Tennant T500 Service Information Manual
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Tennant T500 Service Information Manual

Automatic floor scrubber (battery)
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See also: Operator's Manual
®
Hygenic
Fully Cleanable Recovery Tank
®
Tennant True
Parts
IRIS
®
a Tennant Technology
Pro-Panel™ Controls
Insta-Fit™ Adapter
Smart-Fill™Automatic Battery Watering
North America / International
For the latest Parts Manuals and other
language Operator Manuals, visit:
www.tennantco.com/manuals
T500
Automatic Floor Scrubber
Service Information Manual
*9015504*
(Battery)
9015504
Rev. 01 (1-2018)

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Summary of Contents for Tennant T500

  • Page 1 ® Hygenic Fully Cleanable Recovery Tank ® Tennant True Parts IRIS ® a Tennant Technology Pro-Panel™ Controls Insta-Fit™ Adapter Smart-Fill™Automatic Battery Watering North America / International 9015504 For the latest Parts Manuals and other Rev. 01 (1-2018) language Operator Manuals, visit: *9015504* www.tennantco.com/manuals...
  • Page 2 INTRODUCTION INTENDED USE This manual is available for each new model. It provides The T500 walk-behind fl oor scrubber is intended for necessary operation and maintenance instructions. commercial use, for example in hotels, schools, hospitals, factories, shops, offi ces and rental businesses. It is designed to scrub hard fl...

  • Page 3: Table Of Contents

    Settings (Pro-Panel Model) ....34 I-Drive Testing Procedure ......81 Hydrolink® Battery Watering System Displaying Fault Codes / Warnings (Trojan® Battery Option) .....35 (Pro-Panel Machines Only) ....82 Manaual Hand Pump Batery Watering System (Tab Batter Option) ....36 Automatic Battery Watering System..37 T500 9015504 01-2018...
  • Page 4 Removing / Installing The Water Solenoid Valve ........118 Connecting Hoses To Ptc (Push-To-Connect) Fittings....120 Disconnect Hoses From Ptc (Push-To-Connect) Fittings....121 Control Modules ..........122 Removing / Installing The Control Module..........122 Removing / Installing The Drive Module..........124 Removing / Installing The Interface T500 9015504 01-2018...
  • Page 5 CONTENTS T500 9015504 01-2018...

  • Page 6: Important Safety Instructions - Save These Instructions

    Tennant representative for information on how to disable the cellular communication functionality. FOR SAFETY: To identify actions that must be followed for safe operation of equipment.
  • Page 7 - All work must be done with suffi cient lighting and visibility. - All repairs must be performed by trained personnel. - Use Tennant supplied or approved replacement parts. - Do not modify the machine from its original design. - Block machine tires before jacking machine up.

  • Page 8: Safety Labels - North America

    Batteries emit hydrogen gas. WARNING LABEL - Explosion or fire can result. Keep Electrical hazard. sparks and open flame away when Disconnect battery charging. cables before servicing machine. Located on bottom side of recovery tank. Located on circuit breaker panel. T500 9015504 01-2018...

  • Page 9: Safety Labels - Eu / Intl

    WARNING LABEL - result. Disconnect Spinning brush. charger cord before Keep hands away. servicing. Located on scrub Located on control head. console. WARNING LABEL - Electrical Hazard. Disconnect battery cables before servicing machine. Located on circuit board panel. T500 9015504 01-2018...

  • Page 10: General Information

    GENERAL INFORMATION GENERAL INFORMATION MACHINE COMPONENTS T500 9015504 01-2018...

  • Page 11: Scrub Head Types

    SCRUB HEAD TYPES 26 in / 650 mm Dual Disk 28 in / 700 mm Cylindrical Brush 28 in / 700 mm Orbital Pad 28 in / 700 mm Dual Disk 32 in / 800 mm Dual Disk T500 9015504 01-2018...

  • Page 12: Electrical Schematics

    3 Phase AC Induction Motor Energized Relay Coil Adaptor Harness Motor Encoder N.C. Relay Contacts Sensor (Variable Resistor) Notes Momenary Switch N.O. N.O. Relay Contacts Assembly Contact Switch N.C. Horn or Alarm AC Plug Solenoid Valve Capacitor Light T500 9015504 01-2018...
  • Page 13 REVERSE SWITCH (GND. = REV.) J1-3 P3-2 P1-8 35/GRN 35/GRN PROG_B+ POT LOW J10-3 POT.-1 J1-2 P1-9 34/YEL 34/YEL SPD LIMIT J10-2 J1-1 P1-2 33/ORA 33/ORA 100K PROPEL SPEED LIMIT POT HIGH J10-1 #1204930 STD: #1074941 I-DRIVE T500 9015504 01-2018...
  • Page 14 SW-17: #1212430 N.O. J3-3 59/WHT 13/BLK FLOAT BATTERY WATER LEVEL J4-1 PUMP+ BATTERY WATER PUMP J5-3 SENSE_POWER J5-2 SENSE_SIGNAL J4-2 PUMP- J5-1 SENSE_GND MTR-10: #1220042 BATTERY WATER FLOW SENSOR #1222371 ABW MODULE PCB ASSY: #1220931 ABW MODULE: #1220924 T500 9015504 01-2018...

  • Page 15: Operational Matrix

    • Detergent Tank Not Empty • Battery Charger ON Interlock Spray Nozzle • Key ON (l) • Key OFF (O) (Optional) • Spray Nozzle Button ON • Spray Nozzle Button OFF • Solution Tank Not Empty • Solution Tank Empty T500 9015504 01-2018...

