The Tennant 7200's squeegee function rises when moving in reverse and lowers when moving forward due to an interlock system. When the operator engages the reverse contactor, the squeegee automatically rises to prevent damage or interference. When the operator disengages the reverse contactor and moves forward, the squeegee function resumes, lowering it back for operation.

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Summary of Contents for Tennant 7200

Page 1 7200 Service Manual 330045 Rev. 02 (3- - 02) Home Find... Go To.. Home...
Page 2 This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT Model 7200 ride on scrubber. The set is organized into four major groups: General Information, Chassis, Scrubbing, and Electrical. General Information: Safety precautions, machine transport, machine jacking, machine storage, chassis lubrication, machine specifications, and machine maintenance chart.
Page 3: Table Of Contents
....1-15 THREAD SEALANT AND LOCKING COMPOUNDS ....1-15 7200 330045 (3- -02) Home Find... Go To..
Page 4: General Information
GENERAL INFORMATION 7200 330045 (10- -99) Home Find... Go To..
Page 5: Safety Precautions
- - Turn off machine and remove key. This machine is designed solely for scrubbing dirt 5. When servicing machine: and dust in an indoor environment. Tennant does - - Avoid moving parts. Do not wear loose not recommend using this machine in any other jackets, shirts, or sleeves when environment.
Page 6 ON THE UNDERSIDE OF THE TANK COVER AND ON THE LEFT SIDE OF THE OPERATOR COMPARTMENT. FLAMMABLE SPILLS LABEL - - LOCATED ON THE SEAT SUPPORT. FOR SAFETY LABEL - - LOCATED ON THE SEAT SUPPORT. 350656 7200 330045 (10- -99) Home Find... Go To..
Page 7: Specifications
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 Maximum rated climb and descent angle for trailering 7200 330045 (3- -02) Home Find... Go To..
Page 8: Power Type
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) 7200 330045 (3- -02) Home Find... Go To..
Page 9: Machine Dimensions
(80.0 in) 1360 mm (53.5 in) 1092 mm 405 mm (43.0 in) (16.0 in) 810 mm 1830 mm (72.0 in) (32.0 in) 915 mm SIDE VIEW (36.0 in) FRONT VIEW 350790 MACHINE DIMENSIONS 7200 330045 (3- -02) Home Find... Go To..
Page 10: Maintenance
GENERAL INFORMATION MAINTENANCE 350790 7200 330045 (3- -02) Home Find... Go To..
Page 11 ..Distilled water . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) ..SAE 90 weight gear lubricant NOTE: Also check procedures indicated (H) after the first 50 hours of operation.
Page 12: Pushing, Towing, And Transporting The Machine
FOR SAFETY: Use truck or trailer that will support the weight of the machine. NOTE: Empty the recovery and solution tanks before transporting the machine. 1-10 7200 330045 (3- -02) Home Find... Go To..
Page 13 Tie down the machine to the truck or trailer before transporting. The front tie-down locations are the holes in the front side of the machine frame. 7200 330045 (3- -02) 1-11 Home Find... Go To..
Page 14 Do not drive the machine off the truck or trailer unless the loading surface is horizontal AND 380 mm (15 in) or less from the ground. 1-12 7200 330045 (3- -02) Home Find... Go To..
Page 15: Machine Jacking
FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. The model 7200 can be jacked up from any of the four corners. Always empty the solution and recovery tanks before jacking. FOR SAFETY: When servicing machine, block machine tires before jacking machine up.
Page 16: Storage Information
4. Start the solution flow. Start the power wand solution system and ESt system to circulate the washer solution through the components. 5. The washer solution does not need to be drained from the solution tank. 1-14 7200 330045 (10- -99) Home Find... Go To..
Page 17: Hardware Information
They include the following: 0.75 in 215--280 313--407 (291--380) (424--552) Locktite 515 sealant -- gasket forming material. TENNANT Part No. 75567,15 oz 1.00 in 500--650 757--984 (440 ml) cartridge. (678--881) (1026--1334) NOTE: Decrease torque by 20% when using a Locktite 242 blue -- medium strength thread thread lubricant.
Page 18 GENERAL INFORMATION 1-16 7200 330045 (3- -02) Home Find... Go To..
Page 19 TO REPLACE DRIVE ASSEMBLY CASTER BEARING AND THRUST WASHERS ..2--24 TO REPLACE DRIVE ASSEMBLY PIVOT CONE BEARING ..2--29 7200 330045 (10- -99) Home Find... Go To..
Page 20 CHASSIS 7200 330045 (10- -99) Home Find... Go To..
Page 21: Introduction
CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat, steering, front drive assembly, brakes and tires. 7200 330045 (10- -99) Home Find... Go To..
Page 22: Seat
Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Lift the seat assembly until the prop rod is engaged. 2. Unplug the seat switch wire harness plug from the main harness. 7200 330045 (10- -99) Home Find... Go To..
Page 23 4. Slide the seat assembly to the right until is off the two mount pins. Remove the seat assembly from the machine. 7200 330045 (10- -99) Home Find... Go To..
Page 24: To Install Seat Assembly
4. Route the seat switch harness through the hole in the seat support plate. 5. Plug the seat switch harness into the main harness plug. 6. Disengage the prop rod and lower the seat assembly. 7200 330045 (10- -99) Home Find... Go To..
Page 25: To Adjust Seat Position
The static drag chain prevents the buildup of static electricity in the machine. It is attached the the rear squeegee mount frame. Make sure the chain is in contact with the floor at all times. 7200 330045 (10- -99) Home Find... Go To..
Page 26: Brakes And Tires
It is actuated with a smaller toe lever on the top of the foot brake pedal in the operators compartment. It is deactivated by simply pushing on the foot brake pedal. 7200 330045 (10- -99) Home Find... Go To..
Page 27: To Adjust Service Brakes
5. Move the cable away from the brake lever far enough to remove the slack in the pedal movement. 6. Re--tighten the two jam nuts firmly. Operate the machine and check the brake pedal for a shorter stroke. 7200 330045 (10- -99) Home Find... Go To..
Page 28: To Adjust Parking Brake
5. Move the cable away from the brake lever far enough to remove the slack in the pedal movement. 6. Re--tighten the two jam nuts firmly. Operate the machine and check the brake pedal for a shorter stroke. 2-10 7200 330045 (10- -99) Home Find... Go To..
Page 29: To Replace Drive Assembly Brake Shoes
5. Pull the planetary gear box, outer plate, and motor out of the drive wheel and away from the drive assembly. 2-11 7200 330045 (10- -99) Home Find... Go To..
Page 30 12. Install the new brake shoes on the drive assembly in the same orientation as the old ones were removed. 13. Reinstall the ”C” spring on the new brake shoes. 2-12 7200 330045 (10- -99) Home Find... Go To..
Page 31 16. Install the lock bolt in the end of the hex sleeve. Tighten the lock bolt to 200 Nm (150 ft lb) while holding the hex sleeve from turning. 17. Reinstall the hub cap in the drive assembly. 2-13 7200 330045 (10- -99) Home Find... Go To..
Page 32 22. Reconnect the electrical cables to the drive motor. 23. Remove the jack stands and lower the machine. 24. Reconnect the battery cables. 25. Drive the machine and check the brakes for proper operation. Adjust if necessary. 2-14 7200 330045 (10- -99) Home Find... Go To..
Page 33: Rear Tires And Wheels
CHASSIS REAR TIRES AND WHEELS The rear tires on the model 7200 are semi--pneumatic. The rear tire and wheel assemblies are idler wheels only, they have no braking capabilities. TO REMOVE REAR TIRE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake.
Page 34: To Install Rear Tire
3. Install the washer and nut on the axle. Tighten to 68 -- 81 Nm (50 -- 60 ft lb). 4. Remove the jack stands and lower the machine. 5. Drive the machine and check for proper operation. 2-16 7200 330045 (10- -99) Home Find... Go To..
Page 35: To Replace Rear Wheel Bearings
3. Use a press to remove the wheel bearings from the housing. 4. Press the new wheel bearings into the housing. Press the bearing in until the flange is seated on the housing. 2-17 7200 330045 (10- -99) Home Find... Go To..
Page 36 (43 -- 56 ft lb). NOTE: The lug nuts must face the outside of the machine. 6. Reinstall the rear wheel assembly in the machine. See TO INSTALL REAR TIRE instructions. 2-18 7200 330045 (10- -99) Home Find... Go To..
Page 37: Front Tire And Wheel, And Wheel Drive Support
FRONT WHEEL SUPPORT CASTER BEARING ASSEMBLY The front wheel support caster bearing is located between the bottom swivel plate and the upper swivel plate weldment. The bearing is a flat needle bearing style. 2-19 7200 330045 (10- -99) Home Find... Go To..
