteryLED #4 LED will blink.

1. Push and hold the Squeegee button2. Turn on the key3. Hold the Squeegee button for 5 seconds4. Release the Squeegee button5. Battery #4 LED will begin to blink

SELF TEST MODE

The purpose of the Self Test Mode is to test theoperation of the control board and to exercise allof its outputs. When this mode is engaged,various motors and accessories will beengaged at full power as part of the test.Extreme care must be taken to be sure thattechnicians and bystanders are not injured asa result of this test.

D TO PREVENT INJURY, ALWAYS TURNTHE MACHINE OFF AFTER THEDIAGNOSTIC MESSAGES HAVE BEENDISPLAYED.

D IF THE DIAGNOSTIC MESSAGES DONOT APPEAR, DO NOT ATTEMPT TOSERVICE THIS MACHINE WITHOUTFIRST TURNING IT OFF ANDRETURNING TO ANOTHER MODE.

The Self Test Mode tests each of the followingcontroller board functions:

1. Squeegee actuator.

2. Scrub head actuator.

3. Scrub brush motor current.

4. Hour meter output.

5. Water valve output.

6. ESt pump output.

7. Vacuum fan contactor output.

8. Scrub brush contactor output.

9. ESt Air flush output.

ELECTRICAL

4-757200 330045 (10--99)

When the operator releases the squeegee button,the controller will run the squeegee and the brushhead actuators to the up positions. It will then runthe following procedure:

1. Turn on the vacuum fan and lower thesqueegee actuator.

2. Wait for the actuator to stall, flag error foralways 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 foralways stalled, early stall, or never stalled

7. Check brush motor current with brushmotors off. Flag error for current sensed.

8. Turn on the brush motors.

9. Flag error for zero current, low current, orhigh current.

10. Turn off the brush motors.

11. Cycle and test the ESt pump output.

12. Cycle and test the ESt air flush output.

13. Cycle and test the Vacuum fan output.

14. Cycle and test the Scrub brush motoroutput.

15. Cycle and test the Hour meter output.

16. Cycle and test the water valve output.

17. Blink the squeegee light (green) for systempassed, blink the overflow light (red) forsystem failed.

ELECTRICAL

4-76 7200 330045 (10--99)

SELF TEST ERROR CODES

To interrogate the machine to determine thenature of a diagnostic failure, the operator mustuse the buttons on the instrument panel. We haveassociated a group of error codes to each buttonon the instrument panel. If the operator pressesthe button assigned to a group that has sensed anerror, the controller will display the error codeusing the brush pressure LED’s. If the operatorpresses a button assigned to a group that has notsensed an error, the controller will display no errorcode on the brush pressure LED’s.The error code assignments are as follows:

ACTUATOR GROUP,SQUEEGEE BUTTON PRESSED

PRESSURE 0 PRESSURE 1 PRESSURE 2 PRESSURE 3 ERROR

ON -- -- -- No squeegee actuator zerocurrent

-- ON -- -- Early squeegee stall

ON ON -- -- No squeegee stall

-- -- ON -- No brush actuator zero current

-- -- -- ON Early brush stall

-- -- ON ON No brush stall

BRUSH MOTOR GROUP,SCRUB BUTTON PRESSED

PRESSURE 0 PRESSURE 1 PRESSURE 2 PRESSURE 3 ERROR

ON -- -- -- No brush motor zero current

ON ON -- -- Zero brush motor current

ON ON ON -- Low brush motor current

ON ON ON ON High brush motor current

ACCESSORY OUTPUT GROUPESt BUTTON PRESSED

ESt LED SQUEEGEELED

PRESSURE0

PRESSURE1

PRESSURE2

PRESSURE3

ERROR

ON -- -- -- -- -- Air Flush valveoutput

-- ON -- -- -- -- Hour meter output

-- -- ON -- -- -- Water valve output

-- -- -- ON -- -- ESt pumpoutput

-- -- -- -- ON -- Fan contactoroutput

-- -- -- -- -- ON Brush contactoroutput

ELECTRICAL

4-777200 330045 (10--99)


Manual Mode; Manually operate discretefunctions without interlocks. In this mode, thebattery #3 LED will blink.

1. Push and hold the ESt button2. Turn on the key3. Hold the ESt button for 5 seconds4. Release the ESt button5. Battery #3 LED will begin to blink

MANUAL MODE

The purpose of the manual mode is to allow theoperator to exercise individual functions on themachine. This mode disregards the effects ofvarious interlocks. Do not scrub with themachine in this mode.

FOR SAFETY: When Servicing Machine,Avoid Moving Parts. Do Not Wear LooseJackets, Shirts, Or Sleeves.

After entering the Manual Mode, the controlbuttons assume the following functions:

SCRUB BUTTON

Pressing the Scrub button will turn on and lowerthe main scrub head. Holding the Scrub buttonwhile scrub is active will cause the down pressureto scroll. The head will continue down as longas the technician holds the scrub button. Caremust be exercised by the technician not tohold the button too long. The actuator canstall when fully extended. Damage to thecontroller board and the actuator can resultfrom continuing to provide power to a stalledactuator. The head will stay down with thebrushes running regardless of the state of thepropel pedal reverse switch. The head willautomatically rise when the user turns off thebrushes.

SQUEEGEE BUTTON

Pressing the Squeegee button will turn on thevacuum fan and lower the squeegee. Reverse isignored.

ESt BUTTON

Pressing the ESt button will toggle the EStpump on or off. In the on position, the ESt pumpwill run regardless of the state of the floats. Careshould be taken not to run the ESt pump dry formore than a few seconds. The ESt Air flushvalve will cycle on and off every 5 seconds.


ELECTRICAL

4-78 7200 330045 (10--99)

INTERLOCKS

The operator can start and stop the variousfunctions of the 7200 scrubber using a variety ofclosures and interlocks. What follows are twotables for each of the three basic scrubbingfunctions (Scrub brushes, Squeegee and vacuumfan, and ESt pump). One table lists the actionsrequired for the basic function to be running. Theother table lists the actions that would prevent theoperation from running. If the operator satisfies allof the requirements from the first table, and noneof the situations of the second table exist, theoperator could expect the function to operate.

SCRUB BRUSH OPERATION

SCRUB BRUSH OPERATION ENABLED BY: INDICATOR

D Scrub button D One or more scrub pressure LED’s on

D Forward or reverse propel D Forward or reverse contactors engaged

SCRUB BRUSH OPERATION INHIBITED BY: INDICATOR

D Scrub button D All scrub pressure LED’s off

D Neutral D Forward and reverse contactors disengaged

D Low battery D Battery 1 LED blinking

D Open brush motor circuit breaker D All four scrub pressure LED’s blinking

D Full recovery tank D ”Recovery tank full” LED blinking

SQUEEGEE AND VACUUM FAN OPERATION

SQUEEGEE FUNCTION ENABLED BY: INDICATOR

D Scrub button or squeegee button D Squeegee LED on

D Forward or neutral D Reverse contactor disengaged

SQUEEGEE FUNCTION INHIBITED BY: INDICATOR

D Scrub button or squeegee button D Squeegee LED off

D Reverse D Reverse contactor engaged

D Low battery D Battery 1 LED blinking

D Full recovery tank D ”Recovery tank full” LED blinking

ELECTRICAL

4-797200 330045 (10--99)

ESt AIR FLUSH OPERATION

ESt AIR FLUSH VALVE ENABLED BY: INDICATORD ESt button and Squeegee button D ESt and Squeegee LED’s on

D ESt Air flush valve will open for a 5 secondperiod, at a 45 second interval if both ESt andSqueegee are enabled

ESt AIR FLUSH VALVE INHIBITED BY: INDICATOR

D ESt button and Squeegee button D ESt and Squeegee LED”s off

ESt PUMP OPERATION

ESt PUMP ENABLED BY: INDICATORD ESt button D ESt LED on

D ESt float covered, or ESt 30 second timerrunning. The ESt 30 second timer starts whenthe ESt pump brings the solution level belowthe ESt float.

