7400 Service Manual Tennant Rider Floor Scrubber

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7400
Service Manual
MM428
Rev. 04 (3--02)
This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT
Model 7400.
This manual is organized into seven major groups: General Information, Chassis, Scrubbing, Electrical,
Hydraulics, Engine--G/LPG and Engine--D.
General Information: Machine transport, machine jacking, machine storage, machine specifications, and
machine maintenance chart.
Chassis: Tire/wheel replacement, brake adjustment and replacement, chassis lubrication, steering
adjustment and replacement.
Scrubbing: Scrubber head repair/replacement, brush repair/replacement. squeegee repair/replacement,
and scrubber troubling shooting.
Electrical: Battery maintenance and replacement, instrument panel replacement, and electrical
troubleshooting.
Hydraulics: Valve replacement/repair, motor replacement/repair, cylinder replacement/repair, pump
replacement/repair, filter replacement, and hydraulics troubleshooting.
Engine -- G/LPG: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system
maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine
repairs.
Engine -- D: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system
maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine
repairs.
Manual Number -- MM428
Revision: 04
Published: 3--02
CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Copyright E1996, 1998, 2001, 2002 TENNANT, Printed in U.S.A.
GENERAL INFORMATION
1-1
7400 MM428 (6--01)
CONTENTS
Page
SAFETY PRECAUTIONS 1--3..............
SPECIFICATIONS 1--6....................
GENERAL MACHINE
DIMENSIONS/CAPACITIES 1--6......
GENERAL MACHINE PERFORMANCE1--6
POWER TYPE 1--7.....................
STEERING 1--7........................
HYDRAULIC SYSTEM 1--8..............
BRAKING SYSTEM 1--8................
TIRES 1--8.......................
MACHINE DIMENSIONS 1--9...............
MAINTENANCE 1--10.....................
MAINTENANCE CHART / G/LP 1--10.....
MAINTENANCE CHART / DIESEL 1--12..
PUSHING, TOWING, AND
TRANSPORTING THE MACHINE 1--14...
PUSHING OR TOWING
THE MACHINE 1--14.................
TRANSPORTING THE MACHINE 1--15...
MACHINE JACKING 1--17...............
STORING MACHINE 1--18..............
HARDWARE INFORMATION 1--19..........
STANDARD BOLT TORQUE CHART 1--19
METRIC BOLT TORQUE CHART 1--19...
BOLT IDENTIFICATION 1--19............
THREAD SEALANT AND LOCKING
COMPOUNDS 1--19.................
HYDRAULIC FITTING INFORMATION1--20
HYDRAULIC TAPERED PIPE FITTING (NPT)
TORQUE CHART 1--20..............
HYDRAULIC TAPERED SEAT FITTING (JIC)
TORQUE CHART 1--20..............
HYDRAULIC O--RING FITTING TORQUE
CHART 1--20......................
GENERAL INFORMATION
1-2 7400 MM428 (6--01)
GENERAL INFORMATION
1-3
7400 MM428 (6--01)
SAFETY PRECAUTIONS
The following precautions are used throughout
this manual as indicated in their description:
WARNING: To warn of hazards or
unsafe practices which could result in
severe personal injury or death.
FOR SAFETY: To identify actions which
must be followed for safe operation of
equipment.
The machine is suited to sweep disposable
debris. Do not use the machine other than
described in this Operator Manual. The machine
is not designed for use on public roads.
The following information signals potentially
dangerous conditions to the operator or
equipment:
FOR SAFETY:
1. Do not operate machine:
-- Unless trained and authorized.
-- Unless operator manual is read and
understood.
-- If it is not in proper operating
condition.
-- In flammable or explosive areas unless
designed for use in those areas.
-- In areas with possible falling objects
unless equipped with overhead guard.
2. Before starting machine:
-- Check for fuel, oil, and liquid leaks.
-- Keep sparks and open flame away
from refueling area.
-- Make sure all safety devices are in
place and operate properly.
-- Check brakes and steering for proper
operation.
3. When starting machine:
-- Keep foot on brake and directional
pedal in neutral.
4. When using machine:
-- Use brakes to stop machine.
-- Go slow on inclines and slippery
surfaces.
-- Use care when reversing machine.
-- Do not carry passengers on machine.
-- Always follow safety and traffic rules.
-- Report machine damage or faulty
operation immediately.
5. Before leaving or servicing machine:
-- Stop on level surface.
-- Set parking brake.
-- Turn off machine and remove key.
6. When servicing machine:
-- Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
-- Block machine tires before jacking
machine up.
-- Jack machine up at designated
locations only. Block machine up with
jack stands.
-- Use hoist or jack of adequate capacity
to lift machine.
-- Wear eye and ear protection when
using pressurized air or water.
-- Disconnect battery connections before
working on machine.
-- Avoid contact with battery acid.
-- Avoid contact with hot engine coolant.
-- Allow engine to cool.
-- Keep flames and sparks away from
fuel system service area. Keep area
well ventilated.
-- Use cardboard to locate leaking
hydraulic fluid under pressure.
-- Use Tennant supplied or approved
replacement parts.
WARNING: Engine emits toxic gases.
Severe respiratory damage or
asphyxiation can result. Provide
adequate ventilation. Consult with your
regulatory authorities for exposure
limits. Keep engine properly tuned.
WARNING: Flammable materials can
cause an explosion or fire. Do not use
flammable materials in tank(s).
WARNING: Flammable materials or
reactive metals can cause explosion or
fire. Do not pick up.
WARNING: Moving belt and fan. Keep
away.
WARNING: Strong Vacuum. Keep Away
From Fan Inlet When Fan Is Running.
GENERAL INFORMATION
1-4 7400 MM428 (6--01)
The following safety labels are mounted on the
machine in the locations indicated. If these or any
labels become damaged or illegible, install a new
label in its place.
EMISSIONS LABEL -- LOCATED ON THE SIDE
OF THE OPERATOR COMPARTMENT.
10783
FOR SAFETY LABEL -- LOCATED ON THE
SIDE OF THE OPERATOR COMPARTMENT.
FLAMMABLE SPILLS LABEL -- LOCATED ON
THE SIDE OF THE OPERATOR
COMPARTMENT.
GENERAL INFORMATION
1-5
7400 MM428 (6--01)
FAN AND BELT LABEL -- LOCATED ON THE
ENGINE COMPARTMENT LINTEL.
10783
STRONG VACUUM LABEL -- LOCATED ON
THE VACUUM FAN HOUSING.
FLAMMABLE MATERIALS LABEL -- LOCATED
NEXT TO THE SOLUTION TANK COVERS AND
ON THE DETERGENT TANK.
GENERAL INFORMATION
1-6 7400 MM428 (6--01)
SPECIFICATIONS
GENERAL MACHINE DIMENSIONS/CAPACITIES
Item Dimension/capacity
Length 2460 mm (97 in)
Width 1525 mm (60 in)
Width with optional side brush 1590 mm (62.5 in)
Height 1475 mm (58 in)
Height with overhead guard 2045 mm (80.5 in)
Main scrub brush diameter 280 mm (11 in)
Main scrub brush length 1140 mm (45 in)
Side scrub brush diameter (option) 410 mm (16 in)
Squeegee width 1525 mm (60 in)
Scrubbing path width 1140 mm (45 in)
Scrubbing path width with optional side brush 1450 mm (57 in)
Debris tray volume capacity 42L(1.5 ft
3)
Solution tank 265 L (70 gal)
Recovery tank 272 L (72 gal)
Detergent tank (option) 25 L (6.7 gal)
Total capacity with ESt(option) 397 L (105 gal)
GVWR 2087 kg (4600 lb)
GENERAL MACHINE PERFORMANCE
Item Measure
Maximum forward speed 12.9 kmh (8 mph)
Maximum reverse speed 6.4 kmh (4 mph)
Minimum aisle turn width 3190 mm (125.5 in)
Minimum turning radius, right 2660 mm (104.75 in)
Minimum turning radius, left 2030 mm (79.75 in)
Maximum rated incline for scrubbing 6_
Maximum rated incline for transport of machine 8_
GENERAL INFORMATION
1-7
7400 MM428 (6--01)
POWER TYPE
Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke
Kubota
V1505--B (E)
Piston Diesel 4Natural 478 mm
(3.07 in)
78.4 mm
(3.08 in)
Displacement Net power, governed Net power, maximum
1500 cc (91.4 cu in) 24.6 kw (34 hp) @ 2400 rpm 27.2 kw (37.5 hp) @
3000 rpm
Fuel Cooling system Electrical system
Diesel
Fuel tank: 42 L (11.2 gal)
Water/ethylene glycol
antifreeze
12 V nominal
Total: 7.5 L (2 gal) 37 A alternator
Radiator: 3.8 L (1 gal)
Idle speed, no load (Fast) governed speed, under
load
Engine lubricating oil
without filter
950 +50 rpm 2400 +50 rpm 6 L (6.35 qt)
SAE--CC/CD rated
engine oil
Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke
Ford VSG 1.3 Piston Distributorless-
type spark
4Natural 474 mm
(2.91 in)
75 mm
(2.97 in)
Displacement Net power, governed Net power, maximum
1300 cc (79 cu in) 23.2 kw (32 hp) @ 2400 rpm 39.5 kw (53 hp) @
4000 rpm
Fuel Cooling system Electrical system
Gasoline, 87 octane
minimum, unleaded.
Fuel tank: 42 L (11.2 gal)
Water/ethylene glycol
antifreeze
12 V nominal
LPG,
F
l
t
k
k
(
l
)
Total: 7.5 L (2 gal) 50 A alternator
Fuel tank: 15 kg (33 lb) Radiator: 3.8 L (1 gal)
Idle speed, no load (Fast) governed speed, under
load
Firing order
1350 + 250 rpm 2400 + 50 rpm 1--2--4--3,
counterclockwise
rotation
Spark plug gap Valve clearance, cold Engine lubricating oil
with filter
1 mm (0.04 in) 0.20 mm (0.008 in) intake
0.50 mm (0.002 in) exhaust
3.3 L (3.5 qt) 10W30
SAE--SG/SH
GENERAL INFORMATION
1-8 7400 MM428 (6--01)
STEERING
Type Power source Emergency steering
Front wheel, hydraulic cylinder
and rotary valve controlled
Hydraulic accessory pump Manual
HYDRAULIC SYSTEM
System Capacity Fluid Type
Hydraulic reservoir 38 L (10 gal) TENNANT part no. 65869 -- above 7_C(45_F)
Hydraulic total 74 L (19.5 gal) TENNANT part no. 65870 -- below 7_C(45_F)
BRAKING SYSTEM
Type Operation
Service brakes Mechanical drum brakes (2), one per rear wheel,
cable actuated
Parking brake Utilize service brakes, cable actuated
TIRES
Location Type Size Pressure
Front (1) Solid 460 x 130 mm (5 x 18 in) --
Rear (2) Solid 460 x 130 mm (5 x 18 in) --
GENERAL INFORMATION
1-9
7400 MM428 (6--01)
1327 mm
(52.25 in)
2460 mm
(97 in)
2045 mm
(80.5 in)
1475 mm
(58 in)
1525 mm
(60 in)
1260 mm
(49.6 in)
1610 mm
(63.4 in)
1483 mm
(58.4 in)
1686 mm
(66.4 in)
10919
MACHINE DIMENSIONS
GENERAL INFORMATION
1-10 7400 MM428 (6--01)
MAINTENANCE
1
2
3
4
5
6
7
8
10
11 12
9
5
13
13
13
13
MAINTENANCE CHART / G/LP
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 4Engine air filter Check indicator -- 1
y
Empty dust cap -- 1
4Engine crankcase Check oil level EO 1
8Rear Squeegee Check for damage and wear -- 1
Check deflection -- 1
11 Side Squeegees Check for damage and wear -- 2
10 Scrub brushes Check for damage and wear -- 1
7Recovery tank Clean -- 1
7Recovery tank, EStmode Clean EStfilter -- 1
5Solution tank, EStmode Clean -- 1
50 Hours 10 Scrub brushes Rotate end-for-end or front-to-
rear
-- 1
100 Hours 6Radiator Clean core exterior -- 1
Check coolant level WG 1
4Engine crankcase Change oil and filter element EO 1
13 Cover seals Check for damage and wear -- 4
4Engine Check fan belt tension -- 1
Check and adjust idle speed -- 1
Check and adjust idle mixture -- 1
3Hydraulic fluid reservoir Check fluid level HYDO 1
-- Tires Check for damage -- 3
8Rear squeegee Check leveling -- 1
8Rear squeegee casters Lubricate SPL 2
GENERAL INFORMATION
1-11
7400 MM428 (6--01)
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
100 Hours 10 Scrub brush idlers Lubricate SPL 2
10 Scrub head skirts Check for damage and wear -- 2
-- Side brush skirt Check for damage and wear -- 1
200 Hours 6Radiator hoses and clamps Check for tightness and wear -- 2
4Engine fan belt Check tension -- 1
2 Parking brake Check adjustment -- 1
2Brake pedal Check and adjust travel -- 1
1Front wheel
support bearings
Lubricate SPL 2
400 Hours 9Rear wheel bearings Check, lubricate, and adjust SPL 2
4Engine Clean or replace and adjust -- 4
j
spark plugs
HCheck and adjust valve -- 8
j
clearance
Check and adjust idle speed -- 1
Check and adjust carburetor -- 1
j
idle mixture
Replace PCV valve. Clean PCV -- 1
hoses, tubes, and fittings
Fuel filter, gasoline -- 1
800 Hours 3Hydraulic reservoir Replace filler cap -- 1
y
Replace suction strainer -- 1
Change hydraulic fluid HYDO 1
4Hydraulic fluid filter Change filter element -- 1
-- Hydraulic hoses Check for wear and damage -- All
6 Cooling system Flush WG 1
1Propelling motor HTorque shaft nut -- 1
1Front wheel HTorque wheel nuts -- 1
12 Battery HClean and tighten battery cable -- 1
y
y
connections
NOTE: Also check procedures indicted (H) after
the first 50-hours of operation.
NOTE: More frequent intervals may be required
in extremely dusty conditions.
LUBRICANT/FLUID
EO Engine oil, SAE--SG/SH rated....
HYDO Tennant or approved hydraulic fluid.