Page 38: To Remove Front Drive Assembly
4. Go in operators compartment and loosen the lower steering shaft mount screws. 5. Pull the mount back to give the steering chain slack. Locate and remove the master link and steering chain. 2-20 7200 330045 (10- -99) Home Find... Go To..
Page 39 9. Go to the operators compartment and locate the 4 button head screws holding the drive assembly to the floor plate. Remove the 4 screws while supporting the drive assembly. 10. Remove the drive assembly from the machine. 2-21 7200 330045 (10- -99) Home Find... Go To..
Page 40: To Install Front Drive Assembly
Adjust the steering chain. See TO ADJUST STEERING CHAIN instructions. 8. Reinstall the brake cable on the wheel support. Tighten the jam nut on the brake cable where it attaches to the wheel support. 2-22 7200 330045 (10- -99) Home Find... Go To..
Page 41 13. Remove the jack stands and lower the machine. 14. Reconnect the battery cables. 15. Operate the machine and check for proper operation. Check the brakes for proper operation. Adjust if necessary. See TO ADJUST SERVICE BRAKES instructions. 2-23 7200 330045 (10- -99) Home Find... Go To..
Page 42: To Replace Drive Assembly Caster Bearing And Thrust Washers
3. Pull the planetary gear box, outer plate, and motor out of the drive wheel and away from the drive assembly. 2-24 7200 330045 (10- -99) Home Find... Go To..
Page 43 6. Remove the cotter pin and castle nut from the upper swivel plate weldment. 7. Remove the flat washer and cone bearing from the bottom swivel plate. 8. Lift the bottom swivel plate off the upper swivel plate weldment. 2-25 7200 330045 (10- -99) Home Find... Go To..
Page 44 14. Reinstall the bearing cone and flat washer on the bottom swivel plate. Make sure the bearing cone is greased. 2-26 7200 330045 (10- -99) Home Find... Go To..
Page 45 19. Install the 4 hex screws and washers. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 2-27 7200 330045 (10- -99) Home Find... Go To..
Page 46 See TO INSTALL FRONT DRIVE ASSEMBLY instructions. 21. Operate the machine and check for smooth steering operation. Check the brakes for proper operation. Adjust if necessary. See TO ADJUST SERVICE BRAKES instructions. 2-28 7200 330045 (10- -99) Home Find... Go To..
Page 47: To Replace Drive Assembly Pivot Cone Bearing
3. Pull the planetary gear box, outer plate, and motor out of the drive wheel and away from the drive assembly. 2-29 7200 330045 (10- -99) Home Find... Go To..
Page 48 9. Reinstall the castle nut and tighten to 200 Nm (150 ft lbs). Then tighten to the next nearest hole and install the cotter pin. 10. Reinstall the sprocket on the pivot assembly. 2-30 7200 330045 (10- -99) Home Find... Go To..
Page 49 See TO INSTALL FRONT DRIVE ASSEMBLY instructions. 15. Operate the machine and check for smooth steering operation. Check the brakes for proper operation. Adjust if necessary. See TO ADJUST SERVICE BRAKES instructions. 2-31 7200 330045 (10- -99) Home Find... Go To..
Page 50: Planetary Gear Box
CHASSIS PLANETARY GEAR BOX The model 7200 front drive system includes a self contained planetary gearbox. The electric drive motor provides power to the planetary gearbox which, through a gear reduction, spins the front tire. TO REMOVE PLANETARY GEAR BOX FOR SAFETY: Before Leaving Or Servicing Machine;...
Page 51 Remove the outer plate. 7. Pull the old planetary gear box out of the drive wheel. Remove the old planetary gear box from the machine. 2-33 7200 330045 (10- -99) Home Find... Go To..
Page 52: To Install Planetary Gear Box
Make sure to line up the splines on the motor shaft with the splines of the planetary gear box. Tighten the 4 hex screws to 18 -- 24 Nm (15 -- 20 ft lb). 2-34 7200 330045 (3- -02) Home Find... Go To..
Page 53 4. Reconnect the electrical cables to the drive motor. 5. Remove the jack stands and lower the machine. 6. Reconnect the battery cables. 7. Operate the machine and check the new gearbox for proper operation. 2-35 7200 330045 (10- -99) Home Find... Go To..
Page 54: To Replace Front Tire And Wheel Assembly
6. Go to the other side of the drive assembly and remove the hub cap. This will expose the outer bearing, hex sleeve, and lock bolt. 2-36 7200 330045 (10- -99) Home Find... Go To..
Page 55 10. Install the inner bearing on the new tire/wheel assembly. 11. Reinstall the new tire/wheel assembly in the drive assembly. Make sure the inner and outer wheel bearings are completely greased when re--assembling. 2-37 7200 330045 (10- -99) Home Find... Go To..
Page 56 15. Go to the other side of the drive assembly. Install the planetary gear box, outer plate, and motor assembly into the wheel assembly and onto the pins of the drive assembly. 2-38 7200 330045 (10- -99) Home Find... Go To..
Page 57 17. Reconnect the electrical cables to the drive motor. 18. Remove the jack stands and lower the machine. 19. Reconnect the battery cables. 20. Drive the machine and check for proper operation. 2-39 7200 330045 (10- -99) Home Find... Go To..
Page 58: To Replace Front Drive Assembly Outer Wheel Bearing
6. Use a press to remove the old outer bearing cone from the hex sleeve. Install a new outer bearing on the hex sleeve or replace the bearing and sleeve assembly. Apply grease to the new bearing. 2-40 7200 330045 (10- -99) Home Find... Go To..
Page 59 9. Reinstall the hub cap in the drive assembly. 10. Remove the jack stands and lower the machine. 11. Reconnect the battery cables. 12. Drive the machine and check for proper operation. 2-41 7200 330045 (10- -99) Home Find... Go To..
Page 60: To Replace Front Drive Assembly Inner Wheel Bearing
6. Go to the other side of the drive assembly and remove the hub cap. This will expose the outer bearing, hex sleeve, and lock bolt. 2-42 7200 330045 (10- -99) Home Find... Go To..
Page 61 10. Press a new inner wheel bearing on the wheel shaft. Apply grease to the new bearing. 11. Reinstall the tire/wheel assembly in the drive assembly. Make sure the inner and outer wheel bearings are completely greased when re--assembling. 2-43 7200 330045 (10- -99) Home Find... Go To..
Page 62 15. Go to the other side of the drive assembly. Install the planetary gear box, outer plate, and motor assembly into the wheel assembly and onto the pins of the drive assembly. 2-44 7200 330045 (10- -99) Home Find... Go To..
Page 63 17. Reconnect the electrical cables to the drive motor. 18. Remove the jack stands and lower the machine. 19. Reconnect the battery cables. 20. Drive the machine and check for proper operation. 2-45 7200 330045 (10- -99) Home Find... Go To..
Page 64: Steering
CHASSIS STEERING The steering on the model 7200 is controlled with two sprockets and one chain. A large diameter sprocket is mounted on the top of the front drive assembly and a small diameter sprocket is mounted on the bottom of the steering shaft. The steering chain runs around both of these sprockets.
Page 65: To Replace Steering Chain
7. Route the new chain around both steering sprockets. Install the master link. 8. Remove the jack stands and lower the machine. 9. Operate the machine and check the steering for proper operation. 2-47 7200 330045 (10- -99) Home Find... Go To..
Page 66: To Replace Large Steering Sprocket
4. Install the new sprocket on the pivot assembly. NOTE: Make sure the roll pin in the top of the drive assembly lines up with the hole in the sprocket. 2-48 7200 330045 (10- -99) Home Find... Go To..
Page 67 68 -- 81 Nm (50 -- 60 ft lb). 6. Reinstall the drive assembly in the machine. See TO INSTALL FRONT DRIVE ASSEMBLY instructions. 7. Operate the machine and check for smooth steering operation. 2-49 7200 330045 (10- -99) Home Find... Go To..
Page 68: To Replace Small Steering Sprocket
4. Go under the machine and locate the steering chain. 5. Rotate the steering wheel until the master link on the chain is accessible. 6. Remove the chain master link. Remove the steering chain from both sprockets. 2-50 7200 330045 (10- -99) Home Find... Go To..
Page 69 10. Adjust the steering chain. See TO ADJUST STEERING CHAIN instructions. 11. Remove the jack stands and lower the machine. 12. Operate the machine and check the steering for proper operation. 2-51 7200 330045 (10- -99) Home Find... Go To..