ESt PUMP INHIBITED BY: INDICATOR

D ESt button D ESt LED off

D More than 30 seconds has passed sincethe ESt float has become uncovered

D Solution tank full float covered for morethen 5 seconds

ELECTRICAL

4-80 7200 330045 (10--99)


Input Display Mode; Display the state of floats,limit switches, and sensors. In this mode, thepressure led #2 will blink

1. Push and hold the Scrub button2. Turn on the key3. Hold the Scrub button for 5 seconds4. Release the Scrub button5. Brush pressure LED #2 will begin to blink.

INPUT DISPLAY MODE

The purpose of the Input Display Mode is for thetechnician to observe the effectiveness of variousinputs and sensors on the controller board. Whenin this mode, the operator can scrub with themachine as normal and observe the operation ofthe various inputs.

When in the Input Display Mode, each of thecontrol panel LED’s are associated with one boardinput. When the operator activates an input, thecorresponding LED will become illuminated.

The operator may activate scrub functions in thismode. The LED’s on the instrument panel nolonger correspond to the control status while inthe Input Display Mode. For instance, in thenormal mode, if the squeegee LED is on, thismeans that the squeegee and vacuum fan areactive. In the Input Display Mode, this LEDindicates that the solution tank full float is active.The buttons however, retain their normalfunctions. Pressing the squeegee button will turnon the squeegee, even though the LED may notturn on. The controller will temporarily displayscrub pressure when the operator presses andholds the scrub button. If the operator holds thescrub button long enough, the machine will scrollslowly through the down pressures.

The assignments of LED’s to inputs are asfollows:

Battery 1.--When the least significant battery LEDis blinking, the battery voltage isbelow 31.5V and the batteries are inneed of a charge.

Battery 2.--When the battery 2 LED is on, thereverse contactor is active.

Battery 3.--When the battery 3 LED is on, theforward contactor is active.

Battery 4.--When the battery 4 LED is on, there ispower sensed on the outputs of bothbrush motor circuit breakers.


ELECTRICAL

4-817200 330045 (10--99)

Squeegee -- When the squeegee LED is on,the solution tank full float is active.

Overflow -- When the overflow LED is on, therecovery tank full float is active.

ESt -- When the ESt LED is on, the EStfloat is active.

Pressure 1.--When the pressure 1 LED is on, thescrub is active, and the brushcurrent detected is below theminimum level for the selectedpressure setting.

Pressure 2.--When the pressure 2 LED isblinking, the controller is in the inputdisplay mode.

Pressure 3.--When the pressure 3 is on, thescrub mode is active.

Pressure 4.--When the pressure 4 LED is on, thescrub is active, and the brushcurrent detected is above themaximum level for the selectedpressure setting.

: NOTE: There is a clear folder at theend of this manual that contains threetouch panel overlays. Use each of thethese overlays in their respective testmode as a technical aide during thediagnostic procedure.

ELECTRICAL

4-82 7200 330045 (10--99)

ELECTRICAL

4-837200 330045 (10--99)

TROUBLESHOOTING

The troubleshooting charts that follow areorganized so they lead you through the circuits.They include flow charts and instructions for youas to where to insert your test instruments.

ELECTRICAL

4-84 7200 330045 (10--99)

FU---1 IS OPEN ORCABLE OPEN FROMFU---1 TO M1 CONTACTOR

6/BLU, CB---1, 35/GRN, D---1,7/PUR, OR KEY SWITCH PINS 30TO PIN 15 ARE OPEN

1/RED, FU--1, 5/BRN,CB--2, 8/BLU, D--2, OR25/GRY ARE OPEN

CHECK FOR BATTERYVOLTAGE ON 25/GRY AT KEYSWITCH

POWER UP TESTING

OPERATION: Key switch toto start position-- Current flows into key switch terminal 50

Current flows out of key switch terminal 15, turning on M1 contactorand powering up the machine.

Release key torun 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 tooff position-- M1 is turned off by key switch or emergency stop switch.

Machine turns off.

KEY SWITCH OFF

BATTERYVOLTAGE O VOLTAGE

TURN AND HOLD KEY SWITCHTO THE START POSITION

CHECK FOR BATTERY VOLTAGEON 27/GRN AT M1

BATTERYVOLTAGE

O VOLTAGE

KEY SWITCH PINS 50 TO 1526/ORA, S---2, OR 27/GRNARE OPEN

KEY IN START POSITIONCHECK FOR VOLTAGEACROSS M1 COIL27/GRN TO 13D/BLK

O VOLTAGE

BATTERYVOLTAGE

13D/BLK IS OPEN

KEY IN START POSITIONCHECK VOLTAGE AT M1WIRES 5/BRN AND6/BLU

O VOLTAGE ON EITHER

B+ ON ONESIDE ONLY

VOLTAGE ONBOTH WIRES

REPLACE M1

RELEASE KEY TO STARTPOSITION, CHECK FORVOLTAGE AT M1 WIRES6/BLU AGAIN

BATTERYVOLTAGE

MACHINE ISPOWERED UP

O VOLTAGE ON EITHER

ELECTRICAL

4-857200 330045 (10--99)

13AK/BLK27E/GRN D--8

13D/BLK27/GRN

10A

CB--1

35/GRN

25/GRY

BATTERIES

5/BRN

5/BRN

CB--2

D--2

FU--1

GROUND

8/BLU

MAIN

M1--+

27B/GRN

S--2

26/ORA

S--1

7/PUR

6/BLU

D--1

10A

M1

MAIN

80A

+36VDC

KEY SWITCH

= CLOSED CONTACT

75

15

83

STARTRUNOFF

30

50

6VDC6VDC6VDC6VDC6VDC6VDC

POWER UP TESTING

COMMON CONTACTCNORM.OPEN CONTACTN.O.HOURMETERHM

RCONNECTOR PINP

LEGEND

RELAY COIL

ARMATURERESISTOR

DIODEFUSE

SWITCH

MOTORCIRCUIT BREAKER

ARM

MDFU

S

MTRCB

ELECTRICAL

4-86 7200 330045 (3--02)

D P--16 = Battery voltageD P--15 = Battery voltage when seat switch is closedD P--11 = Battery voltage in reverseD P--12 = Battery voltage in forwardD P--6 = 0 voltage in neutral, +5VDC for full forward or reverseD P--14 = Ground when (M3) brush contactor is on (= low speed)D P--14 = B+ when (M3) is off