WG Water and permanent-type ethylene glycol anti-freeze, --34_C(--30_F)...
SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)...
DW Distilled water....
GENERAL INFORMATION
1-12 7400 MM428 (6--01)
1
2
3
4
5
6
7
8
10
11 12
9
5
13
1
3
13
13
09076
MAINTENANCE CHART / DIESEL
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 4Engine air filter Check indicator -- 1
y
Empty dust cap -- 1
4Engine crankcase Check oil level EO 1
8Rear Squeegee Check for damage and wear -- 1
Check deflection -- 1
11 Side Squeegees Check for damage and wear -- 2
10 Scrub brushes Check for damage and wear -- 1
7Recovery tank Clean -- 1
7Recovery tank, EStmode Clean EStfilter -- 1
5Solution tank, EStmode Clean -- 1
50 Hours 10 Scrub brushes Rotate end-for-end or front-to-
rear
-- 1
4Fuel pipes and clamps Check for tightness and wear -- 1
100 Hours 6Radiator Clean core exterior -- 1
Check coolant level WG 1
4Engine crankcase Change oil and filter EO 1
4Engine fan belt Check tension -- 1
3Hydraulic fluid reservoir Check fluid level HYDO 1
-- Tires Check for damage -- 3
8Rear squeegee Check leveling -- 1
8Rear squeegee casters Lubricate SPL 2
GENERAL INFORMATION
1-13
7400 MM428 (6--01)
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
100 Hours 13 Cover seals Check for damage and wear -- 4
10 Scrub brush idlers Lubricate SPL 2
10 Scrub head skirts Check for damage and wear -- 2
-- Side brush skirt Check for damage and wear -- 1
200 Hours 6Radiator hoses and clamps Check for tightness and wear -- 2
2 Parking brake Check adjustment -- 1
2Brake pedal Check and adjust travel -- 1
1Front wheel Lubricate SPL 2
support bearings
400 Hours 9Rear wheel bearings Check, lubricate, and adjust SPL 2
4Fuel filter Replace cartridge -- 1
6 Cooling system Flush WG 1
800 Hours 3Hydraulic reservoir Replace filler cap -- 1
y
Replace suction strainer -- 1
Change hydraulic fluid HYDO 1
4Hydraulic fluid filter Change filter element -- 1
-- Hydraulic hoses Check for wear and damage -- All
1Propelling motor HTorque shaft nut -- 1
1Front wheel HTorque wheel nuts -- 1
12 Battery HClean and tighten battery cable -- 1
y
y
connections
NOTE: Also check procedures indicted (H) after
the first 50-hours of operation.
NOTE: More frequent intervals may be required
in extremely dusty conditions.
LUBRICANT/FLUID
EO Engine oil, SAE--CC/CD rated....
HYDO Tennant Company or approved hydraulic fluid.
WG Water and permanent-type ethylene glycol anti-freeze, --34_C(--30_F)...
SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)...
DW Distilled water....
GENERAL INFORMATION
1-14 7400 MM428 (6--01)
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE
PUSHING OR TOWING THE MACHINE
If the machine becomes disabled, it can be
pushed from the front or rear, but towed only from
the rear.
The propelling pump has a bypass valve to
prevent damage to the hydraulic system when the
machine is being pushed or towed. This valve
allows a disabled machine to be moved for a very
short distance and at a speed to not exceed 1.6
kp/h (1 mph). The machine is NOT intended to be
pushed or towed a long distance or at a high
speed.
ATTENTION! Do not push or tow
machine for a long distance and without
using the bypass valve, or the machine
hydraulic system may be damaged.
Turn the bypass valve 90_from the normal
position before pushing or towing the machine.
The illustration shows the bypass valve in the
pushing or towing position.
GENERAL INFORMATION
1-15
7400 MM428 (6--01)
TRANSPORTING THE MACHINE
1. Position the rear of the machine at the
loading edge of the truck or trailer.
2. If the loading surface is not horizontal or is
higher than 380 mm (15 in) from the ground,
use a winch to load machine.
If the loading surface is horizontal AND is
380 mm (15 in) or less from the ground, the
machine may be driven onto the truck or
trailer.
3. To winch the machine onto the truck or
trailer, attach the winching chains in the
holes at the bottom of the rear bumper.
If the machine has the optional rear tie down
brackets, attach the winching chains to
them.
4. Turn the bypass valve 90_from the normal
position before winching the machine onto
the truck or trailer. See PUSHING OR
TOWING THE MACHINE section of this
manual. Make sure the machine is centered.
FOR SAFETY: When loading machine
onto truck or trailer, use winch. Do not
drive the machine onto the truck or
trailer unless the loading surface is
horizontal AND is 380 mm (15 in) or less
from the ground.
GENERAL INFORMATION
1-16 7400 MM428 (6--01)
5. Position the machine onto the truck or trailer
as far as possible. If the machine starts to
veer off the centerline of the truck or trailer,
stop and turn the steering wheel to center
the machine.
6. Set the parking brake and block the machine
tires. Tie down the machine to the truck or
trailer before transporting.
The front tie down locations are in the holes
at the bottom of the front bumper. If the
machine has the optional tie down brackets,
use them to tie down the machine.
The rear tie down locations are in the holes
at the bottom of the rear bumper. If the
machine has the optional rear tie down
brackets, use them to tie down the machine.
7. If the loading surface is not horizontal or is
higher than 380 mm (15 in) from the ground,
use a winch to unload machine.
If the loading surface is horizontal AND is
380 mm (15 in) or less from the ground, the
machine may be driven off the truck or
trailer.
FOR SAFETY: When unloading machine
off truck or trailer, use winch. Do not
drive the machine off the truck or trailer
unless the loading surface is horizontal
AND 380 mm (15 in) or less from the
ground.
GENERAL INFORMATION
1-17
7400 MM428 (6--01)
MACHINE JACKING
Empty the recovery and the solution tanks before
jacking the machine.You can jack up the machine
for service at the designated locations. Use a
hoist or jack that will support the weight of the
machine. Always stop the machine on a flat, level
surface and block the tires before jacking the
machine up.
FOR SAFETY: Before leaving or
servicing machine; stop on level
surface, set parking brake, turn off
machine and remove key.
The front jacking location is the left front corner of
the machine frame.
The rear jacking locations are the two rear
corners of the machine frame.
FOR SAFETY: When servicing machine,
block machine tires before jacking
machine up.
FOR SAFETY: When servicing machine,
jack machine up at designated locations
only. Block machine up with jack
stands.
GENERAL INFORMATION
1-18 7400 MM428 (6--01)
STORING MACHINE
When storing the machine for extended periods of
time, the following procedures must be followed to
lessen the chance of rust sludge, or other
undesirable deposits from forming.
1. Drain and clean the solution and recovery
tanks.
2. EStmachines: Run clean water through
the solution system and the EStsolution
pump.
3. Raise the rear squeegee and the scrub
head.
4. Park the machine in a cool, dry area.
5. Remove or charge the battery every three
months.
GENERAL INFORMATION
1-19
7400 MM428 (6--01)
HARDWARE INFORMATION
The following charts state standard plated
hardware tightening ranges for normal assembly
applications. Decrease the specified torque by
20% when using a thread lubricant. Do not
substitute lower grade hardware for higher grade
hardware. If higher grade hardware than specified
is substituted, tighten only to the specified
hardware torque value to avoid damaging the
threads of the part being threaded into, as when
threading into speed nuts or weldments.
STANDARD BOLT TORQUE CHART
Thread
Size
SAE Grade 5
Torque ft lb
(Nm)
SAE Grade 8
Torque ft lb
(Nm)
0.25 in 7--10 (9--14) 10--13 (14--38)
0.31 in 15--20 (20--27) 20--26 (27--35)
0.38 in 27--35 (37--47) 36--47 (49--64)
0.44 in 43--56 (58--76) 53--76 (72--103)
0.50 in 65--85 (88--115) 89--116
(121--157)
0.62 in 130--170
(176--231)
117--265
(159--359)
0.75 in 215--280
(291--380)
313--407
(424--552)
1.00 in 500--650
(678--881)
757--984
(1026--1334)
NOTE: Decrease torque by 20% when using a
thread lubricant.
METRIC BOLT TORQUE CHART
Thread
Size
Class 8.8
Torque ft lb
_Nm)
Class 10.9
Torque ft lb
(Nm)
M4 2(3) 3(4)
M5 4(5) 6(8)
M6 7(9) 10 (14)
M8 18 (24) 25 (34)
M10 32 (43) 47 (64)
M12 58 (79) 83 (112)
M14 94 (127) 133 (180)
M16 144 (195) 196 (265)
M20 260 (352) 336 (455)
M24 470 (637) 664 (900)
NOTE: Decrease torque by 20% when using a
thread lubricant.
Exceptions to the above chart:
Check the machine for exceptions!
BOLT IDENTIFICATION
Identification
Grade Marking
Specification and
Grade
SAE--Grade 5
SAE--Grade 8
ISO--Grade 8.8
ISO--Grade 10.9
01395
THREAD SEALANT AND LOCKING
COMPOUNDS
Thread sealants and locking compounds may be
used on this machine. They include the following:
Locktite 515 sealant -- gasket forming
material. TENNANT Part No. 75567,15 oz
(440 ml) cartridge.
Locktite 242 blue -- medium strength thread
locking compound. TENNANT Part No.
32676, 0.5 ml tube.
Locktite 271 red -- high strength thread
locking compound. TENNANT Part No.
19857, 0.5 ml tube.
GENERAL INFORMATION
1-20 7400 MM428 (6--01)
HYDRAULIC FITTING INFORMATION
HYDRAULIC TAPERED PIPE FITTING (NPT)
TORQUE CHART
NOTE: Ratings listed are when using teflon
thread seal.
Size Minimum
Torque
Maximum
Torque
1/4 NPT 10 ft lb (14 Nm) 30 ft lb (41 Nm)
1/2 NPT 25 ft lb (34 Nm) 50 ft lb (68 Nm)
3/4 NPT 50 ft lb (68 Nm) 100 ft lb (136
Nm)
HYDRAULIC TAPERED SEAT FITTING (JIC)
TORQUE CHART
Tibe O.D.
(in)
Thread Size Maximum
Torque
0.25 0.44--20 9ftlb(12Nm)
0.38 0.56--18 20 ft lb (27 Nm)
0.50 0.75--16 30 ft lb (41 Nm)
0.62 0.88--14 40 ft lb (54 Nm)
0.75 1.12--12 70 ft lb (95 Nm)
1.0 1.31--12 90 ft lb (122 Nm)
HYDRAULIC O--RING FITTING TORQUE
CHART
Tube
O.D.
(in)
Thread
Size
Minimum
Torque
Maximum
Torque
0.25 0.44--20 6ftlb(8Nm) 9ftlb
(12 Nm)
0.38 0.56--18 13 ft lb
(18 Nm)
20 ft lb
(27 Nm)
*10 ft lb
(14 Nm)
12 ft lb
(16 Nm)
0.50 0.75--16 20 ft lb
(27 Nm)
30 ft lb
(41 Nm)
*21 ft lb
(28 Nm)
24 ft lb
(33 Nm)
0.62 0.88--14 25 ft lb
(34 Nm)
40 ft lb
(54 Nm)
0.75 1.12--12 45 ft lb
(61 Nm)
70 ft lb
(95 Nm)
1.0 1.31--12 60 ft lb
(81 Nm)
90 ft lb
(122 Nm)
NOTE: Do not use sealant on o--ring threads.
*Aluminum bodied components
CHASSIS
2-1
7400 MM428 (12--98)
CONTENTS
Page
CHASSIS 2-3............................
SEAT 2-3................................
TO REMOVE SEAT ASSEMBLY 2-3.....
TO REPLACE SEAT ASSEMBLY 2-3.....
OPERATOR SEAT 2-4.................
STATIC DRAG CHAIN 2-4.................
BRAKES AND TIRES 2-5..................
SERVICE BRAKES 2-5.................
TO REPLACE BRAKE SHOES 2-5.......
REAR TIRES AND WHEELS 2-7........
TO REPACK REAR WHEEL
BEARINGS 2-7.....................
FRONT TIRE AND WHEEL, AND
WHEEL SUPPORT 2-9.................
TO REPLACE FRONT DRIVE MOTOR 2-9
TO REPLACE FRONT WHEEL
HOUSING PIVOT BEARINGS 2-11...
CHASSIS
2-2 7400 MM428 (12--98)
CHASSIS
2-3
7400 MM428 (12--98)
INTRODUCTION
This section includes information on the main
chassis related components for example the seat,
steering, brakes, and tires.
CHASSIS
2-4 7400 MM428 (12--98)
SEAT
The seat assembly is adjustable forward and
backward on the 7400.
TO REMOVE SEAT ASSEMBLY
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Tilt the seat assembly forward and engage
theproprod.
2. Remove the four hex screws and nuts
holding the seat assembly hinge to the seat
support.
3. Slide the prop rod to the opening in the slot
and remove.
4. Remove the seat assembly from the
machine.
TO REPLACE SEAT ASSEMBLY
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Position the seat assembly on the seat
support.
2. Reinstall the four hex screws and nuts.
Tighten to 18 -- 24Nm (15 -- 20 ft lb).
3. Slide the seat prop rod through large hole in
slot.
4. Lower the seat.
CHASSIS
2-5
7400 MM428 (12--98)
OPERATOR SEAT
The operator seat is a fixed back style with a
forward-backward adjustment.
Adjust: Pull the lever out, slide the seat
backward or forward to the desired position and
release the lever.
Lift: Pull up on the seat mounting plate until the
seat mount locks up.
Lower: Pull on the release lever and lower the
seat mounting plate.
STATIC DRAG CHAIN
A static drag chain prevents the buildup of static
electricity in the machine. The chain is attached to
the machine with a hex screw by the scrub head
torque tube mount bearing.
Make sure the chain is touching the floor at all
times.
CHASSIS
2-6 7400 MM428 (12--98)
BRAKES AND TIRES
SERVICE BRAKES
The mechanical service brakes are located on the
rear wheels. The brakes are operated by the foot
brake pedal.
Check the brake adjustment every 200 hours of
operation.
TO REPLACE BRAKE SHOES
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Drain the solution and recovery tanks.
2. Make sure the parking brake is not engaged.
3. Remove floor plate from the operators
compartment.