  • Page 16: Fastener Torque

    424 - 550 Nm 508 - 660 Nm 177 - 230 Nm 409 - 530 Nm 574 - 745 Nm 686 - 890 Nm 227 - 295 Nm 520 - 675 Nm 732 - 950 Nm 879 - 1140 Nm T500 9015504 01-2018...

  • Page 17: General Machine Dimensions/Capacities/Performance (North America / Intl)

    Sound power level uncertainty L 83.7 dB(A) 83.7 dB(A) 83.7 dB(A) uncertainty K Machine vibration at hand-arm* <2.5 m/s Ambient operating temperature Min: 36 F/2 C, Max: 110 F/43 C *Values per IEC 60335-2-72. Specifications are subject to change without notice. T500 9015504 01-2018...

  • Page 18: General Machine Dimensions/Capacities/Performance - North America Continued

    Sound power level uncertainty L 85.2 dB(A) 84.0 dB(A) uncertainty K Machine vibration at hand-arm* <2.5 m/s Ambient operating temperature Min: 36 F/2 C, Max: 110 F/43 C *Values per IEC 60335- 2- 72. Specifications are subject to change without notice. T500 9015504 01-2018...

  • Page 19: General Machine Dimensions/Capacities/Performance (Eu)

    Sound power level uncertainty L 83.7 dB(A) 83.7 dB(A) 83.7 dB(A) uncertainty K Machine vibration at hand-arm* <2.5 m/s Ambient operating temperature Min: 2 C, Max: 43 C *Values per IEC 60335-2-72. Specifications are subject to change without notice. T500 9015504 01-2018...

  • Page 20: General Machine Dimensions/Capacities/Performance - Eu Continued

    Sound power level uncertainty L 85.2 dB(A) 84.0 dB(A) uncertainty K Machine vibration at hand-arm* <2.5 m/s Ambient operating temperature Min: 2 C, Max: 43 C *Values per IEC 60335-2-72. Specifications are subject to change without notice. T500 9015504 01-2018...

  • Page 21: Machine Dimensions

    41.3 in / 1049 mm 28 in / 700 mm Model 28 in / 700 mm Model 61.1 in / 1552 mm 46.6 in / 1234 mm 32 in / 800 mm Model 32 in / 800 mm Model T500 9015504 01-2018...
  • Page 22 GENERAL INFORMATION CYLINDRICAL BRUSH MOEL 30.7 in / 780 mm 43.3 in 1100 mm 46.6 in / 1234 mm 59.1 in / 1501 mm T500 9015504 01-2018...
  • Page 23 GENERAL INFORMATION ORBITAL PAD MODEL 28 in / 710 mm 43.3 in 1100 mm 58.5 in / 1486 mm 41.3 in / 1049 mm T500 9015504 01-2018...

  • Page 24: Maintenance

    Check hoses for damage and wear 200 Hours Batteries, terminals and cables Check and clean 750 Hours Vacuum motor Replace carbon brushes 1250 Hours Propel motor Replace carbon brushes Brush motor Replace carbon brushes Brush belt Replace belt T500 9015504 01-2018...

  • Page 25: Machine Maintenance

    No tools are required to perform these maintenance operations. 2. Remove the debris tray and empty. AFTER DAILY USE 1. Drain and rinse out the recovery tank.See DRAINING TANKS. 3. Remove and clean the fl oat shut-off screen. T500 9015504 01-2018...
  • Page 26 SQUEEGEE BLADE REPLACEMENT. 6. Replace brushes when they no longer clean effectively or when the bristles are worn to the yellow indicator 8. Clean scrub head skirt. Check for wear or damage. Replace if worn or damaged T500 9015504 01-2018...
  • Page 27 ATTENTION: Do not disconnect battery cables while charger is plugged in, circuit board damage may result. 11. Severe environment option - Refi ll the severe environment tank with a recommended cleaning detergent at full concentration. Replace cap. T500 9015504 01-2018...

  • Page 28: After Weekly Use

    4. Inspect and clean the seal on the recovery tank lid. Replace seal if damaged. AFTER EVERY 50 HOURS OF USE 1. Drain solution tank. Remove the solution tank fi lter and clean screen (Figure 109). Turn the fi lter bowl counter-clockwise to remove. T500 9015504 01-2018...

  • Page 29: After Every 100 Hours Of Use

    BELTS (Cylindrical Brush Model) FOR SAFETY: Before leaving or servicing machine, stop on level surface, turn off machine, remove key and set parking brake if equipped. Replace belts every 1250 hours. Contact trained personnel for belt replacement. T500 9015504 01-2018...

  • Page 30: Batteries

    The fl ooded (wet) lead-acid batteries require routine watering as described below. Check the battery electrolyte level weekly. NOTE: If machine is equipped with the automatic or manual battery watering system, proceed to the BATTERY WATERING SYSYEM instructions. T500 9015504 01-2018...

  • Page 31: Charging Batteries

    When a battery reaches battery charge receptacle then plug the AC power its end of life and must be replaced, Tennant highly supply cord into a properly grounded wall outlet. recommends that the same battery type be used to Refer to the off-board battery charger’s owner...

  • Page 32: Battery Charger Settings

    Pro-panel recommends using the same battery type. If a different Pro-membrane amp hour or battery type is desired, Call Tennant Technical Support to report new battery type. ATTENTION: Do not disconnect battery cables while charger is plugged in, circuit board damage may result.