PROPEL

OPERATION: D Throttle assembly gives speed and direction information to the controller.D Controller turns on forward or reverse contactors.D 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: D Slide the cover open on the edge of the Curtis 1207--1133 motor controller.D Read error code displayed by blinking light on the motor controller.D Use the error code chart information to determine what section of the propel

system to trouble shoot.D If you have no blinking light, check the power and ground wires to the controller

before replacing the controller.(SeeL MOTOR CONTROLLER LEDDIAGNOSTICS)

POWER AND GROUNDCONNECTIONS CHECK

VERIFY BATTERY VOLTAGE FOR THE FOLLOWING:D 27C/GRN at the throttleD 27A/GRN at the motor controllerD 27/GRN at M1 contactor coilD B+ terminal of the motor controllerD Normally open terminal of M4 and M5

VERIFY GROUND CONTINUITY FOR THE FOLLOWING POINTS:D 13M/BLK at the throttleD B-- terminal of motor controller

" ACTIVATE THE SEAT SWITCH

VERIFY BATTERY VOLTAGE AT THESE POINTS:D 32C/GRN at the speed controlD 32A/GRN at M4D 32/GRN at M5

THROTTLE TESTING

VERIFY VOLTAGE FOR THE FOLLOWING TERMINALS:D A = Battery voltage (input)D B = Battery voltage in reverse (output)D C = Battery voltage in forward (output)D D = Potentiometer ground (input)D E = 0 voltage in neutral, +5VDC for full forward or reverseD F = Ground (input)

CONTROLLER INPUTS

Tennant Acrobat User


1242

ELECTRICAL

4-877200 330045 (3--02)

CONTROLLER POWERSECTION

D P--7 = Potentiometer ground for the throttleD P--3 = Ground = Forward, B+ = Reverse or NeutralD P--2 = Ground = Reverse, B+ = Forward or Neutral

CONTROLLER OUTPUTS

D Check error codes for power output sectionD Check all connections at the motor and motor controllerD Re--check error codesD Replace as per the error codes

L MOTOR CONTROLLER LEDDIAGNOSTICS:

STATUS

MAIN PLUG_____________CURRENT LIMIT

ACCEL. CREEP LOW____________SPEED LIMIT

~

During normal operation, with no faults present,the Status LED flashes a single flash atapproximately 1 flash per second, If the controllerdetects a fault, a 2--digit code (see table below) isflashed continuously until the fault is corrected.For example...code ”3--2”...Welded directioncontactor... appears as:

~~~ ~~(3 -- 2)