4. Loosen the jam nuts on the brake cable turn
buckle. Rotate the turn buckle to loosen the
tension on the brake cable.
5. Jack up one rear corner of the machine.
Place jack stands under machine.
FOR SAFETY: Block machine tires
before jacking machine up. Jack
machine up at designated locations
only. Block machine up with jack
stands.
6. Remove the hub cap from the center of the
tire and wheel assembly.
7. Remove the cotter pin, slotted nut, flat
washer, and bearing cone.
8. Remove the tire and wheel assembly from
the machine.
9. Remove the two springs holding the brake
shoes together. Remove the old brake
shoes.
10. Position the new brake shoes on the brake
mounting plate.
11. Reattach the two brake springs to the new
brake shoes.
CHASSIS
2-7
7400 MM428 (12--98)
12. Pack the wheel bearings with Lubriplate
EMB grease.
13. Slide the tire and wheel assembly on the
axle.
14. Slide the outer bearing, flat washer and nut
on the shaft.
15. Tighten nut with hand wrench until wheel
binds, then back nut off to nearest hole.
16. Insert a new cotter pin through nut and hole.
17. Spin the tire and wheel assembly. The tire
should spin freely.
18. Reinstall the hub cap in the center of the
wheel.
19. Lower the machine.
NOTE: Always replace brake shoes in sets.
20. Repeat the procedure on the other wheel.
21. Rotate the brake cable turn buckle until the
brake cable is tight or until the brake pedal
travels 25--50 mm (1--2 in) before engaging
brakes.
22. Tighten the brake cable turn buckle jam
nuts.
23. Reinstall the floor plate in the operators
compartment.
24. Operate the machine and check the brakes
for proper operation.
CHASSIS
2-8 7400 MM428 (12--98)
REAR TIRES AND WHEELS
The standard machine rear tires are
semi--pneumatic.
Inspect the rear wheel bearings for seal damage,
and repack and adjust every 1600 hours of
operation. Use Lubriplate EMB grease
(TENNANT part no. 01433--1).
TO REPACK REAR WHEEL BEARINGS
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Drain the solution and recovery tanks.
2. Make sure the parking brake is not engaged.
3. Remove floor plate from the operators
compartment.
4. Loosen the jam nuts on the brake cable turn
buckle. Rotate the turn buckle to loosen the
tension on the brake cable.
5. Jack up one rear corner of the machine.
Place jack stands under machine.
FOR SAFETY: Block machine tires
before jacking machine up. Jack
machine up at designated locations
only. Block machine up with jack
stands.
6. Remove the hub cap from the center of the
tire and wheel assembly.
7. Remove the cotter pin, slotted nut, flat
washer, and bearing cone.
8. Remove the tire and wheel assembly from
the machine.
9. Pack the wheel bearings with Lubriplate
EMB grease.
10. Slide the tire and wheel assembly on the
axle.
11. Slide the outer bearing, flat washer and nut
on the shaft.
CHASSIS
2-9
7400 MM428 (12--98)
12. Tighten nut with hand wrench until wheel
binds, then back nut off to nearest hole.
13. Insert a new cotter pin through nut and hole.
14. Spin the tire and wheel assembly. The tire
should spin freely.
15. Reinstall the hub cap in the center of the
wheel.
16. Lower the machine.
17. Repeat the procedure on the other wheel.
18. Rotate the brake cable turn buckle until the
brake cable is tight or until the brake pedal
travels 25--50 mm (1--2 in) before engaging
brakes.
19. Tighten the brake cable turn buckle jam
nuts.
20. Reinstall the floor plate in the operators
compartment.
21. Operate the machine and check the rear
wheels for proper operation.
CHASSIS
2-10 7400 MM428 (12--98)
FRONT TIRE AND WHEEL SUPPORT
The front wheel support pivots the front wheel.
The support has one grease fitting for the
bearings. The front wheel support bearings must
be lubricated every 200 hours of operation. Use
Lubriplate EMB grease
(TENNANT part no. 01433--1).
Torque the front wheel nuts to 142 -- 156 Nm
(105 -- 115 ft lb) after the first 50-hours of
operation, and every 800 hours thereafter.
Torque the front wheel hub nut to (375 ft lb)
TO REPLACE FRONT DRIVE MOTOR
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Engage parking brake, block rear tires.
2. Jack up front of machine. Use jack stands to
support machine.
FOR SAFETY: Block machine tires
before jacking machine up. Jack
machine up at designated locations
only. Block machine up with jack
stands.
3. Remove the front tire and wheel assembly.
4. Remove the cotter pin and slotted nut from
the front wheel drive motor shaft.
5. Use a puller to remove the drive hub from
the tapered shaft of the drive motor.
6. Remove and plug the hydraulic hoses
leading to the front wheel drive motor.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
7. Remove the four drive motor mounting bolts.
8. Slide the motor out of front wheel housing.
CHASSIS
2-11
7400 MM428 (12--98)
9. Remove the hydraulic fittings from the old
motor and install in the new motor in the
same orientation.
10. Slide the new motor in the front wheel
housing. Note the orientation of the motor.
11. Reinstall the four socket--head screws.
Torque to 90 -- 117 Nm (70 -- 85 ft lb).
12. Reconnect the hydraulic hoses to the drive
motor.
NOTE: Make sure the square key is in place on
the shaft of the new motor.
13. Mount the drive hub to tapered motor shaft.
Tighten slotted nut to 500 Nm (375 ft lb).
Install the cotter pin.
14. Install the front tire. Torque the front wheel
nuts to 142 -- 156 Nm (105 -- 115 ft lb).
15. Remove jack stands and lower machine.
16. Operate the machine and check the front
drive motor for any leaks.
CHASSIS
2-12 7400 MM428 (12--98)
TO REPLACE FRONT WHEEL HOUSING
PIVOT BEARINGS
1. Engage parking brake, block rear tires.
2. Disconnect the battery cables from the
battery.
3. Jack up front of machine. Use jack stands to
support machine.
FOR SAFETY: Block machine tires
before jacking machine up. Jack
machine up at designated locations
only. Block machine up with jack
stands.
4. Remove the front tire and wheel assembly.
5. Remove and plug the hydraulic hoses
leading to the front wheel drive motor.
NOTE: Observe hydraulic cleanliness
requirements when opening hydraulic lines.
6. Remove the hydraulic hose clamp from the
top of the wheel housing.
7. Remove the one 3/4 in. hex screw attaching
the rod end of steering cylinder to the front
wheel housing. Retain the spacer.
8. Remove the cotter pin and large slotted nut
from the top of the pivot pin.
9. Loosen the two M10 socket head bolts
holding the pivot pin to the machine frame.
NOTE: Use a floor jack to support the wheel
housing before removing the pivot pin. The wheel
housing and drive motor assembly is very heavy.
10. Remove the pivot pin from the bottom of the
wheel support.
NOTE: Do not loose the thrust washer from on
top of the wheel housing.
11. Remove the wheel housing and drive motor
assembly out of the main frame.
12. Use a steel punch and hammer to drive the
old bearing cups out of the wheel housing.
CHASSIS
2-13
7400 MM428 (12--98)
13. Install a new set of bearing cups in the
wheel housing. Use a large press or a punch
and hammer to install the cups.
14. Pack the new bearing cones with Lubriplate
EMB grease. Coat the bearing cups with
grease.
15. Position the new bearing cones in the wheel
housing.
16. Position the thrust washer on top of the
upper bearing cone.
17. Position the wheel housing back in the
machine.
18. Slide the large pivot pin up through hole in
the machine frame. Thread castle nut on the
top of the pivot pin. Tighten to 34 -- 40 Nm
(25 -- 30 ft lb). Check the wheel housing for
play. If pin is not seated, tap with rubber
mallet and re--torque castle nut.
NOTE: The wheel housing should rotate with a
slight amount of drag.
19. Torque the top socket screw with a hand
torque wrench to 100 -- 115 Nm
(73--85 ft lb).
20. Tighten the castle nut to the next slot and
insert the cotter pin. Torque not to exceed
100 Nm (75 ft lb).
21. Check the casting to see if it rocks or binds.
If it does, loosen top socket screw, move the
casting to seat the bearings, and re--tighten
the socket screw to 100 -- 115 Nm
(73--85 ft lb).
22. Tighten the lower socket screw to
100 -- 115 Nm (73--85 ft lb).
23. Reinstall rod end of steering cylinder to the
top of the wheel housing using the 3/4 in. x
3--1/4 in. hex screw,nyloc nut, and four flat
washers. Tighten to 270 -- 300 Nm
(200 -- 220 ft lb).
CHASSIS
2-14 7400 MM428 (12--98)
24. Reconnect the hydraulic hoses to the drive
motor.
25. Reinstall the hose clamp to the top of the
wheel housing. Tighten M8 hex screws to
18.5 -- 24Nm (15 -- 20 ft lb).
26. Install the front tire. Torque the front wheel
nuts to 142 -- 156 Nm (105 -- 115 ft lb)
27. Re--connect battery cables, start engine, run
propelling in both directions, check for leaks.
28. Remove jack stands, lower machine to the
ground.
SCRUBBING
3-1
7400 MM428 (9--01)
CONTENTS
Page
INTRODUCTION 3-3...................
SOLUTION TANKS 3-4....................
TO REMOVE LH SOLUTION TANK 3-4...
TO INSTALL LH SOLUTION TANK 3-5...
TO REMOVE RH SOLUTION TANK 3-6..
TO INSTALL RH SOLUTION TANK 3-7...
RECOVERY TANK 3-8....................
TO REMOVE RECOVERY TANK 3-8.....
TO INSTALL RECOVERY TANK 3-11.....
SCRUB HEAD 3-13.......................
TO REPLACE MAIN SCRUB
BRUSHES 3-13.....................
CHECKING AND ADJUSTING SCRUB
BRUSH PATTERN 3-14..............
TO REPLACE MAIN BRUSH IDLER
SHAFT BEARINGS 3-16.............
TO REMOVE MAIN BRUSH DRIVE
MOTOR MOUNT PLATE 3-18........
TO INSTALL MAIN BRUSH DRIVE
MOTOR MOUNT PLATE 3-19........
TO REPLACE OPTIONAL SIDE
BRUSH 3-20.......................
SQUEEGEES 3-21........................
TO REPLACE REAR SQUEEGEE
LIFT CABLE 3-21...................
TO REPLACE REAR SQUEEGEE
CENTERING SPRINGS 3-22.........
TO REMOVE REAR SQUEEGEE
FRAME 3-23.......................
TO INSTALL REAR SQUEEGEE
FRAME 3-23.......................
SQUEEGEE BLADES 3-24................
REAR SQUEEGEE 3-24................
TO REPLACE OR ROTATE REAR
SQUEEGEE BLADES 3-24...........
TO ADJUST REAR SQUEEGEE
BLADE DEFLECTION 3-25...........
TO LEVEL THE REAR SQUEEGEE 3-26.
SIDE SQUEEGEES 3-27...............
TO REPLACE SIDE SQUEEGEE
BLADES 3-27.......................
TO REPLACE SIDE BRUSH
SQUEEGEE 3-28...................
SIDE BRUSH SKIRT 3-28...............
VACUUM FAN 3-29.......................
TO REMOVE VACUUM FAN 3-29........
TO INSTALL VACUUM FAN 3-30........
TO REPLACE VACUUM IMPELLER 3-31.
SCRUBBING
7400 MM428 (12--98)
3-2
SCRUBBING
3-3
7400 MM428 (12--98)
INTRODUCTION
When the scrubbing mode is used, water flows
from the solution tank through the solution valve
to the two cylindrical scrub brushes. The brushes
scrub the floor. As the machine is moved forward
the squeegee wipes the dirty solution off the floor,
which is then picked up and drawn into the
recovery tank by the vacuum fan. There are three
settings on the solution flow----high, low, and off.
SCRUBBING
3-4 7400 MM428 (12--98)
SOLUTION TANKS
The two solution tanks hold the clean water and
detergent mixture that will be applied to the floor
for the scrubbing operation. There is a LH and a
RH solution tank. They are connected by a large
diameter solution line.
TO REMOVE LH SOLUTION TANK
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Empty the solution and recovery tanks.
2. Open the engine side door and engine
cover.
3. Unlatch the rear radiator cover panel and tilt
it open.
4. Disconnect the wires going to the float
switch at the back of the LH solution tank.
5. Remove the two hex screws from the rear
tank bracket where it attaches to the LH
solution tank.
6. Remove the one hex screw from the rear,
lower corner of the LH tank. This hex screw
is located near the left hand taillight.
7. Go to the front of the LH solution tank.
Disconnect the solution cross--over line from
the bottom, front of the LH solution tank.
NOTE: Access the the clamp on the cross--over
line is made easier by removing the two vacuum
hoses leading to the recovery tank.
8. Remove the two M8 hex screws from the
front of the LH solution tank near the engine
alternator.
9. The LH solution tank can now be lifted up
and out of the machine frame.
SCRUBBING
3-5
7400 MM428 (12--98)
TO INSTALL LH SOLUTION TANK
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Position the LH solution tank back in the
machine frame.
NOTE: Be careful not to pinch hydraulic hoses or
electrical wires during this procedure.
2. Reinstall the two M8 hex screws in the front
of the LH solution tank near the engine
alternator. Leave hardware loose for now.
3. Reinstall the two M8 hex screws in the top,
rear of the LH solution tank in the rear tank
bracket. Leave hardware loose for now.
4. Reinstall the one M8 hex screw in the rear,
bottom of the LH solution tank near the LH
taillight.
5. Tighten the five M8 hex screws to
18 -- 24 Nm (15 -- 20 ft lb).
6. Reconnect the solution cross--over line at
the bottom of the tank.
NOTE: Reconnect the vacuum hoses if removed
earlier.
7. Reconnect the wires to the float switch at
the back of the LH solution tank.
8. Close the rear radiator cover panel and
latch.
9. Close the engine side door and engine
cover.
10. Fill the LH solution tank with water and
check for leaks.
SCRUBBING
3-6 7400 MM428 (12--98)
TO REMOVE RH SOLUTION TANK
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. The RH solution tank can only be removed
after the LH solution and recovery tanks
have been removed. See TO REMOVE LH
SOLUTION TANK and TO REMOVE
RECOVERY TANK instructions.