  • Page 33: Changing On-Board Battery Charger

    7. Replace the control console. 8. To set the BDI for the new battery type, plug the on-board battery charger cord into an electrical outlet. The machine’s software will automatically reprogram the BDI to the new battery type. T500 9015504 01-2018...

  • Page 34: Changing On-Board Battery Charger

    See battery label to determine type and brand. Press the up and down arrows to scroll through battery selection. NOTE: The battery charger profi le and battery discharge indicator will automatically reprogram when battery type is selected. T500 9015504 01-2018...

  • Page 35: Hydrolink® Battery Watering System

    6. After adding water, replace the dust cap on the battery fi ll hose and store the hand pump hose inside the machine’s battery compartment for future use. T500 9015504 01-2018...

  • Page 36: Manaual Hand Pump Batery Watering System (Tab Batter Option)

    (against the transparent window), the electrolyte is at the correct level, no water is required. 6. After adding water, store the hand pump hose inside the machine’s battery compartment for future use. T500 9015504 01-2018...

  • Page 37: Automatic Battery Watering System

    The automatic battery watering indicator will also alert user to add distilled water when tank is empty. See CONTROL PANEL OPERATION for further details. To store machine equipped with the automatic battery watering system in freezing temperatures, see STORING MACHINE/FREEZE PROTECTION. T500 9015504 01-2018...

  • Page 38: Squeegee Blade Replacement

    To loosen the knobs quickly, squeeze the blade retainer and squeegee frame together 5. Squeeze the squeegee frame and blade retainer together and re-tighten the two outside knobs. 3. Remove worn blade(s) from the blade retainer. T500 9015504 01-2018...

  • Page 39: Ec-H2O Water Conditioning Cartridge Replacement

    Service switch 3. Disconnect the two hose connectors from the top 3 indicator lights of the cartridge by pressing the gray collars inward and pulling the connectors outward. Lift cartridge to remove. Gray Collar Solution flow button T500 9015504 01-2018...

  • Page 40: Machine Jacking

    fl oor of your trailer or truck. NOTE: When transporting machine in an open truck or trailer, secure recovery tank lid. ATTENTION: Do not use control console area or accessory storage rails for tie-down locations, damage may occur. T500 9015504 01-2018...

  • Page 41: Storing Machine

    Models equipped with optional Severe Environment detergent tank - Lift tank from machine and empty the detergent from tank. Return tank. Pour a 1/4 gallon / 1 liter of propylene glycol based recreational vehicle (RV) antifreeze into the detergent tank. T500 9015504 01-2018...
  • Page 42 Severe Environment detergent tank. Add clean water to solution tank and to optional detergent tank and operate the machine to fl ush system. 7. Refi ll the automatic battery watering tank with distilled water, if equipped. T500 9015504 01-2018...

  • Page 43: Faults And Warnings

    2. J10 connector on Scrub and battery. If connections are Controller board unplugged. good, replace control board. 3. Scrub Controller board power dis- connected. 4. Scrub Controller inline power fuse defective/blown. 5. Scrub controller board problem. T500 9015504 01-2018...
  • Page 44 ☼ ● ● ● ☼ 0x0900 Propel Generic Fault 1. Generic i-Drive fault. Power cycle machine. Check 2. Large white i-Drive connector pin 2, connections/wiring. 8, or 9 disconnected. 3. User Interface speed pot connector unplugged. T500 9015504 01-2018...
  • Page 45 1. Propel controller inhibit 1 fault Power cycle machine. tripped. 0x0926 Propel Inhibit 2 1. Propel controller inhibit 2 fault Power cycle machine. Warning tripped. 0x0927 Propel Inhibit 3 1. Propel controller inhibit 3 fault Power cycle machine. Warning tripped. T500 9015504 01-2018...
  • Page 46 Current 2 Fault pressure combination are ap- propriate for machine. Check actuator. 0x0106 Scrub Motor 1 Short 1. Shorted load condition. Check wire harness and Fault 2. Some higher current draw than repair as needed. hardware design limit. T500 9015504 01-2018...
  • Page 47 0x0307 Valve FET Fault 1. Control board problem. Replace control board. FET 2. Power/battery issue on startup. detection includes motor, actuator, detergent pump, vacuum and battery watering pump. T500 9015504 01-2018...
  • Page 48 Current 2 Fault pressure combination are ap- propriate for machine. Check actuator. 0x0616 Wand Pump Short 1. Shorted load condition. Check wire harness and Fault 2. Some higher current draw than repair as needed. hardware design limit. T500 9015504 01-2018...
  • Page 49 1. Control boards not communicating 1. Power cycle machine. munication Fault properly. 2. No communication with a 2. Board lost power (wiring issue). network module. Use CANo- 3. Control board may be damaged. pen troubleshooting tech- niques. T500 9015504 01-2018...
  • Page 50 ● ☼ ● ☼ ● 0x0711 ec-H2O Pump Open 1. Wiring, connector or control board Control board is not detecting Warning issue on the ec-H2O pump. pump current. Check connec- tions for voltage and verify pump is operating. T500 9015504 01-2018...

  • Page 51: Scrubber Display Faults

    Refi ll detergent to clear indicator. If Empty detergent tank level is too low to fault persists, check connections. operate correctly. 2. Detergent tank switch connec- tor unplugged. 3. Scrub Controller connector J4 unplugged. 4. Scrub Controller connector J4 pin 4 disconnected. T500 9015504 01-2018...