Page 70: To Replace Steering Housing Bearings
U--joint. 5. Remove the two hex screws holding the steering bearing housing to the machine frame. Push the bearing housing back in the slots. 2-52 7200 330045 (10- -99) Home Find... Go To..
Page 71 8. Remove the steering housing from the machine. 9. Loosen the two set screws holding the U--joint to the top of the short steering shaft. Remove and retain the U--joint and square key. 2-53 7200 330045 (10- -99) Home Find... Go To..
Page 72 Tighten the set screws tight. 15. Reinstall the U--joint and square key on the top of the steering housing. Tighten the set screws tight. 2-54 7200 330045 (10- -99) Home Find... Go To..
Page 73 37 -- 48 Nm (26 -- 34 ft lb). 21. Remove the jack stands and lower the machine to the floor. Operate the machine and check the steering chain for proper operation. 2-55 7200 330045 (10- -99) Home Find... Go To..
Page 74: To Replace Steering U--Joint
U--joint. 4. Loosen the two set screws holding the U--joint to the top of the short steering shaft. Remove and discard the U--joint and square key. 2-56 7200 330045 (10- -99) Home Find... Go To..
Page 75 6. Position the long steering shaft and steering wheel into the top of the steering U--joint. Tighten the set screws tight. 7. Operate the machine and check the steering U--joint for proper operation. 2-57 7200 330045 (10- -99) Home Find... Go To..
Page 76 CHASSIS 2-58 7200 330045 (10- -99) Home Find... Go To..
Page 77 . . . 3--49 TO REPLACE BRUSH DRIVE BELT 3--49 MANUAL SOLUTION VALVE ..3--53 TO REPLACE SOLUTION VALVE . . . 3--53 7200 330045 (10- -99) Home Find... Go To..
Page 78 SCRUBBING 7200 330045 (10- -99) Home Find... Go To..
Page 79: Introduction
The brushes rotate to scrub the floor. As the machine moves forward the rear squeegee wipes the dirty solution off the floor, which is then picked up and drawn into the recovery tank by the vacuum fan. 7200 330045 (10- -99) Home Find... Go To..
Page 80: Solution Tank
A tank drain hose has been provided to allow the tank to be drained for cleaning. The solution tanks with ESt should be drained and cleaned after every work shift. 7200 330045 (10- -99) Home Find... Go To..
Page 81: To Drain And Clean Solution Tank With Est
FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 5. Remove the drain hose cap from the access caps at the rear of the solution tank. 7200 330045 (10- -99) Home Find... Go To..
Page 82 9. Check the vacuum fan filter on top of the recovery tank. Clean or replace if necessary. 10. Close the tank cover. 11. Replace the drain hoses in the tanks. 7200 330045 (10- -99) Home Find... Go To..
Page 83: To Remove Solution Tank
3. Disconnect the battery plug from the batteries. Remove the two screws holding the battery connector bracket to the front of the solution tank. 4. Remove the battery nearest the right, rear corner of the battery compartment. 7200 330045 (10- -99) Home Find... Go To..
Page 84 8. Remove the four hex screws holding the plastic, rear drain splash tray. Let it drop down for access to the solution tank hardware. 9. Remove the screw on the right side of the solution tank drain cap. 7200 330045 (10- -99) Home Find... Go To..
Page 85 NOTE: Make sure to note the orientation of the electrical harness before removing the solution tank. It is very important to position the harness in the same location when installing a new tank. 7200 330045 (10- -99) Home Find... Go To..
Page 86 Loosen this clamp and remove the hose from the solution tank. 16. The solution tank can now be removed from the machine. 3-10 7200 330045 (10- -99) Home Find... Go To..
Page 87: To Install Solution Tank
5. Install the hex screw in the area to the right of the tank drain cap. Leave loose for now. 3-11 7200 330045 (10- -99) Home Find... Go To..
Page 88 18 -- 24 Nm (15 -- 20 ft lb). 8. Connect the water hose to the top, front nipple on the solution tank. Tighten the worm drive clamp. 9. Connect the float switch to the main harness. 3-12 7200 330045 (10- -99) Home Find... Go To..
Page 89 11. Reconnect the top of the prop arm to the tank cover. 12. Reinstall the plastic, rear drain splash tray over the tank drains. Tighten the four screws. 13. Reinstall the tank drain hose and caps. 3-13 7200 330045 (10- -99) Home Find... Go To..
Page 90 (15 -- 20 ft lb). 16. Reinstall the overhead guard if it was removed earlier. 17. Operate the machine and check the solution tank for any leaks and for proper operation of the float switch. 3-14 7200 330045 (10- -99) Home Find... Go To..
Page 91: Recovery Tank
3. Stop the machine next to a floor drain. 4. Shut off the machine and set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 3-15 7200 330045 (10- -99) Home Find... Go To..
Page 92 Remove the ESt outlet filter, clean, reinstall. 9. Check the vacuum fan filter on top of the recovery tank. Clean or replace if necessary. 3-16 7200 330045 (10- -99) Home Find... Go To..
Page 93 SCRUBBING 10. Close the tank cover. 11. Replace the drain hoses in the tanks. 3-17 7200 330045 (10- -99) Home Find... Go To..
Page 94: To Remove Recovery Tank
4. Make sure the recovery tank is drained and the tank clean out caps removed. 5. Remove the four hex screws holding the plastic, rear drain splash tray. Let it drop down for access to the recovery tank hardware. 3-18 7200 330045 (10- -99) Home Find... Go To..
Page 95 8. Pull the vacuum hose out of the hole in the recovery tank. 9. Remove the plastic tank cover hinge rod. Remove the tank cover from the machine. 3-19 7200 330045 (10- -99) Home Find... Go To..
Page 96 13. Pull the recovery tank up far enough to access the ESt hose on the inside wall. Remove the hose from the recovery tank. 3-20 7200 330045 (10- -99) Home Find... Go To..
Page 97 It is very important to position the harness in the same location when installing a new tank. 15. The recovery tank can now be removed from the machine. 3-21 7200 330045 (10- -99) Home Find... Go To..
Page 98: To Install Recovery Tank
5. Install the hex screw in the area to the left of the tank drain cap. Leave loose for now. 3-22 7200 330045 (10- -99) Home Find... Go To..
Page 99 Reconnect the vacuum fan to the main electrical harness. Tighten the hardware to 18 -- 24 Nm (15 -- 20 ft lb). 9. Reinstall the tank cover and plastic hinge rod. 3-23 7200 330045 (10- -99) Home Find... Go To..
Page 100 12. Reinstall the tank drain hose and caps. 13. Reinstall the overhead guard if it was removed earlier. 14. Operate the machine and check the recovery tank for any leaks and for proper operation of the float switch. 3-24 7200 330045 (10- -99) Home Find... Go To..
Page 101: Scrub Head
SCRUBBING SCRUB HEAD The model 7200 can be equipped with either CYLINDRICAL a cylindrical or a disc style scrub head. The scrub head houses the scrub brushes and their drive mechanisms. The scrub head adjustments are factory set and should not be changed unless scrub head parts are damaged or replaced.
Page 102: To Replace Scrub Head Links
4. Start the machine and raise the scrub head. Check the scrub head links for proper operation. 3-26 7200 330045 (10- -99) Home Find... Go To..
Page 103: To Remove Disc Scrub Head
2. Disconnect the water line leading from the shut--off valve to the scrub head. 3. Disconnect the two scrub brush motors from the main electrical harness. NOTE: Mark the connectors for proper re- -assembly. 3-27 7200 330045 (10- -99) Home Find... Go To..
Page 104 6. Jack up the front of the machine far enough to slide the scrub head out. Install jack stands under the machine frame. 7. The scrub head can now be pulled out from under the machine frame. 3-28 7200 330045 (10- -99) Home Find... Go To..
Page 105: To Install Disc Scrub Head
4. Reconnect the brush drive motors to the main electrical harness. 3-29 7200 330045 (10- -99) Home Find... Go To..
Page 106 5. Reconnect the water line to the scrub head 6. Start the machine and raise the scrub head. Operate the machine and check the scrub head for proper operation. Check the scrub brushes for proper rotation. 3-30 7200 330045 (10- -99) Home Find... Go To..
Page 107: To Remove Cylindrical Scrub Head
2. Disconnect the water line leading from the shut off valve to the scrub head. 3. Disconnect the two scrub brush motors from the main electrical harness. Mark the connectors for proper re--assembly. 3-31 7200 330045 (10- -99) Home Find... Go To..
Page 108 Turn off the machine. NOTE: This will allow more clearance for the scrub head to slide out. 7. The scrub head can now be pulled out from under the machine frame. 3-32 7200 330045 (10- -99) Home Find... Go To..