2. Remove the one hex screw from the rear,
lower corner of the RH tank. This hex screw
is located under the frame, above the drain
cap.
3. Place the operators seat in the raised
position and engage the prop rod.
4. Remove the two M8 hex screws from the
front, right corner of the RH solution tank
where it attaches to the seat support.
5. Disconnect any solution lines still attached to
the RH solution tank.
6. The RH solution tank can now be lifted up
and out of the machine frame.
SCRUBBING
3-7
7400 MM428 (12--98)
TO INSTALL RH SOLUTION TANK
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Position the RH solution tank back in the
machine frame.
NOTE: Be careful not to pinch hydraulic hoses or
electrical wires during this procedure.
2. Reinstall the one M8 hex screw in the rear,
bottom of the RH solution tank. This hex
screw is located under the frame, above the
drain cap. Leave hardware loose for now.
3. Reinstall the two M8 hex screws from the
front, right corner of the RH solution tank
where it attaches to the seat support. Leave
hardware loose for now.
4. Reconnect any solution lines that were
disconnected from the RH solution tank.
5. The remain RH solution tank hardware will
be installed during the recovery tank
installation. See TO INSTALL RECOVERY
TANK and TO INSTALL LH SOLUTION
TANK instructions.
SCRUBBING
3-8 7400 MM428 (12--98)
RECOVERY TANK
The recovery tank holds the used water and
detergent solution pulled off the floor by the
squeegee and scrubbing vacuum fan.
TO REMOVE RECOVERY TANK
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Empty the solution and recovery tanks.
2. Place the operators seat in the raised
position and engage the prop rod.
3. Remove the LH solution tank. See TO
REMOVE LH SOLUTION TANK
instructions.
4. Disconnect the vacuum and squeegee
hoses from the front of the recovery tank.
5. Remove the two hex screws holding the
demister cover on the recovery tank.
Remove the demister cover.
6. If the machine is equipped with an overhead
guard, it must be removed in order to
remove the tank lintel.
NOTE: The engine hood must be supported in the
open position before the next step can be
completed.
7. Remove the clips on the bottom of the
engine hood gas springs. Remove the gas
springs from the ball studs on the support
channel.
8. Remove the hex screws holding the support
channel to the tank lintel and hood lintel.
Remove the support channel from the
machine.
SCRUBBING
3-9
7400 MM428 (12--98)
9. Remove the solution and recovery tank drain
caps from the rear of the machine.
10. Remove the three hex screws holding the
tank drain cover to the machine. Remove
the cover.
11. Remove the hex screws holding the tank
lintel to the frame, recovery tank, RH
solution tank, and seat support. Remove the
lintel from the machine.
12. Mark, disconnect, and plug the three
hydraulic hoses leading to the engine fan
hydraulic motor.
NOTE:Observe hydraulic cleanliness
requirements when opening hydraulic lines.
13. Disconnect the solution line at the front of
the recovery tank if the machine is equipped
with the auto--fill option.
14. Disconnect the wires leading to the float
switch that is located at the front, right
corner of the recovery tank.
NOTE: Machines equipped with ES will have two
switches on the float assembly.
15. Disconnect the solution hose at the back of
the tank if the machine is equipped with the
EStoption.
16. Unplug the main electrical harness from the
EStpump at the rear of the tank.
17. Remove the EStpump and cap assembly
from the recovery tank.
18. Remove the one hex screw and two nyloc
nuts holding the radiator assembly to the
back of the recovery tank. Leave the black
mount plate attached to the recovery tank.
Do not disconnect the hoses from the
radiator.
SCRUBBING
3-10 7400 MM428 (12--98)
19. Carefully pull the radiator assembly back
and out of the way of the recovery tank. Let
the radiator assembly lean against the oil
cooler.
20. Remove the two M8 hex screws attaching
the rear tank bracket to the RH solution tank
21. Remove the one M8 hex screw under the
rear of the tank, just above the drain cap.
22. Carefully push the recovery tank forward, lift
it up, and remove it from the machine.
NOTE: An overhead hoist or two people must be.
used when lifting the recovery tank out of the
machine frame.
SCRUBBING
3-11
7400 MM428 (12--98)
TO INSTALL RECOVERY TANK
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
NOTE: An overhead hoist or two people must be
used when positioning the recovery tank back in
the machine frame.
1. Position the recovery tank back in the
machine frame.
NOTE: Be careful not to pinch hydraulic hoses or
electrical wires during this procedure.
2. Reinstall the tank lintel in the machine.
Reinstall the six M8 hex screws. Leave the
hardware loose for now.
3. Reconnect the solution line at the front of
the recovery tank if machine is equipped
with the auto fill option.
4. Reconnect the float switches at the front of
the recovery tank to the main harness. See
schematic in the ELECTRICAL section.
5. Carefully pivot the radiator assembly back in
position on the rear of the recovery tank.
Reinstall the hardware and tighten to
18 -- 24 Nm (15 -- 20 ft lb).
6. Plug the EStpump back in the main
harness. See schematic in the
ELECTRICAL section.
7. Reinstall the hardware in the rear tank
bracket where it attaches to the RH solution
tank.
8. Reinstall the one M8 hex screw under the
rear of the tank, just above the drain cap.
9. Reinstall the support channel to the tank
lintel and hood lintel. Reinstall the four M8
hex screws.
10. Tighten the all of the M8 hex screws to
18 -- 24 Nm (15 -- 20 ft lb).
SCRUBBING
3-12 7400 MM428 (12--98)
11. Reinstall the engine hood gas springs on the
ball studs on the support channel. Reinstall
the two clips.
12. Reconnect the hydraulic hoses to the engine
fan motor. See schematic in the
HYDRAULIC section.
NOTE:Observe hydraulic cleanliness
requirements when opening hydraulic lines.
13. Reinstall the demister cover on the recovery
tank. Reinstall the two M8 hex screws and
tighten to 18 -- 24 Nm (15 -- 20 ft lb).
14. Reinstall the LH solution tank. See TO
INSTALL LH SOLUTION TANK instructions.
15. Reconnect the two vacuum hoses to the
front of the recovery tank.
16. Reinstall the overhead guard if it was
removed earlier.
17. Reinstall the tank drain cover to the rear of
the tanks. Reinstall the hardware and tighten
to 18 -- 24 Nm (15 -- 20 ft lb).
18. Reinstall the solution and recovery tank
drain covers.
19. Partially fill the recovery tank with water and
check for any leaks and for proper operation
of the float switches.
SCRUBBING
3-13
7400 MM428 (12--98)
SCRUB HEAD
The scrub head contains the two cylindrical
brushes, hydraulic motors, brush idler plate, brush
wrap, and side squeegees. Water from the
solution tank flows to the center of of the scrub
head brush wrap and is spread evenly in front of
the scrub brushes.
TO REPLACE MAIN SCRUB BRUSHES
1. Place the main scrub brushes in the raised
position.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
2. Open the RH brush door.
3. Pull back on the front ball joint locking collar
on the leveling rod. Remove the leveling rod
from the front ball stud.
4. Remove the two hair pins from the brush
wrap attachment pins.
5. Remove the M12 hex screw holding the
brush idler plate arm to the lift tube.
6. Remove the idler plate and side squeegee
assembly from the machine.
NOTE: Thread the mounting bolt into the idler arm
removal hole if you are having trouble removing
the idler arm.
7. Pull the two main brushes off the drive
plugs.
6. Line up the drive end of the new or rotated
brushes with the brush drive plugs. The
cylindrical scrub brushes must be installed
with the V-patterns on the brushes pointing
towards each other. Slide the brushes onto
the brush drive plugs.
8. Reinstall the idler plate and side squeegee
assembly in the machine.
NOTE: Lift up on the brush wrap slightly when
installing the idler plate in the machine so the
attachment pins line up with the holes in the plate.
SCRUBBING
3-14 7400 MM428 (12--98)
9. Align the two pins on the lift tube with the
two holes in the brush idler plate arm.
10. Reinstall the M12 hex screw in the brush
idler plate arm. Tighten to 64 -- 83 Nm
(47 -- 61 ft lb).
NOTE: Apply a small amount of grease to the
threads on the bolt and in the tube.
11. Reinstall the two hair pins in the brush wrap
attachment pins.
12. Reconnect the front of the leveling rod to the
ball stud.
13. Close the RH brush door and operate the
machine. Check the main brushes for proper
operation.
CHECKING AND ADJUSTING SCRUB BRUSH
PATTERN
1. Apply chalk, or some other material that will
not easily blow away, to a smooth, level
floor.
2. Raise the scrub head. Position the scrub
head over the chalked area.
3. Set the parking brake.
4. Lower the scrub head for 15 to 20 seconds
while keeping the scrub head in one spot in
the chalked area.
NOTE: If chalk or other material is not available,
allow the brushes to spin on the floor for two
minutes. A polish mark will remain on the floor.
5. Raise the scrub head, release the parking
brake, and drive the machine away from the
chalked area.
6. Observe the width of the brush pattern. If
the brush patterns have parallel sides and
are the same width, the brushes do not need
taper adjustment.
If one or both of the brush patterns are
tapered, the scrub head will have to be
adjusted to straighten the brush pattern.
10355
10652
SCRUBBING
3-15
7400 MM428 (12--98)
7. Loosen the three scrub head mounting bolts
on the idler or drive side of the scrub head.
Move the scrub head up to decrease the
pattern width on that side of the scrub head.
Move the scrub head down to increase the
pattern width on that side of the scrub head.
Tighten the mounting bolts and check the
pattern again and readjust if necessary.
The brush patterns should be the same
width. If one is narrower then the other, the
scrub head needs to be leveled from front to
rear.
8. Lengthen or shorten the leveling rods on
both sides of the scrub head. Lengthening
the rods will increase the rear brush pattern
width. Shortening the rods will will increase
the front brush pattern.
10653
SCRUBBING
3-16 7400 MM428 (12--98)
TO REPLACE MAIN BRUSH IDLER SHAFT
BEARINGS
1. Place the main scrub brushes in the raised
position.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
2. Open the RH brush door.
3. Pull back on the front ball joint locking collar.
Remove the leveling rod from the front ball
stud.
4. Remove the two hair pins from the brush
wrap attachment pins.
5. Remove the M12 hex screw holding the
brush idler plate arm to the lift tube.
6. Remove the idler plate and side squeegee
assembly from the machine.
NOTE: For better access to the shaft and
bearings----remove the C--clip and brush arm from
the idler plate.
7. Turn the idler plate and side squeegee
assembly over. Remove the cotter pins,
castle nuts, and washers from the idler
plugs.
8. Use a puller to remove the idler plugs from
the tapered shafts. Remove and retain the
square key.
9. Remove the retaining rings from both ends
of the idler shafts.
10. Use a press to remove the tapered shafts
from the idler plate. Push the shafts out
toward the direction of the idler plugs.
NOTE: Use a small amount of heat in the area of
the bearings to help break the loctite loose.
11. Use a press to remove the bearing from the
tapered end of the idler shaft.
12. Use a press to remove the bearing from the
bearing housing in the idler plate. Discard
the old bearings.
13. Use a press to install a new bearing in the
bearing housing on the outside of the idler
plate. The open face of the bearing points in.
Use green loctite #680 on the outer diameter
of the bearing before pressing in place.
SCRUBBING
3-17
7400 MM428 (12--98)
14. Use a press to install a new bearing on the
tapered shaft. The open face of the bearing
points in. Reinstall the retaining ring on the
tapered shaft next to the bearing.
15. Reinstall the tapered shaft and bearing in
the bearing housing on the inside of the
idler plate. Use green loctite #680 on the
outer diameter of the bearing before
pressing in place.
16. Reinstall the retaining ring on the flat end of
the tapered shaft on the outside of the idler
plate.
17. Reinstall the square key on the tapered
shaft. Put a small amount of grease on the
taper.
18. Reinstall the idler plugs, washers, and castle
nuts. Hold the plug from turning and tighten
the castle nut down hard until the slot in the
nut lines up with the hole in the shaft. Install
a new cotter pin.
19. Reinstall the brush arm and C clip if they
were removed earlier.
20. Reinstall the idler plate and side squeegee
assembly in the machine.
NOTE: Lift up on the brush wrap slightly when
installing the idler plate in the machine so the
attachment pins line up with the holes in the plate.
21. Align the two pins on the lift tube with the
two holes in the brush idler plate arm.
22. Reinstall the M12 hex screw in the brush
idler plate arm. Tighten to 64 -- 83 Nm
(47 -- 61 ft lb).
NOTE: Apply a small amount of grease to the
threads on the bolt and in the tube.
23. Reinstall the two hair pins in the brush wrap
attachment pins.
24. Reconnect the front of the leveling rod to the
ball stud.
25. Close the RH brush door and operate the
machine. Check the main brushes for proper
operation.
SCRUBBING
3-18 7400 MM428 (12--98)
TO REMOVE MAIN BRUSH DRIVE MOTOR
MOUNT PLATE
1. Place the main scrub brushes in the raised
position.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
2. Open the LH brush door.
3. Remove the front ball joint on the leveling
rod from the machine frame.
4. Remove the two hair pins from the brush
wrap attachment pins.
5. Remove the M12 hex screw holding the
brush arm to the lift tube.
6. Remove the three hex screws holding the
side squeegee assembly to the motor mount
plate. Remove the side squeegee assembly.
NOTE: For better access to the hydraulic drive
motors----remove the C--clip and brush arm from
the motor plate.
7. Mark, disconnect, and plug the three
hydraulic hoses leading to the main brush
drive motors.
NOTE:Observe hydraulic cleanliness
requirements when opening hydraulic lines.
8. Remove the motor mount plate assembly
from the machine.
SCRUBBING
3-19
7400 MM428 (12--98)
TO INSTALL MAIN BRUSH DRIVE MOTOR
MOUNT PLATE
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Position the motor plate assembly back in
the machine.
NOTE: Lift up on the brush wrap slightly when
installing the motor plate in the machine so the
attachment pins line up with the holes in the plate.
2. Reinstall the two hair pins in the brush wrap
attachment pins.
3. Reconnect the hydraulic hoses to the brush
motors. See schematic in HYDRAULICS
section.
4. Reinstall the brush arm and C clip if they
were removed earlier.
5. Align the two pins on the lift tube with the
two holes in the brush motor plate arm.