  • Page 52: Ec-H2O Nanoclean Icon Faults

    Needs repair. Warning board issue on ec-H2O cell. 0x0723 ec-H2O Cell Over 1. Current draw higher than Current Warning expected. 0x0726 ec-H2O Cell Short 1. Shorted load condition. Warning 2. Some higher current draw than hardware design limit. T500 9015504 01-2018...
  • Page 53 0x0747 ec-H2O WCM Pump 1. Control board problem. Replace control board. FET detec- FET Fault 2. Power/battery issue on startup. tion includes motor, actuator, de- tergent pump, vacuum and battery watering pump. T500 9015504 01-2018...

  • Page 54: Off-Board Charger Error And Fault Codes

    30 seconds and retry charger. If it fails F-0-0-3 again, contact the vehicle or machine F-0-0-4 manufacturer. F-0-0-6 Off-Board Charger Error and Fault Codes table taken from the Delta-Q IC650 Charger Manual. © Delta-Q Technologies Corp. (PN: 710-0138 Rev 3 Date: 14/07/2014) T500 9015504 01-2018...
  • Page 55 TROUBLESHOOTING T500 9015504 01-2018...

  • Page 56: Onboard Battery Charging On

    Interface N.C. P2-2 Module Switch 1/RED Aux. Contactor Relay AC Power Cord Battery Positive + Battery Negative - CAN + CAN-bus + P2-6 AC Volts CAN - CAN-bus - P2-10 J3-3 Interface CAN GROUND Module 113/BLK/WHT P2-1 T500 9015504 01-2018...

  • Page 57: Batteries Fail To Charge / Reduced Run Time (Onboard Charger)

    • Are all battery cells within 0.050 (50 points) specifi c gravity of each other? Terms: AC = Alternating Current AGM = Absorbed Glass Mat Specifi c Gravity = Relative density of a substance compared to water (1.000 specifi c gravity) T500 9015504 01-2018...

  • Page 58: Off Board Battery Charging On

    (4) 6VDC Batteries 6VDC 6VDC 6VDC 6VDC Battery Charger Connector BLACK Cable Not Used N.O. J7-10, J7-7 4/YEL N.C. 5/GRN 6/BLU Interface Module Switch Battery Charger Interlock Switch Aux. Contactor Battery Positive + Relay Battery Negative - T500 9015504 01-2018...

  • Page 59: Batteries Fail To Charge / Reduced Run Time (Off Board Charger)

    • Are all battery cells within 0.050 (50 points) specifi c gravity of each other? Terms: AC = Alternating Current AGM = Absorbed Glass Mat Specifi c Gravity = Relative density of a substance compared to water (1.000 specifi c gravity) T500 9015504 01-2018...

  • Page 60: Power Up On

    AC Power Cord Onboard Battery Charger (Opt) 14/YEL 46/BLU 13/BLK SOLUTION VALVE DET METERING (OPTION) ECH20 (OPTION) (OPTION) Interface Module Touch Panel LCD Option J6 B+ Machine Control Module (Opt) Battery Positive + Battery Negative - AC Volts T500 9015504 01-2018...

  • Page 61: Machine Failed To Power Up

    • Test voltage applied to power-up subsystem as shown on and repair or electrical schematic replace neces- • Are electrical circuits operating as shown on electrical sary compo- schematic? nents Terms: VDC = DC Voltage T500 9015504 01-2018...

  • Page 62: Propel Subsystem

    AUX3_OUT P1-11 TO INTERFACE MODULE Controller (SHIELDED) Operational Matrix: Enabled Disabled Propel attery Charger ON Interlock Fwd/Rev Throttle (Option) Battery Positive + ral - Ready State Command PMC (Propel Motor Battery Negative - Fwd/Rev Switch Controller) Fault Input T500 9015504 01-2018...

  • Page 63: Machine Failed To Propel

    • Key ON sary compo- nents • Enable propel • Test voltage applied to propel subsystem as shown on electrical schematic • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 64: Scrub Motor On

    Enabled Disabled Lower One Step Button Scrub St t One Step Button B tter P ve + Motor ropel Fw Rev Throttle B tter ve - Low B tter V on non- Propel mo ls. tter Interlock T500 9015504 01-2018...

  • Page 65: Scrub Motor Failed To Turn On

    • Enable scrub motor and repair or re- • Test voltage applied to scrub motor subsystem as shown place necessary on electrical schematic components • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 66: Scrub Head Lift Actuator

    Disabled • Head Raised - One Step Button • Head Lowered - Battery Positive + Lift • Low Battery Voltage One Step Button • Load Current Fault Actuator Battery Negative - • Battery Charger ON Interlock (Option) T500 9015504 01-2018...

  • Page 67: Scrub Head Failed To Lift / Lower

    • Enable propel replace neces- sary compo- • Test voltage applied to actuator subsystem as shown on nents electrical schematic • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 68: Vacuum Fan On

    MACHINE CONTROL Approx. 21 Volts Normal Mode MODULE Approx. 12.5 Volts Quiet Mode Operational Matrix: Enabled Disabled Squeegee Lowered Squeegee Raised Vacuum Fan Low Battery Voltage Battery Positive + Fault attery Charger ON Interlock Battery Negative - T500 9015504 01-2018...