~~~ ~~(3 -- 2)

~~~ ~~(3 -- 2)

TABLE 1: LED CODES

LED CODE: LED STATUS: EXPLANATION:

" LED OFF JJJJJJ D No power or defective controller

" SOLID ON VVVVVV D Defective controller

" SINGLE FLASH ~ D Controller operational----No faults

" 1 -- 2 ~ ~~ D Hardware fail--safe error

" 1 -- 3 ~ ~~~ D M-- fault or motor output short

" 1 -- 4 ~ ~~~~ D Sequencing fault (SRO) *

" 2 -- 1 ~~ ~ D 5k�--0 or throttle wiper input fault

" 2 -- 2 ~~ ~~ D Emergency reverse circuit check fault(BB wiring)

" 2 -- 3 ~~ ~~~ D High--pedal--disable--fault (HPD)

TABLE 1 continued on the next page.




See Insert Table 6

ELECTRICAL

4-88 7200 330045 (3--02)

TABLE 1: LED CODES (continued)

LED CODE: LED STATUS: EXPLANATION:

" 2 -- 4 ~~ ~~~~ D Throttle pot low open or shortedto B+ or B--

" 3 -- 1 ~~~ ~ D Contactor or shunt driverover--current

" 3 -- 2 ~~~ ~~ D Welded direction contactor

" 3 -- 3 ~~~ ~~~ D (reserved for future use)

" 3 -- 4 ~~~ ~~~~ D Missing contactor or shunt

" 4 -- 1 ~~~~ ~ D Low battery voltage

" 4 -- 2 ~~~~ ~~ D Over--voltage

" 4 -- 3 ~~~~ ~~~ D Thermal cutback

" 4 -- 4 ~~~~ ~~~~ D (reserved for future use)

* SRO = Static Return to Off. Verify that the throttle signal = Neutral (0 Voc on P--6) when the machine ispowered up.

NOTE: Only one fault is indicated at a time, andfaults are not queued up. Operationalfaults----such as a fault in SRO sequencing----arecleared by cycling the brake or key switch.

PROGRAMMER DIAGNOSTICS

With a programmer, diagnostics andtroubleshooting is more direct than with the LEDalone. The programmer presents completediagnostic information in plain language----nocodes to decipher. Faults are displayed in theDiagnostic Menu, and the status of the controllerinputs/outputs is displayed in the Test Menu.

The following 4--step process is generally used fordiagnosing and troubleshooting an inoperativevehicle: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 isoperational.

EXAMPLE:A vehicle that does not operate in ”forward” isbrought in for repair.

Step 1. Examine the vehicle and its wiring forany obvious problems, such as broken wiresor loose connections

Continued on next page....




See Insert Table 7


Insert for Table 6


Insert for Table 7

ELECTRICAL

4-897200 330045 (10--99)

Step 2. Connect the programmer, put it indiagnostic mode, and read the display faultinformation. In this example, the displayshows ”No Faults Present” indicating thatthe controller has not detected anything outof the norm.

Step 3. Put the programmer in test mode, andobserve the status of the inputs and outputsin the forward direction. In this example, thedisplay shows that the forward switch did notclose when ”forward” was selected, whichmeans the problem is either in the forwardswitch or the switch wiring.

Step 4. Check or replace the forward switch andwiring and repeat the test. If the programmershows the forward switch closing and thevehicle now drives normally, the problemhas been corrected.

NOTE: Refer to the troubleshooting chart (table 2)for suggestions covering a wide range of possiblefaults.

TABLE 2: TROUBLESHOOTING CHART

LEDCODE:

PROGRAMMER LCDDISPLAY:

EXPLANATION: POSSIBLE CAUSE:

1 -- 2 HW FAILSAFE Hardware fail--safeerror

1. Controller defective.

1 -- 3 M-- FAULT M-- output shorted 1. M-- output shorted toground

2. Direction contactor notclosing

3. Direction contactor notclosing fast enough

4. Internal motor short toground

1 -- 4 SRO SRO fault 1. Improper sequence of KSI,brake, and direction inputs.

2. Wrong SRO type selected3. Brake or direction switchcircuit open

4. Sequencing Delay too short

2 -- 1 THROTTLE FAULT 1 5k�--0 or wiper fault 1. Throttle input wire open.2. Throttle input wire shortedto ground.

3. Throttle pot defective.4. Wrong throttle typeselected.

2 -- 2 BB WIRING CHECK Emergency reversewiring fault

1. BB wire open.2. BB check wire open.

2 -- 3 HPD HPD sequencing fault 1. Improper sequence of KSI,brake, throttle inputs.

2. Wrong HPD type selected.3. Mistrusted throttle pot.

ELECTRICAL

4-90 7200 330045 (10--99)

TABLE 2: TROUBLESHOOTING CHART (continued)

LEDCODE:

PROGRAMMER LCDDISPLAY:

EXPLANATION: POSSIBLE CAUSE:

2 -- 4 THROTTLE FAULT 2 Pot low broken orshorted

1. Pot low wire open.2. Pot low wire shorted.3. Wrong throttle typeselected.

3 -- 1 CONT DRVR OC Driver outputovercurrent

1. Direction contactor coilshorted.

2. Shunt field shorted.

3 -- 2 DIR CONT WELDED Welded directioncontactor

1. Direction contactor stuckclosed.

3 -- 4 MISSINGCONTACTOR

Missing contactor orshunt

1. Direction contactor coilopen.

2. Direction contactor missing.3. Shunt field open.4. Wire to shunt or direction

contactor.

4 -- 1 LOW BATTERYVOLTAGE

Low battery voltage 1. Battery voltage �16 volts.2. Corroded battery orcontroller terminal.

3. Loose battery or controllerterminal.

4 -- 2 OVERVOLTAGE Overvoltage 1. Battery voltage �45 volts.2. Vehicle operating withcharger attached.

4 -- 3 THERMALCUTBACK

Over--/under--temp.cutback

1. Temperature �85_C or�25_C.

2. Excessive load on vehicle.3. Improper mounting of

controller.4. Operation in extremeenvironments.

ELECTRICAL

4-917200 330045 (10--99)

PROPEL

27D/GRN

34/ORA

34C/ORA32B/GRN 86 85M6

BACK--UPALARM

ENABLE

LOW

SPEED

13AK/BLK27E/GRN D--813D/BLK

27/GRN

13AC/BLK

10A

CB--1

35/GRN

32/GRN