6. Reinstall the M12 hex screw in the brush
motor plate arm. Tighten to 64 -- 83 Nm
(47 -- 61 ft lb).
NOTE: Apply a small amount of grease to the
threads on the bolt and in the tube.
7. Reinstall the front of the leveling rod ball
joint to the machine frame.
NOTE:Observe hydraulic cleanliness
requirements when opening hydraulic lines.
8. Reinstall the side squeegee assembly to the
motor plate. Tighten the three hex screws to
37 -- 48 Nm (26 -- 34 ft lb).
9. Close the LH brush door and operate the
machine. Check the main brush motors for
proper operation.
SCRUBBING
3-20 7400 MM428 (12--98)
TO REPLACE OPTIONAL SIDE BRUSH
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Rotate the side brush by hand until the
spring clips are visible through the window in
the side brush motor mount plate.
2. Reach in through the opening in the top of
the side brush guard, through the mount
plate window, and pinch the spring clips
together.
3. Drop the brush off the drive hub. Remove
the brush from the machine.
4. Position the new side brush under the
machine.
5. Lift the side brush and line up the hub in the
brush with the motor drive plug. Snap the
brushupinplace.
6. Operate the machine and check the side
brush for proper operation.
SCRUBBING
3-21
7400 MM428 (12--98)
SQUEEGEES
The squeegee channels water into the vacuum
fan suction. The front blade channels the water,
and the rear blade wipes the floor.
There are two types of squeegee blades
available; one for smooth surfaces is standard on
the machine, and one for rough surfaces is an
option.
The side squeegees control water spray and
channel water into the path of the rear squeegee.
Check the side squeegees for damage and wear
daily.
TO REPLACE REAR SQUEEGEE LIFT CABLE
1. Open the debris tray latch and swing the
squeegee assembly out for better access.
2. Start engine, lower rear squeegee, shut off
engine.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
3. Remove the cotter pin and clevis pin from
the squeegee lift cable where it attaches to
the squeegee frame assembly.
4. Remove the cotter pin and clevis pin from
the squeegee lift cable where it attaches to
the squeegee lift bellcrank located near the
lift cylinder.
5. Remove the clevis pin holding the cable
roller to the frame. Remove the roller.
6. Remove and discard the old squeegee lift
cable.
7. Position the new cable in the machine.
Reinstall one end to the squeegee lift
bellcrank located near the lift cylinder.
Re--use the clevis and cotter pin.
8. Reinstall the other end to the squeegee pivot
frame assembly. Re--use the clevis and
cotter pin.
9. Reinstall the cable roller and clevis pin in the
frame.
10. Start the machine and raise the squeegee.
Swing the squeegee assembly back in.
Check the lift cable for proper operation.
SCRUBBING
3-22 7400 MM428 (12--98)
TO REPLACE REAR SQUEEGEE
CENTERING SPRINGS
1. Open the debris tray latch and swing the
squeegee assembly out for better access.
2. Start engine, lower rear squeegee, shut off
engine.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
3. Loosen the jam nuts on the squeegee down
pressure spring rods. This will relax the
tension on the springs.
4. Remove the nyloc nuts from the squeegee
rod ball joints where they are connected to
the debris tray.
NOTE: Remove both the upper and lower nuts on
one side. Do one side at a time.
5. Remove and discard the old squeegee
centering spring.
6. Position a new squeegee centering spring
on the upper and lower ball joint studs.
7. Reinstall the two nyloc nuts and tighten to
37 -- 48 Nm (26 -- 34 ft lb).
8. Repeat this procedure on the other side if
needed.
9. Start the machine and raise the squeegee.
Swing the squeegee assembly back in.
Check the centering springs for proper
operation.
SCRUBBING
3-23
7400 MM428 (12--98)
TO REMOVE REAR SQUEEGEE FRAME
1. Open the debris tray latch and swing the
squeegee assembly out for better access.
2. Start engine, lower rear squeegee, shut off
engine.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
3. Remove vacuum hose from squeegee
frame.
4. Remove the cotter pin and clevis pin from
the squeegee lift cable where it attaches to
the squeegee frame assembly.
5. Loosen the jam nuts on the squeegee down
pressure spring threaded rods. This will
relax the tension on the springs.
6. Remove the four hex screws and nuts
holding the squeegee frame to the squeegee
lift assembly.
7. Remove the squeegee frame from the
machine.
TO INSTALL REAR SQUEEGEE FRAME
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Position the squeegee frame back under the
lift assembly.
2. Reinstall the four hex screws and nuts.
Tighten to 37 -- 48 Nm (26 -- 34 ft lb).
3. Re--connect the squeegee lift cable to the
frame assembly. Re--use the clevis and
cotter pin.
4. Re--apply tension on the down pressure
springs using the threaded rods and jam
nuts.
5. Reinstall the vacuum hose on the squeegee
frame.
6. Start the machine and raise the squeegee.
Swing the squeegee assembly back in.
SCRUBBING
3-24 7400 MM428 (12--98)
SQUEEGEE BLADES
REAR SQUEEGEE
Check the squeegee blades for damage and wear
daily. Rotate or replace either of the squeegee
blades if the leading edge is torn or worn half-way
through the thickness of the blade.
The rear squeegee has two squeegee blades.
Each blade has four wiping edges. To use them
all, start with one wiping edge. To use the next
wiping edge, rotate the blade end-for-end. To use
the next wiping edge, rotate the top edges down,
bottom edges up. To use the last edge, rotate the
blade end-for-end.
Replace any worn or damaged squeegee blades.
TO REPLACE OR ROTATE REAR
SQUEEGEE BLADES
1. Make sure the squeegee is raised off the
floor.
2. Shut the engine off and set the parking
brake.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
3. Open the retaining band clamp and remove
the squeegee blade.
4. Replace or rotate the squeegee blade to
allow a new edge to face the front of the
machine.
5. Place the squeegee blade over the pins of
the squeegee frame.
6. Position the retaining band over the
squeegee blade. Latch the retaining band
clamp.
7. Adjust the squeegee blade leveling and
deflection. See TO ADJUST REAR
SQUEEGEE BLADE DEFLECTION or TO
LEVEL THE REAR SQUEEGEE
instructions.
SCRUBBING
3-25
7400 MM428 (12--98)
TO ADJUST REAR SQUEEGEE BLADE
DEFLECTION
Deflection is the amount of curl the squeegee
blade has when the machine travels forward with
the squeegee lowered to the floor. The best
deflection is when the squeegee wipes the floor
just dry with a minimum amount of deflection.
1. Lower the squeegee and drive the machine
forward.
2. Shut off the engine and set the machine
parking brake.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
3. Look at the deflection over the full length of
the squeegee blade. The correct amount of
deflection for the rear squeegee blade is
15 to 20 mm (0.50 to 0.75 in). The front
slotted squeegee blade should contact the
floor with a slight deflection, 5 mm (0.13 to
0.25 in).
4. To adjust the amount of deflection, unlock
the height adjustment knobs on the two
squeegee casters by sliding the locking
bracket off to the side.
NOTE: If the locking brackets won’t slide over, lift
up the end of the squeegee to pick the caster up
off the floor slightly. Then slide the locking bracket
over.
5. Turn the adjustment knob clockwise to
decrease deflection, turn the adjustment
knob counter-clockwise to increase the
deflection. Be sure to turn the knobs the
same number of turns.
6. Start the engine and drive the machine
forward again to check the squeegee blade
deflection. Readjust the squeegee blade
deflection if necessary.
7. Slide the locking brackets back to lock the
height adjustment knobs.
8. Raise the squeegee when finished.
10918
15 to
20 mm
(0.50 to
0.75 in)
5mm
(0.13 to
0.25 in)
SCRUBBING
3-26 7400 MM428 (12--98)
TO LEVEL THE REAR SQUEEGEE
Leveling of the squeegee assures even contact
over the length of the squeegee blade with the
surface being scrubbed. Make sure this
adjustment is done on an even, level floor.
1. Lower the squeegee and drive the machine
forward.
2. Shut off the engine and set the machine
parking brake.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
3. Look at the deflection over the full length of
the squeegee blade.
4. If the deflection is not the same over the full
length of the blade, loosen the locking nut on
the two rear squeegee balljoints.
NOTE: The rear squeegee links should be
adjusted so there is 11 inches from the center
lines of the two ball joints.
5. Turn the balljoint adjustment nut clockwise,
from the rear of the machine, to increase the
deflection at the ends of the squeegee. Turn
the balljoint adjustment nut
counter-clockwise, from the rear of the
machine, to decrease the deflection at the
ends of the squeegee blade.
6. Tighten the locking nuts.
7. Start the engine and drive the machine
forward again to check the squeegee blade
deflection.
8. Readjust the squeegee blade deflection if
necessary.
11.00 in.
SCRUBBING
3-27
7400 MM428 (12--98)
SIDE SQUEEGEES
The side squeegees control water spray and
channel water into the path of the rear squeegee.
Check the side squeegees for damage and wear
daily. Replace the side squeegee blades
whenever they become damaged or lose their
shape or resilience. Replace the squeegee
deflectors whenever they become worn.
TO REPLACE SIDE SQUEEGEE BLADES
1. Raise the scrub head.
2. Shut off the engine and set the machine
parking brake.
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
3. Remove the cotter pin, clevis pin, deflector,
and the retainer bracket from the front of the
side squeegee.
4. Pull the squeegee blade out the front of the
squeegee frame.
5. Slide the new squeegee blade onto the
frame.
NOTE: Lubricating the squeegee frame where
the squeegee makes contact will make it easier to
install the squeegee blade.
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.
00000
SCRUBBING
3-28 7400 MM428 (12--98)
TO REPLACE SIDE BRUSH SQUEEGEE
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Raise the side brush.
2. Shut off the engine and set the parking
brake.
FOR SAFETY: Before leaving or
servicing machine; stop on level
surface, set parking brake, turn off
machine and remove key.
3. Remove the side brush guard.
4. Remove the retainer clip from the end of the
squeegee.
5. Pull the squeegee blade out the front of the
squeegee frame.
6. Slide the new squeegee blade onto the
frame.
NOTE: Lubricating the squeegee frame where
the squeegee makes contact will make it easier to
install the squeegee blade.
7. Install the retainer clip on the end of the
squeegee.
8. Install the side brush guard.
SIDE BRUSH SKIRT
The side brush skirt is located behind the
squeegee blade. Check the skirt for wear and
damage every 100 hours of operation.
SCRUBBING
3-29
7400 MM428 (12--98)
VACUUM FAN
The vacuum fan, when activated, creates a
vacuum in the recovery tank. Water is pulled from
the rear squeegee to the recovery tank through a
vacuum hose. The vacuum fans impeller is driven
with a high speed hydraulic motor.
TO REMOVE VACUUM FAN
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Open the engine cover, engine side door,
and the front cover.
2. Loosen the hose clamp and remove the
vacuum hose leading from recovery tank to
the center of the vacuum fan housing.
3. Mark, disconnect, and plug the four
hydraulic hoses going to the vacuum fan
NOTE:Observe hydraulic cleanliness
requirements when opening hydraulic lines.
4. Remove three M10 hex screws, washers,
and nyloc nuts holding vacuum fan to
mounting brackets.
5. Remove the vacuum fan assembly from the
machine.
SCRUBBING
3-30 7400 MM428 (12--98)
TO INSTALL VACUUM FAN
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Position the vacuum fan assembly back in
the machine
2. Align the three mounting holes in the
vacuum fan housing with the three rubber
isolators in the mounting brackets. Reinstall
the three M10 hex screws, washers, and
nyloc nuts. Tighten to 18 -- 24 Nm
(13 -- 18 ft lb).
3. Reconnect the hydraulic hoses to the
vacuum fan motor. See schematic
in HYDRAULIC section.
4. Reinstall vacuum hose from recovery tank to
vacuum fan housing. Hand tighten clamps.
5. Start the engine and turn on the vacuum fan.
Check for leaks and proper operation.
SCRUBBING
3-31
7400 MM428 (12--98)
TO REPLACE VACUUM IMPELLER
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Remove the vacuum fan from the machine.
See TO REMOVE VACUUM FAN
instructions.
2. Place the vacuum fan assembly in a vice or
some other holding device.
3. Remove the six hex screws holding the front
housing to rear housing. Remove the front
housing.
NOTE: Mark the front housing in relation to the
rear housing so it is re--assembled correctly.
4. Remove crown nut on impeller shaft. Slide
impeller off shaft.
NOTE: Remove and save the key and any shims
that are on the motor shaft, under the impeller.
5. Install the shims, key, new fan impeller, and
crown nut. Tighten nut to 34 -- 47 Nm
(25 -- 35 ft lb).
NOTE: Be sure the square key is on the motor
shaft. Super gluing the key to the shaft helps keep
it in place when installing the impeller.
NOTE: Use a small amount of blue loctite 242 on
the motor shaft threads.
6. Reinstall the front housing on the rear
housing. Reinstall the six hex screws and
tighten to 22 -- 27 Nm (16 -- 20 ft lb).
NOTE: Tennant part no. 57543 plastic shims must
be used for proper fan to housing clearance.
Remove these shims after housing hardware has
been tightened.
7. Reinstall the vacuum fan assembly in the
machine. See TO INSTALL VACUUM FAN
instructions.
SCRUBBING
3-32 7400 MM428 (12--98)
ELECTRICAL
4-1
7400 MM428 (9--01)
CONTENTS
Page
INTRODUCTION 4-3.........................
BATTERY 4-4............................
TO REPLACE BATTERY 4-5............
INSTRUMENT PANEL 4-6.................
TO REPLACE INSTRUMENT PANEL 4-6.
TO DISASSEMBLE INSTRUMENT
PANEL 4-7.........................
TO REASSEMBLE INSTRUMENT
PANEL 4-8.........................
TO REPLACE MACHINE RELAY 4-9.....
TO REPLACE CIRCUIT BREAKER 4-10..
GAS/LPG ELECTRICAL
SCHEMATIC 4-11...................
GAS/LPG ELECTRICAL
SCHEMATIC 4-12...................
DIESEL ELECTRICAL SCHEMATIC 4-13.
DIESEL ELECTRICAL SCHEMATIC 4-14.
GAS/LPG WIRE HARNESS GROUP 4-15.
GAS/LPG WIRE HARNESS GROUP
(OPTIONS) 4-18....................