  • Page 69: Vacuum Fan Failed To Turn On

    • Enable vacuum fan and repair or re- • Test voltage applied to scrub motor subsystem as shown place necessary on electrical schematic components • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 70: Solution Control On (Conventional)

    Head Lowered - Raised - One-Step Button Solution Solution Control OFF One-Step Button Control Solution Control ON ral - Ready State or bail released Fwd/Rev Throttle (Conventional) Command or Bail Low Battery Voltage Fault activated attery Charger ON Interlock T500 9015504 01-2018...

  • Page 71: Solution Control Failed To Turn On (Conventional)

    • Test voltage applied to solution control (conventional) place necessary subsystem as shown on electrical schematic components • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 72: Solution Control On (Ec-H2O)

    • ecH2O Switch ON (ec-H2O) Neutral - Ready State or • Fwd/Rev Throttle bail released Command or Bail activated Battery Positive + • Low Battery Voltage • ecH2O System Fault Battery Negative - • Battery Charger ON Interlock T500 9015504 01-2018...

  • Page 73: Solution Control Failed To Turn On (Ec-H2O)

    • Test voltage applied to solution control (ec-H2O) place necessary subsystem as shown on electrical schematic components • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 74: Se (Severe Environment) On

    • Neutral - Ready State or bail Battery Negative - Detergent released • Fwd/Rev Throttle Command or Bail Pump activated • Detergent Tank Empty (Option) • Low Battery Voltage • Detergent Tank Not Empty • Fault • Battery Charger ON Interlock T500 9015504 01-2018...

  • Page 75: Se (Severe Environment) Failed To Turn On

    • Enable SE (Severe Environment) detergent pump and repair or re- • Test voltage applied to SE subsystem as shown on place necessary electrical schematic components • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 76: Spray Pump (Option)

    13/BLK INPUT_2 J7-4 Spray Pump Switch BUS BAR 46/BLU B+_STUD GND_STUD 45/GRN 13/BLK FLYBACK GND_1 J7-10 J7-8 13/BLK 47/PUR WAND_PUMP DIGITAL_GND1 J7-9 J12-8 Spray Pump Motor 13/BLK DIGITAL_GND3 J6-10 Battery Positive + Battery Negative - MACHINE CONTROL T500 9015504 01-2018...

  • Page 77: Spray Pump Failed To Turn On

    • Enable spray pump and repair or re- • Test voltage applied to spray pump subsystem as shown place necessary on electrical schematic components • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 78: Abw (Automatic Battery Watering) (Option)

    Battery Water Pump ABW Tank Switch PUMP- J4-2 Battery Positive + Battery Negative - Battery watering pump activates under the following conditions: -10 complete charge cycles -20 opportunity/incomplete charge cycles -17 combined charg cycles ABW Flow Sensor T500 9015504 01-2018...

  • Page 79: Abw (Automatic Battery Watering) System Failed To Turn On

    ABW fl ow sensor, and ABW tank switch as shown place necessary on electrical schematic components • Are electrical circuits operating as shown on electrical schematic? Terms: BDI = Battery Discharge Indicator T500 9015504 01-2018...

  • Page 80: I-Drive Testing (Universal Schematic)

    Directional Switch 9/WHT (closed = reverse) P2-M1 36/BLU REVERSE P1-12 10/TAN P2-M2 37/PUR GND_REF P1-13 100K Ω Throttle Potentiometer 35/GRN Battery Positive + POT LOW P1-8 34/YEL Battery Negative - SPD LIMIT P1-9 33/ORA POT HIGH P1-2 T500 9015504 01-2018...

  • Page 81: I-Drive Testing Procedure

    0 (zero) resistance. Always test through entire circuit. * Switched (+) and Unswitched (+) indicate positive battery voltage applied to circuit board. Negative (-) indicates battery negative (ground) as part of power supply to circuit board. T500 9015504 01-2018...

  • Page 82: Displaying Fault Codes / Warnings (Pro-Panel Machines Only)

    Authorized service providers can download the Service Diagnostics software from the My Tennant portal by visiting www.tennantco.com. Factory- Direct Tennant Service personnel have this software installed on their ServiceLink devices.

  • Page 83: Entering The Manual Mode (Membrane Panel Machines Only)

    M. LED indicates if scrub motor(s) are on or off. N. B and L pressed together simultaneously toggle between ABW pump on or ABW pump off. 15. Turn the key switch to OFF position to exit manual mode and return to operating mode T500 9015504 01-2018...

  • Page 84: Machines Only)

    + (plus) button to set the actuator in the extend direction. Squeeze the bail to move the actuator. Displays E (extend) or R (retract), the scrub actuator PWM (pulse width modulation) duty cycle, and the motor current. T500 9015504 01-2018...
  • Page 85 fl ow setting. Displays the water and the + (plus) button to change the fl ow setting and motor current. ec-H2O fl ow setting (three settings and off). Displays the PWM duty cycle and motor current. T500 9015504 01-2018...
  • Page 86 Displays the fl ow meter measured fl ow rate and motor current. 5. Turn the key switch to the OFF position to turn off the machine and exit the Manual Mode. T500 9015504 01-2018...