Page 109: To Install Cylindrical Scrub Head
4. Install the clevis pin and cotter pin. 5. Reconnect the brush drive motors to the main electrical harness. 3-33 7200 330045 (10- -99) Home Find... Go To..
Page 110 7. Start the machine and raise the scrub head. Operate the machine and check the scrub head for proper operation. Check the scrub brushes for pattern and proper rotation. See TO CHECK AND ADJUST CYLINDRICAL BRUSH PATTERN instructions. 10355 3-34 7200 330045 (10- -99) Home Find... Go To..
Page 111: Disc Scrub Head Skirts
1/8 to 1/4 inch clearance from the bottom of the skirt to the floor. 4. Re--tighten the retainer screws. Operate the machine and check the scrub head skirts for proper water spray control. 3-35 7200 330045 (10- -99) Home Find... Go To..
Page 112: To Replace Disc Scrub Head Skirts
Adjust the skirt and tighten the retainer screws. See TO ADJUST DISC SCRUB HEAD SKIRTS instructions. 4. Operate the machine and check the scrub head skirts for proper water spray control. 3-36 7200 330045 (10- -99) Home Find... Go To..
Page 113: Cylindrical Brush Head Debris Tray
2. Go to the right side of the machine. Locate the scrub head side squeegee. Pull the hair pin out of the squeegee lock pin. 3. Pivot the side squeegee out, away from the scrub head. 3-37 7200 330045 (10- -99) Home Find... Go To..
Page 114 5. Pull the debris tray straight out to the right until it is free of the scrub head lip. Empty the debris tray, 3-38 7200 330045 (10- -99) Home Find... Go To..
Page 115: To Install Debris Tray
3. Swing the right hand side squeegee back to the side of the scrub head. Make sure the lock pin is positioned in the mount hole. Reinstall the hair pin. 4. Start the machine and raise the scrub head. 3-39 7200 330045 (10- -99) Home Find... Go To..
Page 116: To Replace Debris Tray Skirt
4. Reinstall the hardware and hand tighten lightly. 5. Reinstall the debris tray in the machine. See TO INSTALL DEBRIS TRAY instructions. 3-40 7200 330045 (10- -99) Home Find... Go To..
Page 117: Scrub Brushes
4. Press the brush spring clip together with your thumb and index finger. The brush will drop off of the brush drive hub. Pull the brush out from under the scrub head. 3-41 7200 330045 (10- -99) Home Find... Go To..
Page 118 8. Check to make sure the brush is securely mounted on the brush drive hub. 9. Repeat for the other brush. 3-42 7200 330045 (10- -99) Home Find... Go To..
Page 119: Cylindrical Scrub Brushes
25 mm (1 in) from the floor, turn the machine power off. 2. Set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 3-43 7200 330045 (10- -99) Home Find... Go To..
Page 120 5. Pull the old brush out of the scrub head. 6. Position the brush with the double row end towards you. Guide the new brush onto the drive hub. 3-44 7200 330045 (10- -99) Home Find... Go To..
Page 121 The idler door of that side of the scrub head is stamped with the same letter. Make sure the letter on the door matches the letter on the scrub head when replacing the doors. 3-45 7200 330045 (10- -99) Home Find... Go To..
Page 122: To Check And Adjust
A polish mark will remain on the floor. 4. Raise the scrub head and move the machine away from the chalked area. Turn the machine power off. 3-46 7200 330045 (10- -99) Home Find... Go To..
Page 123 2. While holding the flat end of the idler shaft with a wrench, loosen the mounting screw on the outside of the idler door. 3-47 7200 330045 (10- -99) Home Find... Go To..
Page 124 Level the scrub head by turning the scrub head links. Both scrub head links should be adjusted equally. Check the brush patterns again and readjust as necessary until both patterns are the same. 3-48 7200 330045 (10- -99) Home Find... Go To..
Page 125: Cylindrical Brush Drive Belt
Shut off the key. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 2. Remove the scrub brushes. See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions. 3-49 7200 330045 (10- -99) Home Find... Go To..
Page 126 NOTE: It is a tight fit for the belt in the area of the lower belt cover and bottom drive plug. Carefully work the belt past the lower cover- -- -DO NOT remove the lower cover. 3-50 7200 330045 (10- -99) Home Find... Go To..
Page 127 The belt should deflect 0.10 inch. 12. Tighten the drive motor pivot bolts to 18 -- 24 Nm (15 -- 20 ft lb). Re--check the belt tension. 3-51 7200 330045 (10- -99) Home Find... Go To..
Page 128 11 -- 14 Nm (7 -- 10 ft lb). 14. Reinstall the scrub brushes. See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions. 15. Operate the machine and check the scrub brushes for proper operation. 3-52 7200 330045 (10- -99) Home Find... Go To..
Page 129: Manual Solution Valve
TO REPLACE SOLUTION VALVE 1. Drain the solution tank. 2. Lower the scrub head to the floor. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 3-53 7200 330045 (10- -99) Home Find... Go To..
Page 130 Pull the hoses off the fittings. 7. Remove the two screws holding the valve to the machine frame. Remove the manual valve from the machine. 3-54 7200 330045 (10- -99) Home Find... Go To..
Page 131 12. Place the control lever rod in the mount hole and install the cotter pin. 13. Operator the machine and check the water valve for proper operation. 3-55 7200 330045 (10- -99) Home Find... Go To..
Page 132: Squeegees
25 mm (1 in.) from the floor. 2. Turn the machine power off and set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 3-56 7200 330045 (10- -99) Home Find... Go To..
Page 133 SCRUBBING 3. Remove the squeegee suction hose from the squeegee. 4. Remove both squeegee mounting knobs. 5. Pull the squeegee off the machine. 3-57 7200 330045 (10- -99) Home Find... Go To..
Page 134: To Install Rear Squeegee Assembly
2. Place the squeegee under the squeegee pivot. 3. Push the squeegee frame onto the squeegee pivot. 4. Tighten the mounting knobs. 5. Push the squeegee suction hose onto the squeegee fitting. 3-58 7200 330045 (10- -99) Home Find... Go To..
Page 135: To Level Rear Squeegee
2. Lower the squeegee. 3. Drive the machine forward a few feet, then set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 3-59 7200 330045 (10- -99) Home Find... Go To..
Page 136 6. Drive the machine forward with the squeegee down to check the squeegee blade deflection. 7. Readjust the squeegee blade deflection if necessary. 3-60 7200 330045 (10- -99) Home Find... Go To..
Page 137: To Adjust Rear Squeegee Blade Deflection
The 12 mm correct amount of deflection is 12 mm(0.50 (0.50 in) in) for scrubbing smooth floors and 15 mm (0.62 in) for rough floors. 03719 3-61 7200 330045 (10- -99) Home Find... Go To..
Page 138 -clockwise to increase blade deflection. 6. Drive the machine forward again to check the squeegee blade deflection. 12 mm (0.50 in) 7. Readjust the squeegee blade deflection if necessary. 03719 3-62 7200 330045 (10- -99) Home Find... Go To..
Page 139: Rear Squeegee Casters
REAR SQUEEGEE CASTERS The rear squeegee casters each have two grease fittings. Lubricate the pivot point and caster bearing on each squeegee caster with Lubriplate EMB grease (TENNANT part no. 01433--1) every 50 hours. TO ADJUST REAR SQUEEGEE GUIDE ROLLER On the left end of the squeegee is a guide roller that guides the squeegee blade end along a wall.
Page 140: Rear Squeegee Blades
1. Make sure the squeegee is raised off the floor. 2. Turn the machine power off and set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 3-64 7200 330045 (10- -99) Home Find... Go To..
Page 141 6. Insert the rotated or new squeegee blade and then insert the retainer band. 7. Tighten the two retainer knobs until the ends of the front and rear squeegee blades touch. Do not over--tighten. 3-65 7200 330045 (10- -99) Home Find... Go To..
Page 142: To Replace Or Rotate Rear Squeegee (Front) Blade
Surface, Set Parking Brake. 3. Remove the squeegee from the machine. See TO REMOVE SQUEEGEE ASSEMBLY instructions. 4. Remove the rear squeegee blade and retainer. See TO REPLACE OR ROTATE REAR SQUEEGEE (REAR) BLADE. 3-66 7200 330045 (10- -99) Home Find... Go To..
Page 143 9. Insert the rear squeegee blade and retainer. Tighten the two rear blade retainer knobs until the ends of the front and rear squeegee blades touch. Do not over--tighten. 3-67 7200 330045 (10- -99) Home Find... Go To..