32C/GRN

13M/BLK 13M/BLK

12/GRN

BATTERIES

A

B

C

F

D

E

GRN

B/WHT

WHT

W/BRN

ORA

BLK

32A/GRN

27A/GRN

27C/GRN

28/BRN

P--14

S2

S1

M4

M4

M5

M5

B

P--16

FU--1

SWITCHSEAT

P--15

FORWARDM4

REVERSEM5

CURTIS 1207--1133 SPEED CONTROLLER

+36V = REV

+36V = FWD.

THROTTLE

CURTIS

ET--103

GROUND

POT LOW

0 -- 5VDC

GROUND

+36/VDC

MAIN

M1

--+

--+

--+

P--3

P--2

P--6

P--7

P--12

P--11

EMERGENCY--STOP

REV

FWD

34B/ORA

33/PUR

S--3

31/YEL

30/ORA

30/ORA

28/BRN

29/GRY

29/GRY

27B/GRNS--2

26/ORA

S--1

7/PUR

6/BLU

D--1

M1

MAIN

80A

+36VDC

KEY SWITCH

= CLOSED CONTACT

75

15

83

STARTRUNOFF

30

50

A1A2


TRACTIONMOTOR

B--M--A2B+

ARMFIELD


RCONNECTOR PINP

LEGEND

RELAY COIL

ARMATURERESISTOR

DIODEFUSE

SWITCH


ARM

MDFU

S

MTRCB

ELECTRICAL

4-92 7200 330045 (10--99)

VERIFY BATTERY VOLTAGE ON:--10A/YEL AT P3--2 OF CONTROLBOARD--10B/YEL AT P3--7 OF CONTROLBOARD--10C/YEL AT P4--1 OF CONTROLBOARD

ACTIVATE EACH SWITCHDOES THE ASSOCIATEDLIGHT/LIGHTS TURN ONTHEN OFF ?

TOUCH PANEL ANDRIBBON TESTING

OPERATION OF LED’S:D P2--1 = Supplies +5VDC to each LEDD P2--2 through P2--12 will light an LED if they are pulled to

ground by the control board

OPERATION OF SWITCHES:D P1--1 = Supplies ground to each switchD P1--2 = Switched to ground when the ES switch is activatedD P1--4 = Switched to ground when the Scrub button is activatedD P1--6 = Switched to ground when the Squeegee button is activated

KEY SWITCH ON

: MACHINE POWERS UP AND PROPELS

DO ALL THE LIGHTS ON THE TOUCHPANEL TURN ON THEN OFF ?

YES NO

LED’S OK

YES

PANEL OK

NO

CHECK RIBBON CABLEAT THE CONTROLBOARD

OK

REPLACETOUCHPANEL

DO SOME OF THELED’S TURN ON ?

YES

REPLACETOUCHPANEL

VERIFY TOUCH PANELIS CONNECTED TOCONTROL BOARD

NO

YES

VERIFY GROUNDS ON:--13A/BLK AT P3--3 OF CONTROLBOARD--13B/BLK AT P3--8 OF CONTROLBOARD--13C/BLK AT P4--5 OF CONTROLBOARD

NEXT

OK

REPLACETOUCHPANEL

ELECTRICAL

4-937200 330045 (10--99)

RIBBON CABLE (2)

P3--1

39/GRN

P2--12P2--11P2--10P2--9P2--8P2--7P2--6P2--5P2--4P2--3P2--2P2--1

GND.

ES

SCRUB

SQ/VAC

BAT.3

BAT.0

BAT.2

REC.TANK FULL

P2--12

STATIC GND.

TO FRAME

10F/YEL

6A/BLU

CB--3

15A

13AF/BLK

13C/BLK

13B/BLK

13A/BLK

10C/YEL

10B/YEL

10A/YEL

P4--9

P4--10

BATTERIES

P3--9

P3--14 2.3 AMPS

P3--5

P3--4

P3--15

P3--10

P3--13

P3--11

P3--12

P4--1

P3--7

P3--2

P4--11

P4--2

P4--3

P4--5

P3--8

P3--3

P5--1

P5--2

P5--3

P4--7

P4--6

REV SENSE

FWD SENSE

INPUTS

SHUNT

GROUND

+36

VDC

SHIELD

DOWN PRES.0

BAT.1

SQ/VAC

ES

DOWN PRES.3

+5VDC

DOWN PRES.1DOWN PRES.2

FU--1

CIRCUIT BOARD

ELECTRONIC CONTROL

P2--11P2--10P2--9P2--8P2--7P2--6

P2--1P2--2P2--3P2--4P2--5

P2--3

P1--6

P1--4

P1--2

P1--1

PANELLE

DS

GROUND

PANELSWITCHES

CONTROL

POWER

POWER

CONTROL

POWER

POWER

P1--6

P1--4

P1--2

P1--1


M1

MAIN

80A

+36VDC


TOUCH PANEL ANDRIBBON TESTING


RCONNECTOR PINP

LEGEND

RELAY COIL

ARMATURERESISTOR

DIODEFUSE

SWITCH


ARM

MDFU

S

MTRCB

ELECTRICAL

4-94 7200 330045 (10--99)

VERIFY THAT 11/BRNIS NOT SHORTED TOGROUND, THEN,REPLACE THECONTROL BOARD

---LOW BATTERY=#1 BATTERY LED BLINKING---RECOVERY TANK FULL= RED OVERFLOWLED ON

KEY SWITCH ONARE ANY OF THE FOLLOWINGCONDITIONS TRUE ?

VACUUM FAN (S)

OPERATION: To enable the vacuum fan, the following conditions must occur--D 1.-- Vacuum fan/squeegee system selected on the touch panelD 2.-- Machine in neutral or forward positionD 3.-- No ”low battery” condition sensedD 4.-- No ”full recovery tank” condition sensed

VACUUM MOTOR TURNS ON:D 1.-- 11/BRN is switched to ground at control board P3--12,

turning on M2 contactorD 2.-- M2 contactor supplies battery voltage to the vacuum fan(s),

turning them on

: MACHINE POWERS UP, TOUCH PANELAND PROPEL SYSTEMS TEST GOOD

YES NO

CHARGE BATTERIES ORDRAIN RECOVERY TANK

RUN SELF TEST DIAGNOSTIC SOFTWARE--HOLD SQ/VAC BUTTON--TURN ON KEY--RELEASE BUTTON AFTER 5 SEC--BATTERY LED #4 WILL BLINK IN THIS MODE--LET MACHINE RUN UNTIL ONE RED (FAIL)OR GREEN (PASS) LIGHT COMES ON

GREEN(PASS)

RED(FAIL)

CIRCUIT BOARD VACUUMFAN OUTPUT TEST GOOD

DID FAN TURN ON/OFFDURING SELF TEST ?

NO

RUN MANUAL MODE TOTEST THE LOADS

READ ERROR CODES BY HOLDINGDOWN EACH OF THE 3 TOUCH PANELSWITCHES--IS THERE A VAC FAN OUTPUT ERROR ?

NO

YES

DISCONNECT 11/BRN AT M3 CONTACTORRE--RUN THE SELF TEST

GREEN(PASS)

RED(FAIL)

REPLACE M3CONTACTOR

YES

SEE NEXT PAGE....

RUN INPUTTEST MODE

SEE NEXT PAGE....

ELECTRICAL

4-957200 330045 (10--99)

ACTIVATE SQUEEGEE/VAC FANTOUCH PANEL BUTTON---DOES THE VAC FAN TURNON ?

CONTINUED FROM PREVIOUS PAGE CONTINUED FROM PREVIOUS PAGE


RUN INPUTTEST MODE

---HOLD SCRUB BUTTON---TURN ON KEY---RELEASE SCRUB BUTTON AFTER5 SEC---#2 DOWN PRESS LIGHT WILLBLINK IN INPUT MODE

IS BATTERY LED #2 ON ?(SECOND FROM LEFT)

NO

MACHINE TESTS GOOD

34A/ORA AT P4---7 IS SWITCHEDTO GROUND--- ---THIS SHOULD ONLYHAPPEN IN REVERSE--- ---GO TOPROPEL SYSTEM TESTING

YES

---HOLD ES BUTTON---TURN KEY ON---RELEASE BUTTON AFTER5 SEC---#3 BATTERY LED WILLBLINK IN MANUAL MODE

NO

YES

GO TO INPUT TESTING MODE

CHECK FOR BATTERY VOLTAGEFROM:---3A/GRY TO 13AF/BLK AT THEVAC FAN

0 VOLTAGE

BATTERYVOLTAGE

REPLACE VAC FAN

THE CONTROL BOARD IS SWITCHING11/BRN AT P3---12 TO GROUND TOTURN ON M2--- ---M2 IS BAD OR---10D/YEL, 11/BRN, 1A/ORA, CB---7,3/GRY, OR 13AF/BLK ARE OPEN