DIESEL WIRE HARNESS GROUP 4-19..
DIESEL WIRE HARNESS GROUP
(OPTIONS) 4-22....................
ELECTRICAL 4-11...........................
DIAGNOSTICS 4-23.....................
OPERATING MODES 4-24................
NORMAL MODE 4-25.................
SCRUB BUTTON 4-25..............
SQUEEGEE BUTTON 4-26.........
DETERGENT 4-27.................
EStBUTTON 4-27................
OVERFLOW FLOAT 4-27...........
MANUAL MODE 4-28.................
EStBUTTON 4-28................
SIDE BRUSH BUTTON 4-28........
SQUEEGEE BUTTON 4-28.........
ENGINE BUTTON 4-28.............
SCRUB BUTTON 4-28..............
DETERGENT BUTTON 4-28........
INPUT DISPLAY MODE 4-29...........
ERROR DISPLAY MODE 4-30..........
EStLED 4-30.....................
SIDE BRUSH LED 4-31.............
SQUEEGEE LED 4-31..............
SCRUB LED 4-32..................
DETERGENT LED 4-32.............
PRESSURE ADJUST MODE 4-33......
SCRUB BUTTON 4-33..............
RESET SCRUB PRESSURES 4-34.....
TROUBLESHOOTING 4-35...............
INSTRUMENT PANEL DOES NOT
POWER UP (SCHEMATIC) 4-36.....
INSTRUMENT PANEL DOES NOT
POWER UP (FLOW CHART) 4-37...
Page
SCRUB BRUSH WILL NOT TURN ON
AND/OR DOWN (SCHEMATIC) 4-38.
SCRUB BRUSH WILL NOT TURN ON
AND/OR DOWN (FLOW CHART) 4-39
SQUEEGEE AND VACUUM FAN NOT
TURNING ON AND GOING DOWN
(SCHEMATIC) 4-41..............
SQUEEGEE AND VACUUM FAN NOT
TURNING ON AND GOING DOWN
(FLOW CHART) 4-42............
SIDE BRUSH WILL NOT TURN ON AND
GO DOWN (SCHEMATIC) 4-44......
SIDE BRUSH WILL NOT TURN ON
ANDGODOWN(FLOWCHART) 4-45
WATER VALVES NOT OPERATING
(SCHEMATIC) 4-47................
WATER VALVES NOT OPERATING
(FLOW CHART) 4-48...............
HEAD LIGHTS WILL NOT TURN ON
(SCHEMATIC) 4-49.................
HEAD LIGHTS WILL NOT TURN ON
(FLOW CHART) 4-50...............
EStPUMP NOT WORKING
(SCHEMATIC) 4-51................
EStPUMP NOT WORKING
(FLOW CHART) 4-52...............
REVERSE LIGHT OR ALARM NOT
WORKING (SCHEMATIC) 4-54......
REVERSE LIGHT OR ALARM NOT
WORKING (FLOW CHART) 4-55.....
DETERGENT METERING PUMP IS NOT
OPERATING (SCHEMATIC) 4-57....
DETERGENT METERING PUMP IS NOT
OPERATING (FLOW CHART) 4-58...
ALTERNATOR / BATTERY WARNING
LIGHT STAYS ON WHEN ENGINE
IS RUNNING (SCHEMATIC) 4-59.
ALTERNATOR / BATTERY WARNING
LIGHT STAYS ON WHEN ENGINE
IS RUNNING (FLOW CHART) 4-60
ALTERNATOR / BATTERY WARNING
LIGHT WILL NOT TURN ON
(SCHEMATIC) 4-61..............
ALTERNATOR / BATTERY WARNING
LIGHT WILL NOT TURN ON
(FLOW CHART) 4-62............
ENGINE TEMPERATURE LIGHT WILL
NOT TURN ON OR OFF
(SCHEMATIC) 4-63..............
ENGINE TEMPERATURE LIGHT WILL
NOT TURN ON (FLOW CHART) 4-64
ENGINE TEMPERATURE LIGHT WILL
NOT TURN OFF (FLOW CHART) 4-64
ELECTRICAL
4-2 7400 MM428 (9--01)
Page
HYDRAULIC (HIGH) PRESSURE
INDICATOR LIGHT WILL NOT TURN
ON OR OFF (SCHEMATIC) 4-65..
HYDRAULIC (HIGH) PRESSURE
INDICATOR LIGHT WILL NOT TURN
ON (FLOW CHART) 4-66........
HYDRAULIC (HIGH) PRESSURE
INDICATOR LIGHT WILL NOT TURN
OFF (FLOW CHART) 4-66.......
ENGINE OIL PRESSURE WARNING
LIGHT WILL NOT TURN ON OR
OFF (SCHEMATIC) 4-67.........
ENGINE OIL PRESSURE WARNING
LIGHT WILL NOT TURN ON
(FLOW CHART) 4-68.............
ENGINE OIL PRESSURE WARNING
LIGHT WILL NOT TURN OFF
(FLOW CHART) 4-68.............
RECOVERY TANK FULL LIGHT WILL
NOT TURN ON OR OFF
(SCHEMATIC) 4-69...............
RECOVERY TANK FULL LIGHT WILL
NOT TURN ON (FLOW CHART) 4-70.
RECOVERY TANK FULL LIGHT WILL
NOT TURN OFF (FLOW CHART) 4-70
FUEL GAUGE (GAS AND DIESEL)
(SCHEMATIC) 4-71.................
FUEL GAUGE (GAS AND DIESEL)
(FLOW CHART) 4-72................
FUEL GAUGE (LPG) (SCHEMATIC) 4-73.
FUEL GAUGE (LPG) (FLOW CHART) 4-74
ELECTRICAL
4-3
7400 MM428 (12--98)
INTRODUCTION
The machine electrical system consists of the
battery, relays, instrument panels, and related
components. This section includes information on
these components and their troubleshooting.
ELECTRICAL
4-4 7400 MM428 (12--98)
BATTERY
The battery used in the machine is a low
maintenance battery. It has been constructed with
special materials and has extra electrolyte to
reduce or eliminate maintenance. Its design
reduces electrolyte loss and contamination. Do
not add water, remove the battery vent plugs, or
check the battery specific gravity. For specific
instructions, see the battery label.
Do not allow the battery to remain in discharged
condition for any time. Do not operate the
machine if the battery is in poor condition or
discharged beyond 80%, specific gravity below
1.120.
Periodically clean the top surface of the batteries
and the terminals, and check for loose
connections. Use a strong solution of baking
soda and water. Brush the solution sparingly over
the battery tops, terminals, and cable clamps. Do
not allow any baking soda solution to enter the
batteries. Use a wire brush to clean the terminal
posts and the cable connectors. After cleaning,
apply a coating of clear battery post protectant to
the terminals and the cable connectors. Keep the
tops of the batteries clean and dry.
Keep all metallic objects off the top of the
batteries, which may cause a short circuit.
Replace any worn or damaged wires.
The electrolyte level in regular non--sealed
batteries can be checked. The level must always
be above the battery plates. Never add acid to the
batteries, only distilled water. Keep the battery
caps on the batteries always except when adding
water or taking hydrometer readings.
FOR SAFETY: When Servicing Machine,
Avoid Contact With Battery Acid.
ELECTRICAL
4-5
7400 MM428 (12--98)
Using a hydrometer to measure the specific
gravity is a way to determine the charge level and
condition of the batteries. If one or more of the
battery cells test lower than the other battery cells
(0.050 or more), the cell is damaged, shorted, or
is about to fail.
NOTE: Do not take readings immediately after
adding distilled water. If the water and acid are not
thoroughly mixed, the readings may not be
accurate. Check the hydrometer readings against
the following chart to determine the remaining
battery charge level:
SPECIFIC GRAVITY BATTERY
at 27_C(80_F) CHARGE
1.260 -- 1.280 100% Charged
1.230 -- 1.250 75% Charged
1.200 -- 1.220 50% Charged
1.170 -- 1.190 25% Charged
1.110 -- 1.160 Discharged
NOTE: If the readings are taken when the battery
electrolyte is any temperature other than 27_C
(80_F), the reading must be temperature
corrected. Add or subtract to the specific gravity
reading 0.004, 4 points, for each 6_C(10_F)
above or below 27_C(80_F).
TO REPLACE BATTERY
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Raise the seat support and engage the prop
rod.
2. Disconnect the negative then the positive
battery cables.
3. Remove the battery hold down bracket from
the machine.
4. Tilt the battery and lift it out of the machine.
5. Clean the cables and the posts on the new
battery and install back in the machine.
6. Reinstall the battery hold down bracket.
7. Reconnect the positive then the negative
battery cables and close the seat support.
ELECTRICAL
4-6 7400 MM428 (12--98)
INSTRUMENT PANEL
The instrument panel consists of a circuit board, a
touch panel, and a water/dust resistant plastic
enclosure. Its touch panel controls various
machine functions, while its indicator lights keep
the operator informed on machine performance.
TO REPLACE INSTRUMENT PANEL
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Raise the seat support and engage the prop
rod.
2. Remove the battery cables from the battery.
3. Put the steering wheel in the lowest position.
4. Open the front cover on the machine.
5. Remove four M5 pan head screws holding
the instrument panel to the dash panel.
6. Pull the instrument panel back away from
machine.
7. Loosen the allen head screw in center of
wire harness plug. Disconnect the harness.
8. Remove instrument panel from machine.
9. Install the new instrument panel back on the
dash panel with the four M5 pan head
screws and washers. Hand tighten snug.
10. Push the main harness plug back in the
instrument panel.
NOTE: Slot in panel must line up with notch on
plug. Hand tighten the allen head screw.
11. Close the front cover.
12. Reconnect the battery cables and lower the
seat support.
13. Start the machine and check for proper
operation.
ELECTRICAL
4-7
7400 MM428 (12--98)
TO DISASSEMBLE INSTRUMENT PANEL
1. Remove panel from machine. See TO
REPLACE INSTRUMENT PANEL
instructions.
2. Place the instrument panel face down and
remove the twelve larger pan head screws
from the back.
3. The touch panel case can now be separated
from the outer case and new O-ring gasket
installed if necessary.
4. To disassemble the touch panel case further,
remove the four smaller pan head screws
from the center of case box.
5. Remove the case box from the circuit board
/ touch panel assembly.
6. The O--ring and connector gaskets can now
be replaced in the case box if necessary.
7. Remove the eight pan head screws, unplug
the flat connector and ground strap, remove
the touch panel from the circuit board.
8. Any burned-out lamps can now be changed
by turning them 1/4 turn counterclockwise
and lifting out.
9. To replace the hour meter, unplug the two
wires and remove the two pan head screws.
ELECTRICAL
4-8 7400 MM428 (12--98)
TO REASSEMBLE INSTRUMENT PANEL
1. Position the circuit board over the touch
panel. Feed the flat connector from panel
through the slot in board, plug it in and
reconnect the ground strap.
2. Reinstall the eight pan head screws and
lightly hand tighten.
3. Turn the circuit board assembly over and
place it back in the case box.
4. Reinstall the four smaller pan head screws
in center of case box. Lightly hand tighten.
5. Reinstall the touch panel case on the outer
case.
6. Reinstall the twelve pan head screws and
lightly hand tighten.
7. The instrument panel is now ready to be
reinstalled in the machine. See TO
REPLACE INSTRUMENT PANEL
instructions.
ELECTRICAL
4-9
7400 MM428 (12--98)
TO REPLACE MACHINE RELAY
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Raise the seat support and engage the prop
rod.
2. Remove the battery cables from the battery.
3. Open the front cover on the machine.
4. Locate the relays at the front of the
operators compartment, near the hydraulic
steering motor.
5. Lift up on the relay to harness locking tab.
6. Pull the harness plug out of the relay.
7. Remove the pan screw holding the relay to
the operators compartment. Remove and
discard the old relay.
8. Position the new relay on the operators
compartment.
9. Reinstall the pan screw holding the relay to
the operators compartment.
10. Reconnect the harness plug in the relay.
See schematic in the ELECTRICAL section.
11. Reconnect the battery cables to the battery.
12. Lower the seat support.
13. Close the front cover on the machine.
14. Start and operate the machine, checking for
proper operation.
ELECTRICAL
4-10 7400 MM428 (12--98)
TO REPLACE CIRCUIT BREAKER
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake, Turn Off
Machine And Remove Key.
1. Raise the seat support and engage the prop
rod.
2. Remove the battery cables from the battery.
3. Open the front cover on the machine.
4. Locate the circuit breakers at the front of the
operators compartment, near the hydraulic
steering motor.
5. Remove and retain the rubber boot on the
front of the circuit breaker
6. Disconnect the electrical wires on the back
of the circuit breaker.
7. Remove the steel retaining ring holding the
circuit breaker to the dash panel. Remove
the circuit breaker.
8. Position the new circuit breaker in the
mounting hole on the dash panel.
9. Install the retaining ring on the new circuit
breaker. Push the ring on all the way to the
bottom of the circuit breaker.
10. Reconnect the wires to the back of the
circuit breaker. See schematic in the
ELECTRICAL section.
11. Reconnect the battery cables to the battery.
12. Lower the seat support.
13. Close the front cover on the machine.
14. Start and operate the machine, checking for
proper operation.
ELECTRICAL
4-11
7400 MM428 (6--01)
18A/ORA
1E/RED
1/RED
15B/BLU
13E/BLK
19B/BLU
72C/YEL
71C/YEL
72C/YEL
23C/GRY
PIN 20
TIED TO ENG.
OIL PRESS.
PIN 9
SCRUB BR.
MUST BE ON
5 SEC. DELAY
ES PUMP RUNS
30 SEC.
5 SEC. DELAY
1MIN.TOVAC
FAN SHUT--OFF
42B/YEL
42A/YEL42/YEL
56/ORA
3
5
13
10
7
8
17
14
15
4
1
9
18
20
19A/BLU
13R/BLK
13M/BLK
13K/BLK
13D/BLK
13G/BLK
23C/GRY
23C/GRY
23B/GRY 23/GRY
27/PUR
26/BRN
58/BLU
60/GRN
18T/ORA
RECOVERY
TANK
SOLUTION
TANK
S--18 N.C.H.O.
S--17 N.O.H.C.
13F/BLK
72B/GRY
18U/ORA
71B/YEL
ELEC.