  • Page 87: Service Diagnostics Tool

    fi eld. 1. Connect a USB cable from a computer to the machine. Authorized service providers can download the Service Diagnostics software from the My Tennant portal at www.tennantco.com. Factory-Direct Tennant Service personnel have this software installed on their ServiceLink devices.
  • Page 88 8. The Service Diagnostic tool may prompt to cycle the key switch OFF/ON during the process. If prompted, click the OK button and then cycle the key switch to allow the programming to continue. T500 9015504 01-2018...
  • Page 89 SERVICE 9. Cycle the key switch to save selections. T500 9015504 01-2018...

  • Page 90: Reconfi Guring Existing Modules

    fi eld. Authorized service providers can download the Service Diagnostics software from the My Tennant portal by visiting www.tennantco.com. Factory- Direct Tennant Service personnel have this software installed on their ServiceLink devices.
  • Page 91 (this is faster) or the header arrow button to launch all module reprogramming (this is slower). Click the refresh button to display the new confi guration after reprogramming is completed. 7. Cycle the key switch to save changes. T500 9015504 01-2018...

  • Page 92: Programming The Drive Module

    fi eld. Authorized service providers can download the Service Diagnostics software from the My Tennant portal by visiting www.tennantco.com. Factory- Direct Tennant Service personnel have this software installed on their ServiceLink devices.
  • Page 93 SERVICE 5. Click on the i-Drive button. 6. Click on the Program Factory Defaults button to program the drive module. 7. Cycle the key switch to save. T500 9015504 01-2018...

  • Page 94: Reconfi Guring The Machine After New Hardware / Option Installation

    fi eld. Authorized service providers can download the Service Diagnostics software from the My Tennant portal by visiting www.tennantco.com. Factory- Direct Tennant Service personnel have this software installed on their ServiceLink devices.
  • Page 95 6. Select the new hardware setting from the pull down menu. 7. Click on the Program button to confi gure the machine for the new hardware / option. Reprogramming for new hardware should take several minutes to complete. T500 9015504 01-2018...

  • Page 96: Changing The Off-Board Battery Charger Settings

    DISCOVER AGM batteries 200-400 AH range SONNENSCHEIN GEL batteries 200- 400 AH range TPPL, 12XFC48/12XFC58/12XFC60 Changing the Off-Board Battery Charger Setting instructions and photos taken from the Delta-Q IC650 Charger Manual. © Delta-Q Technologies Corp. (PN: 710-0138 Rev 3 Date: 14/07/2014) T500 9015504 01-2018...

  • Page 97: Cleaning Systems

    1. Completely drain the solution tank and the 5. Remove the rear squeegee assembly from the recovery tank. machine. 2. Turn the key to the OFF position. T500 9015504 01-2018...
  • Page 98 10. Remove both transaxle mounting brackets securing the transaxle assembly / wheels to the machine. Set the transaxle mounting brackets, fl at washers, and hex screws aside. T500 9015504 01-2018...

  • Page 99: Removing / Installing The Drive Motor Carbon Brushes

    7. Carefully tip the machine onto the protective blanket. 8. Remove the access cover from the drive motor. 9. Remove the hardware securing the carbon brush in the drive motor. 10. Remove the carbon brush from the drive motor. T500 9015504 01-2018...

  • Page 100: Remove / Install The Cylindrical Scrub Head Assembly

    FOR SAFETY: Before leaving or servicing machine, stop on level surface, turn off machine, remove the scrub brushes aside. key, and set parking brake if equipped. 2. Turn the key to the OFF position and remove the key. T500 9015504 01-2018...
  • Page 101 11. Remove the cotter pin and clevis pin securing the orbital scrub head, reconfi gure the machine for the actuator to the head suspension spring bracket. orbital scrub head. See RECONFIGURING THE MACHINE AFTER NEW HARDWARE / OPTION INSTALLATION in this section of the manual. T500 9015504 01-2018...

  • Page 102: Checking / Adjusting The Cylindrical Scrub Brush Pattern

    Note: Parking brake can be used to hold machine in place if machine is equipped with the optional parking brake. 12. Unfasten yellow latch and remove the idler plate assembly from the scrub head. T500 9015504 01-2018...
  • Page 103 22. Recheck the brush width. Repeat step 19 through adjust the taper for the other brush (idler plate is step 22 as necessary. located on the other side of the scrub head). 17. Reapply chalk and repeat step 5 through step 16 as necessary. T500 9015504 01-2018...

  • Page 104: Removing / Installing The Cylindrical Scrub Head Motor Carbon Brushes

    NOTE: Carbon brushes should be replaced as sets. 8. Reinstall the removed carbon brushes / install the new carbon brushes into the cylindrical brush motor in the reverse order of removal. T500 9015504 01-2018...

  • Page 105: Remove / Install The Disk Scrub Head Assembly

    FOR SAFETY: When servicing machine, Disconnect 2. Turn the key to the OFF position and remove the battery connection and charger cord before key. working on machine. 3. Remove scrub brushes from the scrub head. Set the scrub brushes aside. T500 9015504 01-2018...
  • Page 106 8. Disconnect all solution supply hoses from the scrub head. 9. Remove the cotter pin and clevis pin securing the actuator to the head suspension spring bracket. 10. Remove the cotter pins and clevis pins securing the head lift arms to the scrub head assembly. T500 9015504 01-2018...

  • Page 107: Removing / Installing The Disk Scrub Head Motor Carbon Brushes

    NOTE: Carbon brushes should be replaced as sets. 8. Reinstall the removed carbon brushes / install the new carbon brushes into the disk brush motor in the reverse order of removal. T500 9015504 01-2018...