ELECTRICAL

4-96 7200 330045 (10--99)

RIBBON CABLE (2)

34/ORA

P3--1

17.5 AMPS PER MOTOR

39/GRN

D--8

3A/GRY

13AG/BLK3B/GRYMTR

M2

VAC FAN

+ --

P2--12P2--11P2--10P2--9P2--8P2--7P2--6P2--5P2--4P2--3P2--2P2--1

GND.

ES

SCRUB

SQ/VAC

BAT.3

BAT.0

BAT.2

REC.TANK FULL

P2--12

STATIC GND.TO FRAME

10F/YEL

6A/BLU

CB--3

15A

13S/BLK

13AF/BLK

13C/BLK

13B/BLK

13A/BLK

10D/YEL

10C/YEL

10B/YEL

10A/YEL

P4--9

P4--10

BATTERIES

P3--9

P3--14 2.3 AMPS

P3--5

P3--4

P3--15

P3--10

P3--13

P3--11

P3--12

P4--1

P3--7

P3--2

P4--11

P4--2

P4--3

P4--5

P3--8

P3--3P5--1

P5--2

P5--3

P4--7P4--6

34A/ORA

P--14

P--16

REV SENSEFWD SENSE

INPUTS

SHUNT

GROUND

+36

VDC

SHIELD

DOWN PRES.0

BAT.1

SQ/VAC

ES

DOWN PRES.3

+5VDC


FU--1

CLOSED =

DISABLEVAC/SQGE

CIRCUIT BOARDELECTRONIC CONTROL

P--15

REVERSEM5

P2--11P2--10P2--9P2--8P2--7P2--6

P2--1P2--2

P2--4P2--5

P2--3

P1--6

P1--4

P1--2

P1--1

PANELLE

DS


GROUND

CB--7

PANELSWITCHES

CONTROL

POWER

POWER

CONTROL

POWER

POWER

P1--6

P1--4

P1--2

P1--1


--+

24/GRY

REC.TANK FULLN.O.C

S--411/BRN

P--3

P--2

P--6

P--7

P--12

P--11

34B/ORA

20A OR 40A

3/GRY2/ORA

M1

MAIN

80A

M2

+36VDC 6VDC6VDC6VDC6VDC6VDC6VDC

MTR1A/RED

B--M--A2B+

VAC FANS

VACUUM FAN (S)


RCONNECTOR PINP

LEGEND

RELAY COIL

ARMATURERESISTOR

DIODEFUSE

SWITCH


ARM

MDFU

S

MTRCB

ELECTRICAL

4-977200 330045 (10--99)

ELECTRICAL

4-98 7200 330045 (10--99)

IF THE ERROR = ”NO SQUEEGEE STALL”(SQUEEGEE BUTTON HELD----DOWN PRESSURE#1 AND #2 ARE ON16/YEL, 17/GRY, OR SQUEEGEE ACTUATOR AREOPEN

IF THE ERROR = ”EARLY SQUEEGEE STALL”(SQUEEGEE BUTTON HELD----DOWN PRESSURE #2LIGHT ON--DISCONNECT SQUEEGEE ACTUATOR AND RETEST--ERROR STILL EXISTS----VERIFY WIRE 16/YEL AND17/GRY ARE NOT SHORTED TO GROUNDTHEN REPLACE THE CONTROL BOARD

CIRCUIT BOARDSQUEEGEE OUTPUTSTEST GOOD

---LOW BATTERY=#1 BATTERY LED BLINKING---RECOVERY TANK FULL= RED OVERFLOWLED ON

KEY SWITCH ONARE ANY OF THE FOLLOWINGCONDITIONS TRUE ?

SQUEEGEE

OPERATION: To lower the squeegee actuator, the following conditions must occur--D 1.-- Vacuum fan/squeegee system selected on the touch panelD 2.-- Machine in neutral or forward positionD 3.-- No ”low battery” condition sensedD 4.-- No ”full recovery tank” condition sensed

SQUEEGEE ACTUATOR EXTEND OR RETRACT:D 1.-- 16/YEL at P3--10 and 17/GRY at P3--15 are both at battery

voltage in the off positionD 2.-- Is pulsed low to extend, is pulsed

low to retract the squeegee actuator

YES NO

CHARGE BATTERIES ORDRAIN RECOVERY TANK


RED(FAIL)

GREEN(PASS)

DID SQUEEGEE LOWER/RAISEDURING SELF TEST ?

NO


READ ERROR CODES BY HOLDINGDOWN EACH OF THE 3 TOUCH PANELSWITCHES--ARE THERE ANY SQUEEGEE OUTPUTERRORS ?

NO

YES

YES

SEE NEXT PAGE....

RUN INPUTTEST MODE

SEE NEXT PAGE....


IF THE ERROR = ”NO SQUEEGEE ACTUATORZERO CURRENT” (SQUEEGEE BUTTONHELD----DOWN PRESSURE #1 LIGHT ON--REPLACE THE CONTROL BOARD

ELECTRICAL

4-997200 330045 (10--99)

ACTIVATE SQUEEGEE/VAC FANTOUCH PANEL BUTTON---DOES THE SQUEEGEEACTUATOR LOWER ?

CONTINUED FROM PREVIOUS PAGE CONTINUED FROM PREVIOUS PAGE


RUN INPUTTEST MODE


IS BATTERY LED #2 ON ?(SECOND FROM LEFT)

NO

MACHINE TESTS GOOD

34A/ORA AT P4---7 IS SWITCHEDTO GROUND--- ---THIS SHOULD ONLYHAPPEN IN REVERSE--- ---GO TOPROPEL SYSTEM TESTING

YES


NO

YES

GO TO INPUT TESTING MODE

0 VOLTAGE

BATTERY VOLTAGEOR --- BATTERYVOLTAGE

REPLACE ACTUATOR

DISCONNECT SQUEEGEE ACTUATORMEASURE VOLTAGE FROM 16/YEL TO17/GRY AT SQUEEGEE ACTUATOR

16/YEL OR 17/GRY ARE OPEN

ELECTRICAL

4-100 7200 330045 (10--99)

RIBBON CABLE (2)

P3--1

39/GRN

P2--12P2--11P2--10P2--9P2--8P2--7P2--6P2--5P2--4P2--3P2--2P2--1

GND.

ES

SCRUB

SQ/VAC

BAT.3

BAT.0

BAT.2

REC.TANK FULL

P2--12

STATIC GND.TO FRAME

10F/YEL

6A/BLU

CB--3

15A

13C/BLK

13B/BLK

13A/BLK

10C/YEL

10B/YEL

10A/YEL

P4--9

P4--10

BATTERIES

P3--9

P3--14 2.3 AMPS

P3--5

P3--4

P3--15

P3--10

P3--13

P3--11

P3--12

P4--1

P3--7

P3--2

P4--11

P4--2

P4--3

P4--5

P3--8

P3--3P5--1

P5--2

P5--3

P4--7P4--6

34A/ORA

P--14

P--16

REV SENSEFWD SENSE

INPUTS

SHUNT

GROUND

+36

VDC

SHIELD

DOWN PRES.0

BAT.1

SQ/VAC

ES

DOWN PRES.3

+5VDC


FU--1


P--15

P2--11P2--10P2--9P2--8P2--7P2--6

P2--1P2--2

P2--4P2--5

P2--3

P1--6

P1--4

P1--2

P1--1

PANELLE

DS


GROUND

PANELSWITCHES

CONTROL

POWER

POWER

CONTROL

POWER

POWER

P1--6

P1--4

P1--2

P1--1


P--3

P--2

P--6

P--7

P--12

P--11

M1

MAIN

80A

+36VDC6VDC6VDC6VDC6VDC6VDC6VDC

B--M--A2B+


RCONNECTOR PINP

LEGEND

RELAY COIL

ARMATURERESISTOR

DIODEFUSE

SWITCH


ARM

MDFU

S

MTRCB

SQUEEGEE

34B/ORA

33A/PUR

33/PUR

AB

SQUEEGEE UP/DN

17/GRY

16/YELMTR

ELECTRICAL

4-1017200 330045 (10--99)

ELECTRICAL

4-102 7200 330045 (10--99)

ARE ALL 4 BRUSH DOWNPRESSURE LED’S FLASH-ING ?---OPEN BRUSH CIRCUITBREAKER SENSED

TURN ON SCRUBSYSTEM--- ---DO BOTHBRUSH MOTORS RUN ?

22/BRN IS SHORTEDTO GROUND OR CIRCUITBOARD IS BAD----NOTE:IF BOARD IS BAD,VERIFY THAT D--6 ANDD--7 ARE GOOD

PERFORM BATTERYMAINTENANCE

GOOD

LIFT AND LOWER RECOVERYTANK FULL FLOAT (S--4)DOES THE OVERFLOW LEDTURN ON THEN OFF ?

DRAIN RECOVERYTANK----TURN SCRUBSYSTEM BACK ON----ISOVERFLOW LED STILL ON ?

KEY ON--- ---TURN ON SCRUB SYSTEM,PROPEL FORWARD. IS THE SCRUBSYSTEM AUTOMATICALLY TURNED OFF ?(TOUCH PANEL LED TURNS OFF)