Page 144 10. Install the squeegee assembly on the squeegee pivot. See TO INSTALL SQUEEGEE ASSEMBLY instructions. 11. Adjust the squeegee blade leveling and deflection as stated in TO LEVEL SQUEEGEE and ADJUST SQUEEGEE BLADE DEFLECTION instructions. 3-68 7200 330045 (10- -99) Home Find... Go To..
Page 145: Rear Squeegee Wheel Cams
Decrease end deflection: Turn the squeegee leveling knob clockwise to decrease the deflection at the end of the squeegees. 3-69 7200 330045 (10- -99) Home Find... Go To..
Page 146: To Replace Rear Squeegee Lift Cable
4. Locate the rear squeegee lift cable. Remove the cotter pin and clevis pin from the end of the lift cable where it attaches to the lift pivot bracket. 3-70 7200 330045 (10- -99) Home Find... Go To..
Page 147 Reinstall the clevis pin and cotter pin. 8. Attach the other end of the new lift cable to the lift pivot bracket. Reinstall the clevis pin and cotter pin. 3-71 7200 330045 (10- -99) Home Find... Go To..
Page 148 10. Reinstall the plastic, rear drain splash tray. Hand tighten the mounting hardware. 11. Reinstall the tank caps. 12. Start the machine and raise the rear squeegee. Check the new cable for proper operation. 3-72 7200 330045 (10- -99) Home Find... Go To..
Page 149: Side Squeegee Blades
Check the side squeegees for damage and wear daily. Replace the side squeegee blades if they become damaged or lose their shape. Replace the squeegee deflectors if they become worn. CYLINDRICAL SCRUB HEAD DISC SCRUB HEAD 3-73 7200 330045 (10- -99) Home Find... Go To..
Page 150: To Replace Side Squeegee Blades
5. Slide a new squeegee blade into the frame. 6. Replace the retainer bracket, deflector, clevis pin, and cotter pin. 7. Repeat for the side squeegee on the other side of the scrub head. 3-74 7200 330045 (10- -99) Home Find... Go To..
Page 151: Vacuum Fan
FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Open the recovery/solution tank cover. 2. Locate the vacuum fan on the left, front of the recovery tank. 3-75 7200 330045 (10- -99) Home Find... Go To..
Page 152 4. Disconnect the vacuum fan motor from the main electrical harness. 5. Remove the vacuum fan assembly from the machine. Be careful not to loose the rubber seal on the outlet of the vacuum housing. 3-76 7200 330045 (10- -99) Home Find... Go To..
Page 153: To Install Vacuum Fan Assembly
ELECTRICAL section. 4. Drop the vacuum fan assembly straight down into the tank mounting area. Make sure the rubber seal is in place on the outlet of the vacuum housing. 3-77 7200 330045 (10- -99) Home Find... Go To..
Page 154 5. Install the two screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 6. Close the tank cover and operate the machine. Check the vacuum fan for proper operation. 3-78 7200 330045 (10- -99) Home Find... Go To..
Page 155: Scrubbing Troubleshooting
Uneven brush pressure, level scrub head Broken brush drive belts on cylindrical scrub head, replace belt Check with TENNANT representative for advice Low battery charge Charge batteries until the charger automatically turns off 3-79 7200 330045 (10- -99) Home Find... Go To..
Page 156 SCRUBBING 3-80 7200 330045 (10- -99) Home Find... Go To..
Page 157 4-105 ESt SYSTEM ....4-106 ESt FILTER FLUSH SYSTEM ..4-109 7200 330045 (3- -02) Home Find... Go To..
Page 158 ELECTRICAL 7200 330045 (10- -99) Home Find... Go To..
Page 159: Introduction
ELECTRICAL INTRODUCTION The machines electrical system consists of the batteries, instrument panel, drive motor, actuators, switches, relays, and circuit breakers. 7200 330045 (10- -99) Home Find... Go To..
Page 160: Batteries
If needed, add just enough distilled water to cover the plates. Never add acid to the batteries. Do not overfill. Always keep the battery caps on, except when adding water or taking hydrometer readings. 7200 330045 (3- -02) Home Find... Go To..
Page 161: Charging The Batteries
3. Lift the operator seat to access the batteries. The support arm automatically engages when the seat is lifted all the way up. 4. Check the water level in all battery cells. 7200 330045 (3- -02) Home Find... Go To..
Page 162 5. Unplug the machine connector from the batteries. 6. Plug the charger connector into the battery connector. WARNING: Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and open flame away. Keep covers open when charging. 7200 330045 (3- -02) Home Find... Go To..
Page 163 7. Plug the battery charger into the wall outlet. NOTE: If the red “ABNORMAL CYCLE” lamp lights when the TENNANT charger is plugged into a wall outlet, the charger cannot charge the battery and there is something wrong with the battery.
Page 164: To Replace Batteries
The support arm automatically engages when the seat is lifted all the way up. 4. Un--plug the battery connector from in front of the solution tank. FOR SAFETY: Disconnect Battery Connections Before Working On machine. 7200 330045 (10- -99) Home Find... Go To..
Page 165 11. Check the batteries and charge if necessary. See TO CHARGE BATTERIES instructions. 12. Reconnect the battery connector at the front of the solution tank. 13. Lower the seat support and operate the machine. Check for proper operation. 7200 330045 (10- -99) Home Find... Go To..
Page 166: Instrument Panel
CONTROL PANEL instructions. FOR SAFETY: Disconnect Battery Connections Before Working On machine. 2. Locate the circuit board cover on the inside, front wall of the steering support, behind the control panel. 4-10 7200 330045 (10- -99) Home Find... Go To..
Page 167 5. Un--plug the two ribbon cables from the circuit board. 6. Locate the four touch panel lock clips on the under side of the dash panel. Remove the lock clips. 4-11 7200 330045 (10- -99) Home Find... Go To..
Page 168 10. Place the touch panel bezel over the touch panel. Line up the posts on the bezel with the mount holes in the dash panel. 11. Install the four lock clips on the bezel posts. 4-12 7200 330045 (10- -99) Home Find... Go To..
Page 169 14. Reinstall the six nuts on the circuit breaker cover. Hand tighten lightly. 15. Pivot the control panel back in position. Reinstall the two screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 4-13 7200 330045 (10- -99) Home Find... Go To..
Page 170 ELECTRICAL 16. Lift the operator seat and reconnect the battery connector at the front of the solution tank. 17. Close the seat support. Start the machine and check for proper operation. 4-14 7200 330045 (10- -99) Home Find... Go To..
Page 171: Control Panel
The support arm automatically engages when the seat is lifted all the way up. 2. Un--plug the battery connector from in front of the solution tank. FOR SAFETY: Disconnect Battery Connections Before Working On machine. 4-15 7200 330045 (10- -99) Home Find... Go To..
Page 172 3. Lower the seat support. 4. Remove the two screws at the top of the control panel mount plate. 5. Pivot the mount plate down until it is resting against the seat support. 4-16 7200 330045 (10- -99) Home Find... Go To..
Page 173: To Replace Circuit Board
2. Locate the circuit board cover on the inside, front wall of the steering support, behind the control panel. 3. Remove the six nuts holding the circuit board cover on the frame. 4-17 7200 330045 (10- -99) Home Find... Go To..
Page 174 See schematic in this section. 10. Position the circuit board cover back up to the inside, front wall of the steering support, behind the control panel. 4-18 7200 330045 (10- -99) Home Find... Go To..
Page 175 18 -- 24 Nm (15 -- 20 ft lb). 13. Lift the operator seat and reconnect the battery connector at the front of the solution tank. 14. Close the seat support. Start the machine and check for proper operation. 4-19 7200 330045 (10- -99) Home Find... Go To..
Page 176: Circuit Breakers
10 A Power wand 10 A Horn 10 A Instrument panel 20 A Vacuum Fan 40 A Heavy duty vacuum fan 25 A Scrub brush motor 25 A Scrub brush motor 4-20 7200 330045 (10- -99) Home Find... Go To..
Page 177: To Replace Circuit Breaker
2. Locate the circuit breakers on the upper edge of the control panel. 3. Locate the circuit breaker that needs changing. 4. Disconnect the wires from the back of circuit breaker. 4-21 7200 330045 (10- -99) Home Find... Go To..
Page 178 8. Position the new circuit breaker in the mount hole. Note that the circuit breaker and mount hole are ”D” shaped. The circuit breaker can only be installed one way. (lower amp only) 4-22 7200 330045 (10- -99) Home Find... Go To..
Page 179 18 -- 24 Nm (15 -- 20 ft lb). 12. Lift the operator seat and reconnect the battery connector at the front of the solution tank. 13. Close the seat support. Start the machine and check for proper operation. 4-23 7200 330045 (10- -99) Home Find... Go To..