  • Page 108: Remove / Install The Orbital Scrub Head Assembly

    2. Turn the key to the OFF position and remove the key. 3. Disconnect the battery cable from the machine. FOR SAFETY: When servicing machine, Disconnect battery connection and charger cord before working on machine. T500 9015504 01-2018...
  • Page 109 15. Reinstall the removed scrub head / install the new scrub head onto the machine in the reverse order of removal. 8. Remove the hex screws and fl at washers securing the head lift bracket to the scrub head. T500 9015504 01-2018...

  • Page 110: Removing / Installing The Orbital Scrub Head Motor Carbon Brushes

    3. Remove the front scrub head cover from the machine. 4. Remove the cap from the motor. 5. Remove the pan screw and spring clip securing the carbon inside the motor and carefully pull the carbon brush assembly from the brush motor. T500 9015504 01-2018...
  • Page 111 SERVICE T500 9015504 01-2018...

  • Page 112: Remove / Install The Lower Orbital Head Isolators

    (Qty. 4) (Qty. 6) Scrubber plate Head spacer (Qty. 4) Pad driver plate Eccentric balance Hex nuts (Qty. 6) Flat screws (Qty. 4) Flat screws (Qty. 9) Lower isolators (Qty. 4) Pad driver face Scrub pad T500 9015504 01-2018...
  • Page 113 6. Loosen the set screw securing the concentric motor weight to the motor shaft. 7. Remove the lower plate and the lower isolators. 8. Install the lower orbital head isolators in the reverse order in which they were removed. T500 9015504 01-2018...

  • Page 114: Removing / Installing The Vacuum Fan

    FOR SAFETY: When servicing machine, Disconnect harness from the vacuum fan. battery connection and charger cord before working on machine. 1. Completely drain the recovery tank. 2. Turn the key to the OFF position. 3. Disconnect the battery cable from the machine. T500 9015504 01-2018...

  • Page 115: Removing / Replacing The Vacuum Fan Carbon Brushes

    REMOVING / INSTALLING THE VACUUM FAN in this section manual. 2. Remove hardware securing the vacuum fan cover 8. Cut the cable tie securing the vacuum fan / exhaust assembly to the motor. muffl er to the vacuum fan mount. T500 9015504 01-2018...

  • Page 116: Installing Carbon Brushes

    NOTE: Carbon brushes should be replaced as sets. 3. Reinstall the vacuum fan onto the machine. See REMOVING / INSTALLING THE VACUUM FAN in this section of manual. T500 9015504 01-2018...
  • Page 117 SERVICE T500 9015504 01-2018...

  • Page 118: Removing / Installing The Water Solenoid Valve

    1. Completely drain both the recovery tank and the when lifting batteries. solution tank. 5. Remove the rear squeegee assembly from the 2. Turn the key to the OFF position. machine. Set the rear squeegee assembly aside and hardware aside. T500 9015504 01-2018...
  • Page 119 10. Disconnect the main wire harness from the water solenoid valve. 11. Remove the water solenoid valve from the machine. 12. Reinstall the interface module / install the new water solenoid valve in reverse order of disassembly. T500 9015504 01-2018...

  • Page 120: Connecting Hoses To Ptc (Push-To-Connect) Fittings

    4. Pull on the fi tting to ensure the hose connection is edges. secure. 5. Test the fi tting / hose connections for leaks prior to leaving the site. T500 9015504 01-2018...

  • Page 121: Disconnect Hoses From Ptc (Push-To-Connect) Fittings

    fi tting and pull the hose from the fi tting. NOTE: Be sure there is no pressure in the system and the system is emptied of all solution before disconnecting hose(s) from the fi tting. T500 9015504 01-2018...

  • Page 122: Control Modules

    Control mounting bracket Drive module Flat washers (Qty. 2) Pan screws (Qty. 2) Button screws (Qty. 8) Circuit board Standoffs mounting (Qty. 6) heat shrink SEMS hex screws (Qty. 2) Main circuit board Lock Main scrub washer circuit board T500 9015504 01-2018...
  • Page 123 / control modules. Attach the other end of the static ground strap to the machine chassis. 5. Carefully pull the circuit board mounting heat shrink / circuit board away from the machine. T500 9015504 01-2018...

  • Page 124: Removing / Installing The Drive Module

    FOR SAFETY: When servicing machine, Disconnect battery connection and charger cord before working on machine. 1. Completely drain the recovery tank. 1. Turn the key to the OFF position. 2. Disconnect the battery cables. T500 9015504 01-2018...
  • Page 125 8. If a new drive module was installed, the new drive module must be programmed for the machine onto which it was installed. See PROGRAMMING THE DRIVE MODULE in this section of the manual. T500 9015504 01-2018...

  • Page 126: Removing / Installing The Interface

    2. Disconnect the battery cable from the machine. NOTE: To avoid damaging electronic components, a static ground strap must be worn at all times while handling circuit boards / control modules. Attach the other end of the static ground strap to the machine chassis. T500 9015504 01-2018...
  • Page 127 9. If a new interface module was installed, the new interface module must be programmed for the machine onto which it was installed. See PROGRAMMING A NEW INTERFACE MODULE in this section of the manual. T500 9015504 01-2018...