SPARK
CONT.
COOLANT TEMP.
SENSOR
67/ORA
10K OHMS
VAR. RELUCTANCE
SENSOR
64/BRN
65/BLU
66/GRN
68/BRN T
13PP/BLK
70/GRN
PLUGS
12
11
10
9
8
7
6
4
3
2
13N/BLK
FILTER SWITCH
S--14
HYDRAULIC
M6
LIGHTS
85 86 LP CLOSES BELOW
40 PSI
M7
REVERSE
85 86
83/BRN
10/GRY
15/BLU
CB--1
15A
36/GRN
35/BRN
13H/BLK
14/GRN
18A/ORA
N.C.H.O.
N.C.H.O.
GAS--DIESEL
13P/BLK
13B/BLK
C
S--4 OIL SWITCH
15A/BLU
FUEL PUMP
10A/GRY
M2
STARTER RELAY
M1
S--6
18A/
ORA
18A/
ORA
71C/YEL
18C/ORA
18/ORA
8730
FLOW SWITCH
15/
BLU
M4 8685
28/YEL
C
M5 57/GRN
5.0A
S--15
23A/GRY
ES PUMP
MTR
DETERGENT METERING
85 86
REVERSE
RECOVERY TANK
S--8
S--1
M322/
YEL
8685 M3
1E/
RED
CB--6
19/BLU
A
2/
ORA
C
IGNITION
SWITCH
S--3
CB--5
43/BLU
13L/BLK
13J/BLK
55A MAX.
CHARGE
1C/RED
1D/RED
2/ORA
A
L2
1B/RED
5/YEL
18D/ORA
12V
540 C.C.A.
20A/BLU
20/BLU
10/GRY
4/YEL
84/GRN
86/PUR
HG
FEDC
B
A
CLOSES AT225
°F
ELECTRONIC
INSTRUMENT
PANEL
COOLANT TEMP
SENDER
FUEL SENDER
SE--1
SE--2
HORN BUTTON
15A
HORN
17
50
BATT.
30
19
ACC
START
SENSE
GOV
CONTROL
THROTTLE
ACTUATOR
13A/BLK
STARTER MOTOR
13/BLK
B
A
TTER
Y
ALTERNATOR
GND
OUT
1A/RED
STARTER RELAY
M1 MTR
SHEET 1
GAS/LPG ELECTRICAL SCHEMATIC
ELECTRICAL
4-12 7400 MM428 (6--01)
SHEET 2
GAS/LPG ELECTRICAL SCHEMATIC
ELECTRICAL
4-13
7400 MM428 (6--01)
8/GRN
FU--1
40A
13Q/BLK
GLOW PLUGS
MAGNETIC
PICKUP
7/YEL
72C/GRY
71C/YEL
84/GRN
86/PUR
18C/ORA
THROTTLE
ACTUATOR
23C/GRY
PIN 20
TIED TO ENG.
OIL PRESS.
PIN 9
SCRUB BR.
MUST BE ON
5 SEC. DELAY
ES PUMP RUNS
30 SEC.
5 SEC. DELAY
1MIN.TOVAC
FAN SHUT--OFF
42A/YEL42/YEL
56/ORA
3
5
13
10
7
8
17
14
15
4
1
9
18
20
19A/BLU
13R/BLK
13K/BLK
13D/BLK
13G/BLK
23C/GRY
23C/GRY
23B/GRY 23/GRY
27/PUR
26/BRN
58/BLU
60/GRN
RECOVERY
TANK
SOLUTION
TANK
S--18 N.C.H.O.
S--17 N.O.H.C.
13N/BLK
FILTER SWITCH
S--14
HYDRAULIC
M6
LIGHTS
85 86
M7
REVERSE
85 86
83/BRN
10/GRY
15/BLU
15A
CB--1
15A
CB--5
15A
CB--5
15A
36/GRN
35/BRN
13H/BLK
14/GRN
18A/ORA
N.C.H.O.
GAS--DIESEL
13P/BLK
13B/BLK
C
S--4 OIL SWITCH15A/BLU
FUEL PUMP
10A/GRY
M2
STARTER RELAY
M1
18A/
ORA
18A/
ORA
18/ORA
8730
FLOW SWITCH
15/
BLU
M4 8685
28/YEL
M5 57/GRN
5.0A
S--15
23A/GRY
ES PUMP
MTR
DETERGENT METERING
85 86
REVERSE
RECOVERY TANK
S--8
S--1
M3
22/
YEL
8685 M3
1E/
RED CB--6
19/BLU
A
2/
ORA
C
IGNITION
SWITCH
S--3
CB--5
43/BLU
13L/BLK
13J/BLK
55A MAX.
CHARGE
1C/RED
1D/RED
2/ORA
A
L2
1B/RED
5/YEL
12V
540 C.C.A.
20A/BLU
20/BLU
10/GRY
4/YEL
HG
FEDC
B
A
CLOSES AT
225
°
F
ELECTRONIC
INSTRUMENT
PANEL
COOLANT TEMP
SENDER
FUEL SENDER
SE--1
SE--2
HORN BUTTON
15A
HORN
17
50
BATT.
30
19
ACC
START
SENSE
GOV
CONTROL
13A/BLK
STARTER MOTOR
13/BLK
BATTERY
ALTERNATOR
GND
OUT
1A/RED
STARTER RELAY
M1
1/RED MTR
SHEET 3
DIESEL ELECTRICAL SCHEMATIC
ELECTRICAL
4-14 7400 MM428 (6--01)
SHEET 4
DIESEL ELECTRICAL SCHEMATIC
ELECTRICAL
4-15
7400 MM428 (6--01)
13H/BLK
13H/BLK
96/GRY
96B/GRY
46/BRN
46C/BRN
BRN
BLK
RED
62E/BRN
13II/BLK
89B/ORA
13J/BLK
13M/BLK
13F/BLK
13N/BLK
13TT/BLK
13P/BLK
13B/BLK
1D/RED
1A/RED
1C/RED
AC
CIRCUIT 2
CIRCUIT 1
25D/GRY
25D/GRY
BA
25A/GRY
AB
EH
E
46C/BRN WATER
VALV E
CONTROL
42A/YEL
CC
BB
VIEW B--B
WATER CONTROL
SWITCH
36/GRN
13R/BLK
43/BLU
RED
GRN
BLK
BRN
BLK
RED
MAIN PANEL
96/GRY
95/BLU
95/BLU
5/YEL
5/YEL
4/YEL
SIDE BRUSH
VALV E LOW
OPTION
SOLUTION
SWITCHES
OPTION
R.H. TAIL--LIGHT
SEE MAIN SCRUB VALVE
HYD. FILTER SWITCH
OPTIONS
REC TANK -- INNER SWITCH
NO C
NC
62D/BRN
13HH/BLK
89A/ORA
BACK--UP
ALARM
ES PUMP
AUTO FILL
ROT. LIGHT
SEE OPTIONS
SEE OPTIONS
DETERGENT PUMP
28/YEL
13J/BLK
13K/BLK
13R/BLK
13F/BLK
18C/ORA
71C/YEL
CBA
10/GRY
42/YEL
62A/YEL
CBA
AB
ABC
A
B
1E/RED
HORN
1/RED
TO
BATTERY
STARTER
TO MAIN
HARNESS
85/BLU
83/BRN
84/GRN
86/PUR
72C/YEL 18D/ORA
13E/BLK
71C/YEL 1D/RED
20D/BLU
20/BLU
10A/GRY
10/GRY
VIEW C--C
GOVERNOR
CONTROL VIEW F--F
KEY SWITCH
ALTERNATOR
WATER
TEMPERATURE
SENDER
13A/BLK
SEE
OPTIONS
FUEL
SENDER
42A/YEL
13L/BLK
1/RED
BATTERY
GAS AND DIESEL
LOCATION
TO
ENGINE
13/BLK
13P/BLK
14/GRN
FUEL PUMP
HORN
SWITCH
15B/BLU
13B/BLK
86/PUR
84/GRN
13M/BLK
D.I.S. ENGINE
HARNESS
ACTUATOR
OIL
PRESSURE
SWITCH
L.P.
SWITCH
72C/YEL
13X/BLK
13Y/BLK
13DD/BLK
13G/BLK
GOVERNOR
CONTROL
L.H. HEADLIGHT
62B/YEL
62A/YEL
13DD/BLK
13CC/BLK
13CC/BLK
R.H. HEADLIGHT
62/YEL
FF
17
19
30
50
L.H. TAIL--LIGHT
RELAYS
LOWHIGH
REVERSE
FLOW
SWITCH
SIDE BRUSH VALVE
OPTION
DIODE
BRAKE SWITCH
OPTION
DA
HE
CIRCUIT BREAKERS
WATER CONTROL
SWITCH
C
AB
1
SHEET 5
GAS/LPG WIRE HARNESS GROUP
ELECTRICAL
4-16 7400 MM428 (6--01)
18U/BLK
30
85
86
87
87A
VIEW A--A
RELAYS
M2 FUEL PUMP
M3 INSTRUMENT PANEL
M4 HYD. SOLENOIDS
M5 ES PUMP
M6 HEADLIGHTS
M7 REVERSE
21B/GRY
25/GRY
72C/YEL
71C/YEL
70/GRN
13PP/BLK
18T/ORA
68/BRN
68/BRN
67/ORA
66/GRN
65/BLU
VIEW G--G
UNIVERSAL
ELECTRONIC
SPARK CONTROL
UNIVERSAL
ELECTRONIC
SPARK CONTROL
66/GRN
65/BLU
VARI BL E
RELUCTANCE
SENSOR
70/GRN
64/BRN
COOLANT
SENSOR
71B/YEL
72B/GRY
DISTRIBUTORLESS
IGNITION
COIL
D.I.S. ENGINE
HARNESS TO MAIN
HARNESS
13F/BLK
18C/ORA
71C/YEL
72C/YEL
AC
GG
12
11
10
9
8
7
6
5
4
3
2
1
B
1F/RED
92/PUR
18/ORA
18C/ORA
20/BLU
4/YEL
65/GRY
65A/GRY
22/YEL
4A/YEL
1C/RED
59/BRN
59A/BRN
20C/BLU
CIRCUIT
BREAKERS
CB--1 IGNITION
CB--2 ES PUMP
CB--3 HEADLIGHTS
CB--4 BACK--UP ALARM
CB--5 HORN
CB--6 INSTRUMENT PANEL (5.0A)
CB--7 SCRUB SOLENOIDS
CB--8 SIDE BRUSH SOLENOIDS AND
WATER VALVES
CB--3
MAIN
HARNESS
CB--1CB--2CB--4
CB--5CB--6CB--7CB--8
20B/BLU
20A/BLU
24/PUR
25A/GRY
1E/RED
21A/GRY
21/GRY
DIODE
ASSY
19B/BLU
13D/BLK
AB
AB
10A/GRY
92/PUR
M5 M6 M7M2 M3 M4
93/ORA62/YEL
58/BLU19A/BLK
65/GRY
57/GRN
66/BRN
59/BRN
60/GRN
14/GRN
15A/BLU
18A/ORA
18A/ORA
22/YEL
19/BLU
18A/ORA
23B/GRY
1F/RED
18A/ORA
21/GRY
23C/GRY 23C/GRY 23C/GRY
2345 7
MAIN
HARNESS
SECTION B--B
85 COIL+
86 COIL --
30 COMMON CONTACT
87 N.O. CONTACT
87A N.C. CONTACT
B
B
AA
2
4
SHEET 6
GAS/LPG WIRE HARNESS GROUP
ELECTRICAL
4-17
7400 MM428 (6--01)
MAIN INSTRUMENT
PANEL SOCKET
REAR VIEW
SV2
24B/PUR
12
18
24
23
22
21
20
19
13 7
6
5
4
3
2
1
24B/PUR
48/GRY
47/BRN
24B/PUR
24B/PUR
45/GRY
AB
AB
BA
BA
24B/PUR
46A/BRN
AB
A
B
AB
AB
A
B
25C/GRY
AB
A
B
46A/BRN
A
B
AB
SV7 46A/BRN
24B/PUR
SCRUB VALVE
BLOCK
MAIN
HARNESS
51C/PUR
SV5
SV1SV6
SV4
SV3
HYDRAULIC SOLENOID VALVES
SV--1 SCRUB BRUSH ON
SV--2 VACUUM FAN ON
SV--3 SQUEEGEE DOWN
SV--4 DOWN PRESS. PROPORTIONAL VALVE
SV--5 SCRUB BRUSH DOWN
SV--6 SIDE BRUSH ON
SV--7 SCRUB BRUSH UP -- HOLD
58/BLU
83/BRN
1A/RED
21B/GRY
13S/BLK
13T/BLK
13U/BLK
45/GRY
60/GRN
46/BRN
48/GRY
15/BLU
2/ORA
42/ORA
51/PUR
47/BRN
28/YEL
56/YEL
36/GRN
35/BRN
52/YEL
43/BLU
57/GRN
26/BRN
23/GRY
13A/BLK
1B/RED
2/ORA
E
S
EXC
L2
B
P
CONN. A.SOC. NO.