Page 180: Fuses
1. Open the control panel. See TO ACCESS CONTROL PANEL instructions. FOR SAFETY: Disconnect Battery Connections Before Working On machine. 2. Locate the electrical fuse on the bottom, left side of the control panel. 4-24 7200 330045 (10- -99) Home Find... Go To..
Page 181 18 -- 24 Nm (15 -- 20 ft lb). 7. Lift the operator seat and reconnect the battery connector at the front of the solution tank. 8. Start the machine and check for proper operation. 4-25 7200 330045 (10- -99) Home Find... Go To..
Page 182: Directional Control Pedal
NOTE: When the directional pedal returns to the neutral position the scrub head will stop. After a short delay, the scrub head will also raise. 4-26 7200 330045 (10- -99) Home Find... Go To..
Page 183: To Replace Motor Controller
FOR SAFETY: Disconnect Battery Connections Before Working On machine. 2. Locate the controller box in the center of the control panel. 3. Disconnect the wires and power cables leading to the controller. 4-27 7200 330045 (10- -99) Home Find... Go To..
Page 184 See the schematic in this section. 7. Pivot the control panel back in position. Reinstall the two screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 4-28 7200 330045 (10- -99) Home Find... Go To..
Page 185: To Replace Taillight Bulb
1. Drain the tanks, then remove tank drain caps. 2. Loosen the bottom screws holding the drip tray. 3. Rotate the tray outward from the bottom. This allows access to the taillight assembly. 4-29 7200 330045 (3- -02) Home Find... Go To..
Page 186: Electric Motors
Connections Before Working On machine. 2. Raise the front of the machine and place jack stands under the frame. 3. Mark and remove the four electrical cables leading to the drive motor. 4-30 7200 330045 (10- -99) Home Find... Go To..
Page 187 See the schematic in this section. 8. Remove the jack stands and lower the machine. 9. Reconnect the battery cables. 10. Drive the machine and check the new drive motor for proper operation. 4-31 7200 330045 (10- -99) Home Find... Go To..
Page 188: To Replace Disc Scrub Head Brush Motor
3. Go in under the scrub head and remove the screw and washer from the center of the brush drive plug. 4. Drop the drive plug down off the motor shaft. Make sure to retain the square key. 4-32 7200 330045 (10- -99) Home Find... Go To..
Page 189 8. Lift the brush motor off the deck of the scrub head and remove it from the machine. Note the orientation of the brush motor power cable. The new motor must be orientated the same direction. 4-33 7200 330045 (10- -99) Home Find... Go To..
Page 190 Install the four screws and tighten to 11 -- 14 Nm (7 -- 10 ft lb). 4-34 7200 330045 (10- -99) Home Find... Go To..
Page 191 REPLACE SIDE SQUEEGEE BLADES instructions in the SCRUBBING section. 16. Start the machine and operate the scrubbing function. Check for proper operation and rotation of the new motor. FRONT OF MACHINE SCRUB BRUSH ROTATION 4-35 7200 330045 (10- -99) Home Find... Go To..
Page 192: To Replace Cylindrical Scrub Head Brush Motor
SCRUBBING section. 2. Remove the scrub brushes. See TO REPLACE DISC SCRUB BRUSHES instructions in the SCRUBBING section. 3. Start the machine and lower the scrub head. Shut off the key. 4-36 7200 330045 (10- -99) Home Find... Go To..
Page 193 Remove the belt cover from the scrub head. 7. Loosen the jam nut on the belt tension bolt under the brush motor. Turn the tension bolt down far enough to slip the the belt off the cogged pulley. 4-37 7200 330045 (10- -99) Home Find... Go To..
Page 194 Align the mounting holes on the motor with the holes in the pivot mount bracket. Install the two screws. Snug the hardware for now. 12. Slip the brush belt over the cogged pulley. 4-38 7200 330045 (10- -99) Home Find... Go To..
Page 195 15. Tighten the two motor pivot screws to 18 -- 24 Nm (15 -- 20 ft lb). Re--check the belt tension. 16. Reconnect the brush motor into the main harness. NOTE: See schematic in this section. 4-39 7200 330045 (10- -99) Home Find... Go To..
Page 196 18. Reinstall the scrub brushes. See TO REPLACE CYLINDRICAL SCRUB BRUSHES instructions in the SCRUBBING section. 19. Operate the machine and check the scrub brush motor for proper operation. 4-40 7200 330045 (10- -99) Home Find... Go To..
Page 197: Lift Actuators
ELECTRICAL LIFT ACTUATORS The lift actuators are electric devices that, with a push of a switch, raise and lower either the scrub head or the rear squeegee. 4-41 7200 330045 (10- -99) Home Find... Go To..
Page 198: To Replace Scrub Head Lift Actuator
Remove the two screws. 4. Raise the seat support and unplug the battery connector. FOR SAFETY: Disconnect Battery Connections Before Working On machine. 4-42 7200 330045 (10- -99) Home Find... Go To..
Page 199 8. Remove the cotter pin and clevis pin holding the actuator to the bottom of the spring mount bracket. Remove the actuator. Note the orientation of the actuator on the bracket. 4-43 7200 330045 (10- -99) Home Find... Go To..
Page 200 Tighten all four screws to 18 -- 24 Nm (15 -- 20 ft lb). 4-44 7200 330045 (10- -99) Home Find... Go To..
Page 201 15. Raise the seat support and plug in the battery connector. Lower the seat assembly. 16. Operate the machine and check the scrub head lift actuator for proper operation. 4-45 7200 330045 (10- -99) Home Find... Go To..
Page 202: To Replace Rear Squeegee Lift Actuator
4. Remove the four screws. Let the squeegee mount channel and squeegee assembly drop down to access the lift actuator. 5. Remove the long hex screw and nyloc nut from the motor end of the lift actuator. 4-46 7200 330045 (10- -99) Home Find... Go To..
Page 203 9. Reinstall the hex screw and nut in the motor end of the lift actuator. 10. Reinstall the cotter pin and clevis in the tube end of the lift actuator. 4-47 7200 330045 (10- -99) Home Find... Go To..
Page 204 (26 -- 34 ft lb). 12. Reconnect the squeegee lift actuator to the main electrical harness. See schematic in this section. 13. Start the machine and check the rear squeegee actuator for proper operation. 4-48 7200 330045 (10- -99) Home Find... Go To..
Page 205: Est Pump
Servicing Machine; Stop On Level Surface, Set Parking Brake. 1. Make sure the solution and recovery tanks are empty. 2. Remove the vacuum fan assembly. See TO REMOVE VACUUM FAN ASSEMBLY instructions. 4-49 7200 330045 (10- -99) Home Find... Go To..
Page 206 6. Loosen the worm drive clamps holding the solution hoses to the ESt pump. Pull the hoses off the pump fittings. 7. Pull the ESt pump assembly out of the machine. 4-50 7200 330045 (10- -99) Home Find... Go To..
Page 207 11. Position the pump assembly in the tank area. Place both solution hoses on the pump fittings. Hand tighten the worm drive clamps. 12. Reconnect the pump to the main electrical harness. See schematic in this section. 4-51 7200 330045 (10- -99) Home Find... Go To..
Page 208 18 -- 24 Nm (15 -- 20 ft lb). 14. Reinstall the vacuum fan assembly. See TO INSTALL VACUUM FAN ASSEMBLY instructions. 15. Operate the machine and check the ESt pump for proper operation. 4-52 7200 330045 (10- -99) Home Find... Go To..
Page 209: To Replace Est Pump (Later Machines)
1. Make sure the solution and recovery tanks are empty. 2. Remove the vacuum fan assembly. See TO REMOVE VACUUM FAN ASSEMBLY instructions. 3. Locate the ESt pump under the solution/recovery tanks, behind the rear squeegee mount frame. 4-53 7200 330045 (10- -99) Home Find... Go To..
Page 210 7. Pull the ESt pump assembly out of the machine. 8. Remove the plastic fittings from the old pump and install in the new pump in the same orientation. 4-54 7200 330045 (10- -99) Home Find... Go To..
Page 211 See schematic in this section. 12. Reinstall the vacuum fan assembly. See TO INSTALL VACUUM FAN ASSEMBLY instructions. 13. Operate the machine and check the ESt pump for proper operation. 4-55 7200 330045 (10- -99) Home Find... Go To..
Page 212: Solution Solenoid Valve
1. Drain the solution and recovery tanks. 2. Start the machine and lower the scrub head. Turn off the key. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake. 4-56 7200 330045 (10- -99) Home Find... Go To..