SCRUB SYSTEM

YESNO

IS THE OVERFLOWLED ON ? (RED)

YES

YES

NO

IS #1 BATTERYLED FLASHING ?

NO

YES

TEST OVERFLOWSWITCH

RUN INPUTTEST MODE


YES

SYSTEM TESTSGOOD

NO

ALWAYSON

ALWAYSOFF

S--4 FLOAT SWITCH ISOPEN IN THE UP POSITION,OR, 24/GRY AND 13S/BLKARE OPEN

S--4 FLOAT SWITCH ISSHORTEDIN THE DOWN POSITIONOR 24/GRY IS SHORTEDTO GROUND

TEST FOR LOWBATTERIES

REPLACE BOARD

LOWRUN MANUAL MODE


YES

NO

NOTE: A SHORTED MOTOR OR D--6,D--7 WILL OPEN CIRCUIT BREAKER


DID THE MACHINE PASS SELF TEST ?

YES

DID THE BRUSH HEADLOWER AND LIFTDURING SELF TEST ?

YES

SCRUB SYSTEM ISPASSING SELFDIAGNOSTICS

NO

THE ACTUATOR IS STUCKREPLACE ACTUATOR


YES

NONO

RECORD ERROR,THEN GO TO ”SELFTEST ERROR BREAK-DOWN ON PAGES4--63 AND 4--64

12A/GRN IS BEING PULLED TO GROUNDAT P3--11----THIS SHOULD TURN ON M3CONTACTOR AND SUPPLY VOLTAGE TO62A/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

ELECTRICAL

4-1037200 330045 (10--99)

SELF TEST ERRORBREAKDOWN

IF ERROR READS = ”BRUSH CONTACTOR OUTPUT”(ES BUTTON HELD, DOWN PRESSURE LED #4 IS LIT)

--- DISCONNECT 12A/GRN AT M3 AND RERUN SELF TEST--- NO ERROR NOW = REPLACE M3--- SAME ERROR STILL: DISCONNECT CONTROL BOARD, VERIFY12A/GRN IS NOT SHORTED TO GROUND--- ---THEN REPLACE THECONTROL BOARD

IF ERROR READS = ”NO BRUSH ACTUATOR ZEROCURRENT”

(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 #4 IS LIT)--- DISCONNECT BRUSH HEAD ACTUATOR AND RE---RUN SELF TEST--- SAVE ERROR: 18/BRN AND 19/GRN ARE SHORTED OR CONTROLBOARD IS BAD--- NOW GET ”NO BRUSH STALL” ERROR: REPLACE BRUSH HEADACTUATOR

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 ZEROCURRENT”

(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: THECIRCUIT BOARD SHOULD BE REPLACED

IF ERROR READS = ”ZERO BRUSH MOTORCURRENT”

(SQUEEGEE BUTTON HELD, DOWN PRESSURE LED #2 IS LITAND 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 HARNESSCONNECTIONS--- VERIFY THAT THE SHUNT IS HOOKED UP AS PER SCHEMATIC--- REPLACE THE SHUNT AS NECESSARY

ELECTRICAL

4-104 7200 330045 (10--99)

SELF TEST ERRORBREAKDOWN

IF ERROR READS = ”LOW BRUSH CURRENT”(SCRUB BUTTON HELD, DOWN PRESSURE LED #3 IS LIT)--- GO INTO MANUAL MODE, TURN ON SCRUB BRUSHES--- ---VERIFYBOTH BRUSHES ARE OPERATING--- IF ONLY ONE MOTOR IS OPERATING: REPLACE OPEN WIRE ORMOTOR--- 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 THEMACHINE: THE SCRUB SYSTEM IS PASSING SELF--DIAGNOSTICS-- DETERMINE WHAT OTHER ERROR WAS CAUSINGTHE SELF TEST FAILURE-- --TROUBLESHOOT THATSECTION

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, TURNINGON M3, AND SUPPLYING VOLTAGE TO BRUSH MOTORS--- M3 IS BAD OR 12A/GRN, 10E/YEL, 1B/RED, 4/YEL, 4A/YEL, CB---8,CB---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 FROM64/PUR TO 66/GRN AT THE BRUSH MOTORS--- --- IF VOLTAGE = B+REPLACE BRUSH MOTORS--- IF VOLTAGE = 0 VOLTAGE--- ---GO TO STEP 6

ELECTRICAL

4-1057200 330045 (10--99)

+

RIBBON CABLE (2)

P3--1

20--25 AMPSPER MOTORDN.PRESS.#4

39/GRN

A B

B(A)A(B)

B

A

A

B64C/PUR

62C/BLU

64/PUR

62/BLU

13AB/BLK

13AC/BLKD--7

D--687A

/WHT

88A/RED

M3

BRUSH--

P2--12P2--11P2--10P2--9P2--8P2--7P2--6P2--5P2--4P2--3P2--2P2--1

GND.ES

SCRUBSQ/VAC

BAT.3

BAT.0

BAT.2

REC.TANK FULL

P2--12

STATIC GND.TO FRAME

10F/YEL

6A/BLU

CB--3

15A13S/BLK

13DD/BLK

13AJ/BLK

13AH/BLK

13C/BLK13B/BLK

13A/BLK

12A/GRN

10C/YEL10B/YEL

10A/YEL

10E/YEL

22A/BRN

22/BRN

22A/BRN

P4--9

13AA/SHIELD

P4--10

BA

BATTERIES

64D/PUR

62D/BLU

P3--9

P3--14 2.3 AMPSP3--5

P3--4

P3--15

P3--10

P3--13

P3--11

P3--12

P4--1P3--7

P3--2

P4--11

P4--2

P4--3P4--5

P3--8P3--3P5--1P5--2

P5--3

P4--7P4--6

34A/ORA

33A/PUR

P--14

BRUSH HEAD UP/DN

25A

25A

D--4

D--3

SENSE LINE

SENSELIN

E

P--16

REV SENSEFWD SENSE

INPUTS

SHUNT

GROUND

+36

VDC

SHIELD

DOWN PRES.0

BAT.1

SQ/VAC

ES

DOWN PRES.3

+5VDC


FU--1

CLOSED =DISABLEVAC/SQGE


P--15

P2--11P2--10P2--9P2--8P2--7P2--6

P2--1P2--2P2--3P2--4P2--5

P1--6P1--4

P1--2P1--1

PANELLE

DS


GROUND

CB--9

CB--8

PANELSWITCHES

CONTROLPOWER

POWER

BR.MOTOR FAULT

62B/BLU

CONTROL

POWERPOWER

P1--6

P1--4

P1--2

P1--1


87/CLR

88/BLK

24/GRY

REC.TANK FULLN.O.C

S--4

19/GRN

88/BLK

87/CLR

66A/GRN

66B/GRN

P--3

P--2

P--6

P--7

P--12P--11

64B/PUR34B

/ORA

33/PUR

BR.MOTO

RFA

ULT

64A/PUR

62A/BLU

4A/YEL

4/YEL

M1

MAIN

80A

M3

+36VDC

A

A

MTR


LEFT BRUSH MOTOR

RIGHT BRUSH MOTOR

MTR

MTR

1B/RED

B--M--A2B+

18/BRN

SCRUB SYSTEM


RCONNECTOR PINP

LEGEND

RELAY COIL

ARMATURERESISTOR

DIODEFUSE

SWITCH


ARM

MDFU

S

MTRCB

ELECTRICAL

4-106 7200 330045 (10--99)

WHEN RECOVERY TANK 1/2 FULL SWITCH(S---5) IS CLOSED (FLOAT IN UP POSI-TION) THE ES TOUCH PANEL LIGHTTURNS ON--- IS THE ES LIGHT ON WHEN S---5CLOSES ?

RUN INPUTTEST MODE

20/GRY IS SWITCHED TO GROUND ATP3---14--- ---MOTOR SHOULD RUN---ES PUMP MOTOR OR 10H/YEL OR20/GRY IS OPEN

---HOLD ES BUTTON---TURN KEY ON---RELEASE BUTTON AFTER5 SEC---#3 BATTERY LED WILLBLINK IN MANUAL MODE---TURN ON ES SYSTEM--- ---IS THE PUMP RUNNING ?

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--DO YOU GET ”ES PUMP OUTPUT” ERROR ?--RED FAIL LIGHT ON, HOLD ES BUTTONDOWN, DOWN PRESSURE LED #2 IS LIT

ESt SYSTEM

OPERATION: When ES system selected on the touch panel and input floats are inthe proper position