  • Page 128: Removing / Installing The Bail Switch, Speed Potentiometer, Or Directional Switch

    (Qty. 5) Bottom control Speed panel housing range dial Bail handle shaft Pan screws Flat washers Self tap (Qty. 2) (Qty. 2) screw Self tap screws (Qty. 9) Bail handle Button screws (Qty. 2) Control handle cover T500 9015504 01-2018...
  • Page 129 4. Remove the pan screws and fl at washers securing console to the machine. the instrument panel to the console. 5. Carefully separate the touch panel from the console. 6. Disconnect all wire harness / electrical connections from the instrument panel. Set the instrument panel aside. T500 9015504 01-2018...
  • Page 130 13. Remove the self tap screws from rear of the replacing the potentiometer or directional switch, operator console and separate the console remove the nut securing the potentiometer or assembly. directional switch. 11. Remove the bail handle from the bottom control housing. T500 9015504 01-2018...
  • Page 131 15. Remove the bail switch. 16. Reinstall the bail switch, speed potentiometer, and / or directional switch in the reverse order of disassembly. T500 9015504 01-2018...

  • Page 132: Removing / Installing The On-Board Battery Charger

    FOR SAFETY: When servicing machine, Disconnect battery connection and charger cord before working on machine. 1. Turn the key to the OFF position. 2. Disconnect the battery cable from the machine. T500 9015504 01-2018...
  • Page 133 Panel can be confi gured through the touch panel. All other models must be confi gured through separate confi guration software via a mini-USB programming port on the back of the operator console. (See SERVICE DIAGNOSTICS TOOL in this section of the manual) T500 9015504 01-2018...

  • Page 134: Options

    Battery fill caps (Qty. 4) Smart fill In-line filter module Battery Flat washers fill pump (Qty. 2) Hex screws Pan screws (Qty. 2) (Qty. 2) Flat Batteries Molded hose washers (Qty. 4) (Qty. 2) Drain cap T500 9015504 01-2018...

  • Page 135: Tab Battery Option

    Tank Actuator bracket Battery water tube In-line filter Smart fill module Battery Flat washers fill pump (Qty. 2) Hex screws Pan screws (Qty. 2) (Qty. 2) Flat Batteries Molded hose washers (Qty. 4) (Qty. 2) Drain cap T500 9015504 01-2018...

  • Page 136: Abw Pump Not Priming (Air In The System)

    ON position, and observe panel for a fault code. If there is no fault code, the machine is again ready for use. If there is a fault code, proceed to the following steps to eliminate air from the ABW system. T500 9015504 01-2018...

  • Page 137: Abw Pump Is Timing Out (1 Minute)

    4. Replace damaged / worn fi ttings, hoses, and battery caps as necessary. 5. Clean all water / electrolyte from the tops of the batteries and from inside battery tray. 6. Add distilled water to the battery watering system tank. T500 9015504 01-2018...

  • Page 138: Abw Overfi Lls The Batteries

    5. Clean all water / electrolyte from the tops of the batteries and from inside battery tray. 6. Add distilled water to the battery watering system tank. 7. Turn the key to the ON position. 8. Verify ABW pump is functioning properly and the fault is cleared. T500 9015504 01-2018...

  • Page 139: Replacing The Abw Liquid Level Sensor

    3. If necessary empty the solution from the tank. 4. Disconnect the main wire harness from the liquid level sensor. 5. Remove the liquid level sensor from the tank. 6. Reinstall the liquid level sensor in reverse order of disassembly. T500 9015504 01-2018...

  • Page 140: Removing / Installing The Ec-H2O Pump (Option)

    REMOVING / INSTALLING THE ec-H2O PUMP (OPTION) Circuit breaker ec-H2O module SEMS hex screws (Qty. 3) Actuator bracket ec-H2O ec-H2O cartridge mounting bracket Dispenser Switch pump assembly FRONT To: Scrub head Pressure switch FRONT Water solenoid valve To: Solution tank Inline filter T500 9015504 01-2018...
  • Page 141 6. Position a protective blanket next to the side of the machine that will be tipped onto the fl oor. 7. Carefully tip the machine onto the protective blanket. 8. Remove the hex screws securing the rear frame to the machine. T500 9015504 01-2018...

  • Page 142: Se (Severe Environment) Group (Option)

    SE (SEVERE ENVIRONMENT) GROUP (OPTION) Detergent pump Hex screws assembly (Qty. 2) To: ec-H2O module Knob Potentiometer Pan screws (Qty. 2) Detergent pump bracket Detergent pump Actuator bracket assembly To: Scrub head Liquid FRONT level senser Tank T500 9015504 01-2018...
  • Page 143 6. Install new detergent pump assembly onto the 12. Reinstall the liquid level sensor in reverse order of detergent pump bracket. disassembly. 7. Reassemble / reinstall the detergent pump bracket 13. Refi ll the tank. / detergent pump assembly in reverse order of disassembly. T500 9015504 01-2018...

  • Page 144: Removing / Installing The Recovery Tank Rinse Pump (Option)

    To: Recovery tank rinse hose assembly Recovery tank rinse hose solution pump Rear frame FRONT Water solenoid valve To: Scrub Hex screws (Qty. 4) Hex nuts head securing rear frame (Qty. 4) To: Solution to machine tank Inline filter T500 9015504 01-2018...
  • Page 145 4. Remove the rear squeegee assembly from the machine. 5. Completely lower the squeegee pivot bracket to access all hardware securing the recovery tank rinse pump to the rear frame. 6. Remove the hardware securing the recovery tank rinse pump to the rear frame. T500 9015504 01-2018...
  • Page 146 SERVICE T500 9015504 01-2018...

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