Page 213 5. Mark and disconnect the wires leading to the solenoid valve. 6. Loosen the two worm drive clamps holding the water hoses to the valve. Mark the hoses and pull them off the fittings. 4-57 7200 330045 (10- -99) Home Find... Go To..
Page 214 Hand tighten the two worm drive clamps. 10. Re--connect the wires to the new solenoid valve. See schematic in the section. 11. Start the machine and operate. Check the new valve for proper operation. 4-58 7200 330045 (10- -99) Home Find... Go To..
Page 215: Vacuum Fan
This vacuum pulls water from the lowered squeegee into the recovery tank. The vacuum fan is equipped with a easily serviceable air filter. 4-59 7200 330045 (10- -99) Home Find... Go To..
Page 216: To Replace Vacuum Fan
Remove the vacuum fan. NOTE: Make sure to install a gasket on the bottom of the new fan. 3. Position the new fan on the housing in the same orientation as the old fan. 4-60 7200 330045 (10- -99) Home Find... Go To..
Page 217 5. Reinstall the vacuum fan assembly in the machine. See TO INSTALL VACUUM FAN ASSEMBLY instructions in the SCRUBBING section. 4-61 7200 330045 (10- -99) Home Find... Go To..
Page 218: Electrical Schematic (000000--008237)
ELECTRICAL ELECTRICAL SCHEMATIC (000000- - 008237) 350764 - - ALL 4-62 7200 330045 (3- -02) Home Find... Go To..
Page 219 ELECTRICAL ELECTRICAL SCHEMATIC (000000- - 008237) 350764 - - ALL 4-63 7200 330045 (3- -02) Home Find... Go To..
Page 220: Electrical Schematic (008238-- )
28A/BR N BOARD PULL--DN RESISTOR SEAT SWITCH 32C/ORA 27D/GRN 27A/GRN 27F/GRN 28B/BRN CURTIS ET--10 3 6A/BL U 10F/YE L 6B/BL U 8/BLU 25/GRY 35/GR N 7/PUR 6/BLU 392180 - - ALL 4-64 7200 330045 (3- -02) Home Find... Go To..
Page 221 ELECTRICAL ELECTRICAL SCHEMATIC (008238- - MEMBRANE TOUCH PANEL PANEL SWITCHES PANEL LEDS 392180 - - ALL 4-65 7200 330045 (3- -02) Home Find... Go To..
Page 222: Wire Harnesses Group (000000--008237)
ELECTRICAL WIRE HARNESSES GROUP (000000- - 008237) 4-66 7200 330045 (3- -02) Home Find... Go To..
Page 223 ELECTRICAL WIRE HARNESSES GROUP (000000- - 008237) 4-67 7200 330045 (3- -02) Home Find... Go To..
Page 224 ELECTRICAL WIRE HARNESSES GROUP (000000- - 008237) 4-68 7200 330045 (3- -02) Home Find... Go To..
Page 225: Operating Modes
ELECTRICAL OPERATING MODES The Model 7200 has 4 different operating modes. The machine operator can access each mode by pressing various buttons on the control panel, holding them, and turning on the key. The common operating modes are detailed in the following charts.
Page 226: Normal Mode
2. The machine will delay a few seconds and the squeegee will start to raise. 3. The vacuum fan will turn off after a slight delay. 4-70 7200 330045 (10- -99) Home Find... Go To..
Page 227: Squeegee Button
The overflow indicator will remain illuminated until at least one of the following action occur: 1. The overflow float switch becomes inactive (S--4 is open) and the scrub button is pushed. Continued on next page... 7200 330045 (10- -99) 4-71 Home Find... Go To..
Page 228: Battery Gauge
The hour meter logs hours if the machine is in one of the following modes. 1. Propelling 2. Vacuum fans running. INTERLOCKS The 7200 has several interlocks which can inhibit or cancel machine functions. D REVERSE -- When the operator engages the reverse contactor, the following function will become inhibited: --SQUEEGEE will rise.
Page 229 The battery meter will be reset the next time the key is turned on. D FULL RECOVERY TANK -- The 7200 will cancel the following functions if the recovery tank float switch is turned on:...
Page 230: Self Test Mode
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. 4-74 7200 330045 (10- -99) Home Find... Go To..
Page 231 15. Cycle and test the Hour meter output. 16. Cycle and test the water valve output. 17. Blink the squeegee light (green) for system passed, blink the overflow light (red) for system failed. 7200 330045 (10- -99) 4-75 Home Find... Go To..
Page 232: Self Test Error Codes
ACCESSORY OUTPUT GROUP ESt BUTTON PRESSED ESt LED SQUEEGEE PRESSURE PRESSURE PRESSURE PRESSURE ERROR Air Flush valve output Hour meter output Water valve output ESt pump output Fan contactor output Brush contactor output 4-76 7200 330045 (10- -99) Home Find... Go To..
Page 233: Manual Mode
ESt pump dry for more than a few seconds. The ESt Air flush valve will cycle on and off every 5 seconds. Continued on next page... 7200 330045 (10- -99) 4-77 Home Find... Go To..
Page 234: Interlocks
ELECTRICAL INTERLOCKS The operator can start and stop the various functions of the 7200 scrubber using a variety of closures and interlocks. What follows are two tables for each of the three basic scrubbing functions (Scrub brushes, Squeegee and vacuum fan, and ESt pump).
Page 235: Est Air Flush Operation
D ESt button D ESt LED off D More than 30 seconds has passed since the ESt float has become uncovered D Solution tank full float covered for more then 5 seconds 7200 330045 (10- -99) 4-79 Home Find... Go To..
Page 236: Input Display Mode
Battery 3.--When the battery 3 LED is on, the forward contactor is active. Battery 4.--When the battery 4 LED is on, there is power sensed on the outputs of both brush motor circuit breakers. Continued on next page... 4-80 7200 330045 (10- -99) Home Find... Go To..
Page 237 NOTE: There is a clear folder at the end of this manual that contains three touch panel overlays. Use each of the these overlays in their respective test mode as a technical aide during the diagnostic procedure. 7200 330045 (10- -99) 4-81 Home Find... Go To..
Page 238 ELECTRICAL 4-82 7200 330045 (10- -99) Home Find... Go To..
Page 239: Troubleshooting
TROUBLESHOOTING The troubleshooting charts that follow are organized so they lead you through the circuits. They include flow charts and instructions for you as to where to insert your test instruments. 7200 330045 (10- -99) 4-83 Home Find... Go To..
Page 240: Power Up Testing
POSITION, CHECK FOR VOLTAGE AT M1 WIRES 6/BLU AGAIN BATTERY VOLTAGE 6/BLU, CB--- 1, 35/GRN, D--- 1, MACHINE IS 7/PUR, OR KEY SWITCH PINS 30 POWERED UP TO PIN 15 ARE OPEN 4-84 7200 330045 (10- -99) Home Find... Go To..
Page 241 D- -8 27B/GRN 26/ORA 27/GRN 13D/BLK S- -2 MAIN = CLOSED CONTACT LEGEND CIRCUIT BREAKER FUSE MOTOR DIODE CONNECTOR PIN RELAY COIL SWITCH RESISTOR ARMATURE HOURMETER N.O. NORM.OPEN CONTACT COMMON CONTACT 7200 330045 (10- -99) 4-85 Home Find... Go To..
Page 242: Propel
P-- 6 = 0 voltage in neutral, +5VDC for full forward or reverse P-- 14 = Ground when (M3) brush contactor is on (= low speed) P-- 14 = B+ when (M3) is off 4-86 7200 330045 (3- -02) Home Find... Go To..
Page 243: Controller Outputs
2 - - 1 " D Emergency reverse circuit check fault 2 - - 2 " (BB wiring) D High--pedal--disable--fault (HPD) 2 - - 3 " TABLE 1 continued on the next page. 7200 330045 (3- -02) 4-87 Home Find... Go To..
Page 244: Programmer Diagnostics
A vehicle that does not operate in ”forward” is brought in for repair. Step 1. Examine the vehicle and its wiring for any obvious problems, such as broken wires or loose connections Continued on next page..4-88 7200 330045 (3- -02) Home Find... Go To..
Page 245 Insert for Table 6...
Page 246 Insert for Table 7...
Page 247 2. BB check wire open. 2 - - 3 HPD sequencing fault 1. Improper sequence of KSI, brake, throttle inputs. 2. Wrong HPD type selected. 3. Mistrusted throttle pot. 7200 330045 (10- -99) 4-89 Home Find... Go To..
Page 248 4 - - 3 THERMAL Over- -/under- -temp. 1. Temperature >85_C or CUTBACK cutback <25_C. 2. Excessive load on vehicle. 3. Improper mounting of controller. 4. Operation in extreme environments. 4-90 7200 330045 (10- -99) Home Find... Go To..