D Recovery tank is 1/2 full = S---5 is closedD Solution tank NOT full = S---9 is openedD P3---14 is switched to ground, turning on the ES pumpNOTE: 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

STILL HAVEERROR

NO ERROR

DISCONNECT ES PUMPAND RE--TEST

NO ERROR

REPLACE THE BOARD

RUN MANUAL MODETEST

NO

YES

---HOLD SCRUB BUTTON---TURN ON KEY---RELEASE SCRUB BUTTON AFTER5 SEC---#2 DOWN PRESS LIGHT WILLBLINK IN INPUT MODE---VERIFY FLOAT OPERATION

NO

YES

SEE NEXT PAGE....

ERROR ”ES OUTPUT”


VERIFY THAT 20/GRY IS NOTSHORTED TO GROUND,THEN REPLACE THE ESPUMP

ELECTRICAL

4-1077200 330045 (10--99)

S---5 IS SHORTED WITHTHE FLOAT DOWN OR23/GRN IS SHORTEDTO GROUND

CONTINUED FROM PREVIOUS PAGE

NOYES

23/GRN, 13R/BLK,OR S---5 FLOATSWITCH IS OPEN

NO

YES

SYSTEM TESTS GOOD

DOES ES LIGHT TURNOFF WHEN S---5 ISOPEN ? (FLOAT DOWN)

YES

NO

WHEN SOLUTION TANK FULL SWITCH (S---9)IS CLOSED (FLOAT IN UP POSITION) THEOVERFLOW LIGHT TURNS ON--- --- IS THEOVERFLOW LIGHT ON WHEN S---9 CLOSES ?

YES

DOES THE OVERFLOWLIGHT TURN OFFWHEN S---9 IS OPEN ?(FLOAT DOWN)

NO

S---9 FLOAT SWITCH, 14/GRY,OR 13Q/BLK IS OPEN

S---9 IS SHORTED WITHTHE FLOAT DOWN OR14/GRY IS SHORTEDTO GROUND

ELECTRICAL

4-108 7200 330045 (10--99)

RIBBON CABLE (2)

P3--1

39/GRNP2--12P2--11P2--10P2--9P2--8P2--7P2--6P2--5P2--4P2--3P2--2P2--1

GND.

ES

SCRUB

SQ/VAC

BAT.3

BAT.0

BAT.2

REC.TANK FULL

P2--12

STATIC GND.TO FRAME

10F/YEL

6A/BLU

CB--3

15A

13C/BLK

13B/BLK13A/BLK

P4--10

BATTERIES

P3--9

P3--5P3--4

P3--15

P3--10

P3--13

P3--11

P3--12P4--1

P3--7

P3--2P4--11

P4--3P4--5

P3--8P3--3P5--1P5--2P5--3

P4--7P4--6

REV SENSEFWD SENSE

INPUTS

SHUNT

GROUND

+36

VDC

SHIELD

DOWN PRES.0

BAT.1

SQ/VAC

ES

DOWN PRES.3

+5VDC


FU--1


P2--11P2--10P2--9P2--8P2--7P2--6

P2--1P2--2P2--3P2--4P2--5

P1--6

P1--4

P1--2

P1--1

PANELLE

DS

GROUND

PANELSWITCHES

CONTROLPOWER

POWER

P1--6

P1--4

P1--2

P1--1

MEMBRANETO

UCHPANEL

M1

MAIN

80A

+36VDC


ESt SYSTEM


RCONNECTOR PINP

LEGEND

RELAY COIL

ARMATURERESISTOR

DIODEFUSE

SWITCH


ARM

MDFU

S

MTRCB

13Q/BLK

13R/BLK

ES OFFFULLSOLUTION TANK

S--9P4--9 14/GRY (ES OPTION)

CLOSED =N.O.C

P4--2(ES OPTION)CLOSED =ES ENABLE

1/2 FULLREC.TANK23/GRN

C N.O.

S--5

10H/YELP3--14 2.3 AMPS

20/GRY

ES PUMP

MTR

ELECTRICAL

4-1097200 330045 (10--99)

SYSTEM IS TESTING GOOD---REVIEW OPERATIONDESCRIPTION--- --- IS SYSTEMPROPERLY ENABLED ?

38/ORA IS SWITCHEDTO GROUND ATP3---1--- ---VALVE SHOULDTURN ON---VALVE, 10J/YEL, OR38/ORA IS OPEN

RUN MANUAL MODETEST

ESt FILTER FLUSHSYSTEM

---HOLD ES BUTTON---TURN KEY ON---RELEASE BUTTON AFTER5 SEC---#3 BATTERY LED WILLBLINK IN MANUAL MODE---TURN ON ES SYSTEM--- ---DOES SV---1 TURN ON ?

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--DO YOU GET ”AIR FLUSH VALVE” ERROR ?--RED OVERFLOW LIGHT ON = FAIL SELFTEST--PRESS ES BUTTON----ES LED TURN ON

OPERATION: To enable the ESt flush system----the vacuum fan and ESt systemmust be turned onD P3--14 will switch to ground for 5 seconds every

45 seconds----turning on SV--1D Every time SV--1 is turned on an air burst clears

debris from the ESt pump filter

STILL HAVEERROR

NO ERROR

DISCONNECT ESFLUSH SOLENOIDAND RE--TEST

NO

ERROR

REPLACE BOARD

NO ERROR

REPLACE SV--1

YES


ELECTRICAL

4-110 7200 330045 (10--99)

RIBBON CABLE (2)

39/GRNP2--12P2--11P2--10P2--9P2--8P2--7P2--6P2--5P2--4P2--3P2--2P2--1

GND.

ES

SCRUB

SQ/VAC

BAT.3

BAT.0

BAT.2

REC.TANK FULL

P2--12

STATIC GND.TO FRAME

10F/YEL

6A/BLU

CB--3

15A

13C/BLK

13B/BLK13A/BLK

P4--10

BATTERIES

P3--9

P3--5P3--4

P3--15

P3--10

P3--13

P3--11

P3--12P4--1

P3--7

P3--2P4--11

P4--3P4--5

P3--8P3--3P5--1P5--2P5--3

P4--7P4--6

REV SENSEFWD SENSE

INPUTS

SHUNT

GROUND

+36

VDC

SHIELD

DOWN PRES.0

BAT.1

SQ/VAC

ES

DOWN PRES.3

+5VDC


FU--1


P2--11P2--10P2--9P2--8P2--7P2--6

P2--1P2--2P2--3P2--4P2--5

P1--6

P1--4

P1--2

P1--1

PANELLE

DS

GROUND

PANELSWITCHES

CONTROLPOWER

POWER

P1--6

P1--4

P1--2

P1--1


M1

MAIN

80A

+36VDC


ESt FILTER FLUSHSYSTEM


RCONNECTOR PINP

LEGEND

RELAY COIL

ARMATURERESISTOR

DIODEFUSE

SWITCH


ARM

MDFU

S

MTRCB

P4--9

P4--2

P3--14 2.3 AMPS

P3--138/ORA10J/YEL

ES FILTER FLUSH

SV--1ES PUMP

We Need Your Help...As part of Tennant’s Zero Defects Program, we want to know about errors you havefound or suggestions you may have regarding our machine manuals. If you find anerror 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.

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TechnicalPublications#15701NorthLilacDriveP.O.Box1452Minneapolis,MN55440--9947

TENNANTCOMPANY

We Need Your Help...As part of Tennant’s Zero Defects Program, we want to know about errors you havefound or suggestions you may have regarding our machine manuals. If you find anerror 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 PageMachine - Report Error - Suggestion

Name Date

Customer Number

CompanyAddress

City/State/Zip Code

Tapehere Foldalongdottedlines

NOPOSTAGENECESSARYIFMAILEDINTHE

UNITEDSATES

BUSINESSREPLYMAIL FIRSTCLASSMAILPERMITNO.94MINNEAPOLIS,MN

POSTAGEWILLBEPAIDBYADDRESSEE

TechnicalPublications#15701NorthLilacDriveP.O.Box1452Minneapolis,MN55440--9947

TENNANTCOMPANY

Documents

7200 Service Manual - PSJanitorial.com 7200... · This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT Model 7200 ride on scrubber. The