Page 249: Propel
26/ORA 27B/GRN S- -2 27/GRN 27D/GRN MAIN EMERGENCY- -STOP = CLOSED CONTACT LEGEND CIRCUIT BREAKER FUSE MOTOR DIODE CONNECTOR PIN RELAY COIL SWITCH RESISTOR ARMATURE HOURMETER N.O. NORM.OPEN CONTACT COMMON CONTACT 7200 330045 (10- -99) 4-91 Home Find... Go To..
Page 250: Touch Panel And Ribbon Testing
NEXT VERIFY GROUNDS ON: - -13A/BLK AT P3- -3 OF CONTROL BOARD - -13B/BLK AT P3- -8 OF CONTROL BOARD - -13C/BLK AT P4- -5 OF CONTROL BOARD REPLACE TOUCH PANEL 4-92 7200 330045 (10- -99) Home Find... Go To..
Page 251 P2- -12 SQ/VAC P2- -12 39/GRN RIBBON CABLE (2) STATIC GND. LEGEND TO FRAME CIRCUIT BREAKER FUSE MOTOR DIODE CONNECTOR PIN RELAY COIL SWITCH RESISTOR ARMATURE HOURMETER N.O. NORM.OPEN CONTACT COMMON CONTACT 7200 330045 (10- -99) 4-93 Home Find... Go To..
Page 252: Vacuum Fan (S)
REPLACE THE REPLACE M3 CONTACTOR CONTROL BOARD DID FAN TURN ON/OFF DURING SELF TEST ? RUN MANUAL MODE TO RUN INPUT TEST THE LOADS TEST MODE SEE NEXT PAGE..SEE NEXT PAGE..4-94 7200 330045 (10- -99) Home Find... Go To..
Page 253 THE CONTROL BOARD IS SWITCHING 11/BRN AT P3--- 12 TO GROUND TO TURN ON M2--- --- M2 IS BAD OR --- 10D/YEL, 11/BRN, 1A/ORA, CB--- 7, 3/GRY, OR 13AF/BLK ARE OPEN 7200 330045 (10- -99) 4-95 Home Find... Go To..
Page 254 P2- -12 SQ/VAC P2- -12 LEGEND 39/GRN CIRCUIT BREAKER FUSE RIBBON CABLE (2) MOTOR DIODE STATIC GND. CONNECTOR PIN RELAY COIL TO FRAME SWITCH RESISTOR ARMATURE HOURMETER N.O. NORM.OPEN CONTACT COMMON CONTACT 4-96 7200 330045 (10- -99) Home Find... Go To..
Page 255 ELECTRICAL 7200 330045 (10- -99) 4-97 Home Find... Go To..
Page 256: Squeegee
IF THE ERROR = ”NO SQUEEGEE STALL” (SQUEEGEE BUTTON HELD- -- -DOWN PRESSURE #1 AND #2 ARE ON 16/YEL, 17/GRY, OR SQUEEGEE ACTUATOR ARE OPEN SEE NEXT PAGE..SEE NEXT PAGE..4-98 7200 330045 (10- -99) Home Find... Go To..
Page 257 MEASURE VOLTAGE FROM 16/YEL TO HAPPEN IN REVERSE--- --- GO TO 17/GRY AT SQUEEGEE ACTUATOR PROPEL SYSTEM TESTING BATTERY VOLTAGE OR --- BATTERY VOLTAGE REPLACE ACTUATOR 16/YEL OR 17/GRY ARE OPEN 7200 330045 (10- -99) 4-99 Home Find... Go To..
Page 258 P2- -12 SQ/VAC P2- -12 LEGEND 39/GRN CIRCUIT BREAKER FUSE RIBBON CABLE (2) MOTOR DIODE STATIC GND. CONNECTOR PIN RELAY COIL TO FRAME SWITCH RESISTOR ARMATURE HOURMETER N.O. NORM.OPEN CONTACT COMMON CONTACT 4-100 7200 330045 (10- -99) Home Find... Go To..
Page 259 ELECTRICAL 7200 330045 (10- -99) 4-101 Home Find... Go To..
Page 260: Scrub System
S- -4 FLOAT SWITCH IS 62/BLU, OR 64/PUR IS OPEN SHORTED IN THE DOWN POSITION NOTE: A SHORTED MOTOR OR D- -6, D- -7 WILL OPEN CIRCUIT BREAKER OR 24/GRY IS SHORTED TO GROUND 4-102 7200 330045 (10- -99) Home Find... Go To..
Page 261: Self Test Error Breakdown
--- THE SHUNT SIGNAL IS NOT GETTING TO THE CONTROL BOARD --- CHECK WIRES 88/BLK, 87/CLR, AND THE SHUNT HARNESS CONNECTIONS --- VERIFY THAT THE SHUNT IS HOOKED UP AS PER SCHEMATIC --- REPLACE THE SHUNT AS NECESSARY 7200 330045 (10- -99) 4-103 Home Find... Go To..
Page 262 -- IF NONE OF THESE ERRORS ARE FOUND ON THE MACHINE: THE SCRUB SYSTEM IS PASSING SELF-- DIAGNOSTICS -- DETERMINE WHAT OTHER ERROR WAS CAUSING THE SELF TEST FAILURE-- -- TROUBLESHOOT THAT SECTION 4-104 7200 330045 (10- -99) Home Find... Go To..
Page 263: Scrub System
P2- -12 P3- -9 39/GRN LEGEND RIBBON CABLE (2) STATIC GND. CIRCUIT BREAKER FUSE TO FRAME MOTOR DIODE CONNECTOR PIN RELAY COIL SWITCH RESISTOR ARMATURE HOURMETER N.O. NORM.OPEN CONTACT COMMON CONTACT 7200 330045 (10- -99) 4-105 Home Find... Go To..
Page 264: Est System
WHEN RECOVERY TANK 1/2 FULL SWITCH (S--- 5) IS CLOSED (FLOAT IN UP POSI- TION) THE ES TOUCH PANEL LIGHT TURNS ON --- IS THE ES LIGHT ON WHEN S--- 5 CLOSES ? SEE NEXT PAGE..4-106 7200 330045 (10- -99) Home Find... Go To..
Page 265 WHEN S--- 9 IS OPEN ? S--- 9 FLOAT SWITCH, 14/GRY, (FLOAT DOWN) OR 13Q/BLK IS OPEN SYSTEM TESTS GOOD S--- 9 IS SHORTED WITH THE FLOAT DOWN OR 14/GRY IS SHORTED TO GROUND 7200 330045 (10- -99) 4-107 Home Find... Go To..
Page 266 P2- -12 SQ/VAC P2- -12 39/GRN RIBBON CABLE (2) STATIC GND. TO FRAME LEGEND CIRCUIT BREAKER FUSE MOTOR DIODE CONNECTOR PIN RELAY COIL SWITCH RESISTOR ARMATURE HOURMETER N.O. NORM.OPEN CONTACT COMMON CONTACT 4-108 7200 330045 (10- -99) Home Find... Go To..
Page 267: Est Filter Flush System
TO GROUND AT P3--- 1--- --- VALVE SHOULD TURN ON --- VALVE, 10J/YEL, OR 38/ORA IS OPEN SYSTEM IS TESTING GOOD --- REVIEW OPERATION DESCRIPTION--- --- IS SYSTEM PROPERLY ENABLED ? 7200 330045 (10- -99) 4-109 Home Find... Go To..
Page 268 P2- -12 SQ/VAC P2- -12 39/GRN RIBBON CABLE (2) STATIC GND. TO FRAME LEGEND CIRCUIT BREAKER FUSE MOTOR DIODE CONNECTOR PIN RELAY COIL SWITCH RESISTOR ARMATURE HOURMETER N.O. NORM.OPEN CONTACT COMMON CONTACT 4-110 7200 330045 (10- -99) Home Find... Go To..
Page 269 We Need Your Help... As part of Tennant’s Zero Defects Program, we want to know about errors you have found or suggestions you may have regarding our machine manuals. If you find an error or have a suggestion, please complete this postage-paid form and mail it to us.
Page 270 Home Find... Go To..
Page 271 We Need Your Help... As part of Tennant’s Zero Defects Program, we want to know about errors you have found or suggestions you may have regarding our machine manuals. If you find an error or have a suggestion, please complete this postage-paid form and mail it to us.
Page 272 Home Find... Go To..

Tennant 7200 Service Manual

Section 1

Section 2

Chassis

Scrubbing

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Chapters

Troubleshooting

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Summary of Contents for Tennant 7200

Table of Contents