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CONNECTOR WIRIN
G
MANDO
ALTERNATOR
60559
TO
MAIN
HARNESS
TO
ENGINE
BLOCK
BA
SHEET 7
GAS/LPG WIRE HARNESS GROUP
ELECTRICAL
4-18 7400 MM428 (6--01)
SHEET 8
GAS/LPG WIRE HARNESS GROUP (OPTIONS)
ELECTRICAL
4-19
7400 MM428 (6--01)
13DD/BLK
43/BLU 1D/RED
1C/RED
1A/RED
62A/YEL
BRN
BLK
RED
62E/BRN
13II/BLK
89B/ORA
WATER CONTROL
SWITCH
CIRCUIT 2
CIRCUIT 1
25A/GRY
AB
BA
MAGNETIC
PICK--UP
13Y/BLK 72E/GRN
GLOW PLUGS
8/GRN
7/YEL
8/GRN
7A/YEL
7/YEL
TO
MAIN
HARNESS 1D/RED
20D/BLU
20/BLU
10A/GRY
10/GRY
AC
17
19
30
50
BA
25D/GRY
AB
E H
E
46C/BRN
13H/BLK
13H/BLK
WATER
VALV E CONTROL
CC
BB
VIEW B--B
WATER CONTROL
SWITCH
36/GRN
13R/BLK
RED
GRN
BLK
BRN
BLK
RED
MAIN PANEL
96/GRY
25D/GRY
95/BLU
95/BLU
5/YEL
96/GRY
96B/GRY
46/BRN
46C/BRN
5/YEL
4/YEL
SIDE BRUSH
VALV E LOW
OPTION
SOLUTION SWITCHES
R.H. TAIL--LIGHT
SEE MAIN SCRUB VALVE
HYD. FILTER SWITCH
OPTIONS
REC TANK -- INNER SWITCH
NO C
NC
62D/BRN
13HH/BLK
89A/ORA
BACK--UP
ALARM ES PUMP
AUTO FILL
ROT. LIGHT
SEE OPTIONS
SHEET 12
DETERGENT PUMP
28/YEL
13J/BLK
13K/BLK
13M/BLK
13J/BLK
13R/BLK
10/GRY
42/YEL
62A/YEL
CBA
ABC
1E/RED
HORN
1/RED
TO
BATTERY
STARTER
85/BLU
83/BRN
84/GRN
86/PUR
72C/YEL 18D/ORA
13E/BLK
71C/YEL
VIEW C--C
GOVERNOR CONTROL
VIEW F--F
KEY SWITCH
ALTERNATOR
WATER
TEMPERATURE
SENDER
13A/BLK
FUEL
SENDER
42A/YEL
13L/BLK
1/RED
BATTERY
GAS AND DIESEL
LOCATION
TO
ENGINE
13/BLK
13P/BLK
14/GRN
FUEL PUMP
HORN
SWITCH
15B/BLU
13B/BLK
86/PUR
84/GRN
ACTUATOR
OIL
PRESSURE
SWITCH
13N/BLK
13X/BLK
13TT/BLK
13P/BLK
13B/BLK
13Y/BLK
13G/BLK
GOVERNOR
CONTROL
L.H. HEADLIGHT
62B/YEL
13DD/BLK
13CC/BLK
13CC/BLK
R.H. HEADLIGHT
62/YEL
FF
L.H. TAIL--LIGHT
RELAYS
LOW
HIGH
REVERSE
FLOW
SWITCH
SIDE BRUSH
VALV E
OPTION
DIODE
BRAKE SWITCH
OPTION
DA
HE
CIRCUIT BREAKERS
C
A B
1
SHEET 9
DIESEL WIRE HARNESS GROUP
ELECTRICAL
4-20 7400 MM428 (6--01)
30
85
86
87
87A
21B/GRY
25/GRY
1F/RED
92/PUR
18/ORA
18C/ORA
20/BLU
4/YEL
65/GRY
65A/GRY
22/YEL
4A/YEL
1C/RED
59/BRN
59A/BRN
20C/BLU
CIRCUIT
BREAKERS
CB--1 IGNITION
CB--2 ES PUMP
CB--3 HEADLIGHTS
CB--4 BACK--UP ALARM
CB--5 HORN
CB--6 INSTRUMENT PANEL (5.0A)
CB--7 SCRUB SOLENOIDS
CB--8 SIDE BRUSH SOLENOIDS AND
WATER VALVES
CB--3
MAIN
HARNESS
CB--1CB--2CB--4
CB--5CB--6CB--7CB--8
20B/BLU
20A/BLU
24/PUR
25A/GRY
1E/RED
21A/GRY
21/GRY
VIEW A--A
ROTATED
DIODE
ASSY
19B/BLU
13D/BLK
A
B
AB
RELAYS
M2 FUEL PUMP
M3 INSTRUMENT PANEL
M4 HYD. SOLENOIDS
M5 ES PUMP
M6 HEADLIGHTS
M7 REVERSE
10A/GRY
92/PUR
M5 M6 M7M2 M3 M4
93/ORA62/YEL
58/BLU
19A/BLK
65/GRY
57/GRN
66/BRN
59/BRN
60/GRN
14/GRN
15A/BLU
18A/ORA
18A/ORA
22/YEL
19/BLU
18A/ORA
23B/GRY
1F/RED
18A/ORA
21/GRY
23C/GRY 23C/GRY 23C/GRY
234567
MAIN
HARNESS
SECTION B--B
85 COIL+
86 COIL --
30 COMMON CONTACT
87 N.O. CONTACT
87A N.C. CONTACT
BB
AA
2
SHEET 10
DIESEL WIRE HARNESS GROUP
ELECTRICAL
4-21
7400 MM428 (6--01)
SV2
24B/PUR
24B/PUR
48/GRY
47/BRN
24B/PUR
24B/PUR
45/GRY
AB
AB
BA
B
A
24B/PUR
46A/BRN
AB
A
B
AB
A
B
AB
A
B
25C/GRY
AB
AB
46A/BRN
A
B
AB
SV7 46A/BRN
24B/PUR
SCRUB VALVE
BLOCK
MAIN
HARNESS
51C/PUR
SV5
SV1SV6
SV4
SV3
HYDRAULIC SOLENOID VALVES
SV--1 SCRUB BRUSH ON
SV--2 VACUUM FAN ON
SV--3 SQUEEGEE DOWN
SV--4 DOWN PRESS. PROPORTIONAL VALVE
SV--5 SCRUB BRUSH DOWN
SV--6 SIDE BRUSH ON
SV--7 SCRUB BRUSH UP -- HOLD
MAIN INSTRUMENT
PANEL SOCKET
REAR VIEW
12
18
24
23
22
21
20
19
13 7
6
5
4
3
2
1
58/BLU
83/BRN
1A/RED
21B/GRY
13S/BLK
13T/BLK
13U/BLK
45/GRY
60/GRN
46/BRN
48/GRY
15/BLU
2/ORA
42/ORA
51/PUR
47/BRN
28/YEL
56/YEL
36/GRN
35/BRN
52/YEL
43/BLU
57/GRN
26/BRN
23/GRY
13A/BLK
1B/RED
2/ORA
E
S
EXC
L2
B
P
CONN. A.
SOC. NO.
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CONNECTOR WIRING
MANDO
ALTERNATOR
60559
TO
MAIN
HARNESS
TO
ENGINE
BLOCK
SHEET 11
DIESEL WIRE HARNESS GROUP
ELECTRICAL
4-22 7400 MM428 (6--01)
13DD/BLK
43/BLU 1D/RED
1C/RED
1A/RED
62A/YEL
BRN
BLK
RED
62E/BRN
13II/BLK
89B/ORA
WATER CONTROL
SWITCH
CIRCUIT 2
CIRCUIT 1
25A/GRY
AB
BA
MAGNETIC
PICK--UP
13Y/BLK 72E/GRN
GLOW PLUGS
8/GRN
7/YEL
8/GRN
7A/YEL
7/YEL
TO
MAIN
HARNESS 1D/RED
20D/BLU
20/BLU
10A/GRY
10/GRY
AC
17
19
30
50
BA
25D/GRY
AB
E H
E
46C/BRN
13H/BLK
13H/BLK
WATER
VALV E CONTROL
CC
BB
VIEW B--B
WATER CONTROL
SWITCH
36/GRN
13R/BLK
RED
GRN
BLK
BRN
BLK
RED
MAIN PANEL
96/GRY
25D/GRY
95/BLU
95/BLU
5/YEL
96/GRY
96B/GRY
46/BRN
46C/BRN
5/YEL
4/YEL
SIDE BRUSH
VALV E LOW
OPTION
SOLUTION SWITCHES
R.H. TAIL--LIGHT
SEE MAIN SCRUB VALVE
HYD. FILTER SWITCH
OPTIONS
REC TANK -- INNER SWITCH
NO C
NC
62D/BRN
13HH/BLK
89A/ORA
BACK--UP
ALARM ES PUMP
AUTO FILL
ROT. LIGHT
SEE OPTIONS
SHEET 12
DETERGENT PUMP
28/YEL
13J/BLK
13K/BLK
13M/BLK
13J/BLK
13R/BLK
10/GRY
42/YEL
62A/YEL
CBA
ABC
1E/RED
HORN
1/RED
TO
BATTERY
STARTER
85/BLU
83/BRN
84/GRN
86/PUR
72C/YEL 18D/ORA
13E/BLK
71C/YEL
VIEW C--C
GOVERNOR CONTROL
VIEW F--F
KEY SWITCH
ALTERNATOR
WATER
TEMPERATURE
SENDER
13A/BLK
FUEL
SENDER
42A/YEL
13L/BLK
1/RED
BATTERY
GAS AND DIESEL
LOCATION
TO
ENGINE
13/BLK
13P/BLK
14/GRN
FUEL PUMP
HORN
SWITCH
15B/BLU
13B/BLK
86/PUR
84/GRN
ACTUATOR
OIL
PRESSURE
SWITCH
13N/BLK
13X/BLK
13TT/BLK
13P/BLK
13B/BLK
13Y/BLK
13G/BLK
GOVERNOR
CONTROL
L.H. HEADLIGHT
62B/YEL
13DD/BLK
13CC/BLK
13CC/BLK
R.H. HEADLIGHT
62/YEL
FF
L.H. TAIL--LIGHT
RELAYS
LOW
HIGH
REVERSE
FLOW
SWITCH
SIDE BRUSH
VALV E
OPTION
DIODE
BRAKE SWITCH
OPTION
DA
HE
CIRCUIT BREAKERS
C
A B
1
SHEET 12
DIESEL WIRE HARNESS GROUP (OPTIONS)
ELECTRICAL
4-23
7400 MM428 (12--98)
DIAGNOSTICS
The Model 7400 has an on--board diagnostic
system. Each time the control board is powered
up, it performs a self test. If the self test passes,
the “OK” light is illuminated.
This trouble shooting section describes the
different operating modes that are available, how
to enter that mode, and a detail description of how
that mode works.
ELECTRICAL
4-24 7400 MM428 (12--98)
OPERATING MODES
The Model 7400 has 6 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.
Operating Modes Entry Sequence
(how to activate)
Normal Mode;Normal operation.
More info pages 4--25 thru 4--27
Default (when key is turned on)
Manual Mode; Manually operate discrete
functions without interlocks.
More info page 4--28
1. Push and hold the ES button
2. Turn on the key
3. Hold the ES button until the maintenance light
comes on.
4. Release the ES button
Input Display Mode; Display the state of floats,
limit switches, and sensors.
More info page 4--29
1. Push and hold the Squeegee button
2. Turn on the key
3. Hold the Squeegee button until the maintenance
light comes on.
4. Release the Squeegee button
Error Display Mode; Display the cause of a
self--test failure.
More info pages 4--30 thru 4--32
1. Push and hold the Detergent button
2. Turn on the key
3. Hold the Detergent button until the maintenance
light comes on.
4. Release the Detergent button
Pressure Adjust Mode; Adjust the pressure
levels for the three down pressure settings.
More info page 4--33
1. Push and hold the Side Brush button
2. Turn on the key
3. Hold the Side Brush button until the
maintenance light comes on.
4. Release the Side Brush button
Reset Scrub Pressures; Return the down
pressure settings to the factory defaults.
More info page 4--34
1. Push and hold the Scrub button
2. Turn on the key
3. Hold the scrub button
4. Wait for the maintenance light
5. While holding the Scrub button, press and hold
the Side Brush button
6. Wait for the maintenance light to go out
7. Release the Scrub and Side Brush buttons
8. Turn the key off
9. Restart the machine
ELECTRICAL
4-25
7400 MM428 (12--98)
Operating Mode Entry Sequence
(how to activate)
Normal Mode;Normal operation. Default (when key is turned on)
NORMAL MODE
The purpose of the normal mode is for the general
operation of the machine. The machine will
normally start in this mode. What follows is a brief
description of each of the operations in the normal
mode.
SCRUB BUTTON
The purpose of the scrub button is to turn the
scrubbing operations on and off and adjust the
scrubbing down pressure. Pressing the scrub
button while the scrubbing operation is currently
inactive will initiate the following actions:
1. The engine speed will be set to high.
2. If the machine is not in reverse, the main
brushes will turn on and lower. The down
pressure setting will be the same used
during the last scrub cycle. The solution will
flow at the high or low rate according to the
water position switch.
3. If the machine is in reverse, the brushes will
stay up until reverse is no longer sensed.
4. If the side brush LED is on, the side brush will
turn on and lower. The down pressure
setting will be the same used during the last
scrub cycle.
5. The vacuum fan will turn on.
6. If the machine is not in reverse, the squeegee
will lower.
7. If the machine is in reverse, the squeegee will
stay up until reverse is no longer sensed.
8. If any of the detergent LED’s are active, the
water valves are turned on, and the machine
is not in reverse, the detergent pump will
run. The detergent pump will run at its slow
rate if one LED is on. The detergent pump
will run at its fast rate if two LED’s are on.
ELECTRICAL
4-26 7400 MM428 (12--98)
SCRUB BUTTON (continued)
If the operator pushes and holds the scrub button,
the pressure settings will begin to scroll. The
pressure settings displayed after releasing the
scrub button will become the new default down
pressure setting.
If the scrub function was active and the operator
pushes, then releases the scrub button, the
following actions will take place:
1. The main brushes will turn off and rise.
2. The side brush will turn off and rise.
3. The solution flow will turn off.
4. The detergent pump will turn off.
5. A delay will pass, and then the squeegee will
rise.
6. Another small delay will pass and the vacuum
fan will turn off.
SQUEEGEE BUTTON
Pressing the squeegee button will start or stop the
water pickup operation. If the operator presses
the squeegee button while the squeegee LED is
currently not illuminated will cause the following
actions:
1. The squeegee LED will be illuminated.
2. The squeegee will drop and the vacuum fan
will turn on, if the machine is not in reverse.
If the machine goes into reverse while the
squeegee is active, the squeegee will rise.
Pressing the squeegee button while the squeegee
LED is on will cause the following actions:
1. The squeegee LED will turn off.
2. The squeegee will raise.
3. There will be a 30 second delay.
4. The vacuum fan will turn off.
ELECTRICAL
4-27
7400 MM428 (12--98)
DETERGENT
Pressing the detergent button will cause the
detergent display to scroll through its three
modes. The detergent pump will run only if the
main scrub brushes are active and the solution
switch is on.
DOff (all LEDs off) -- detergent pump off.
DLow (left LED is on) -- detergent pump on low.
DHigh (both LED’s are on) -- detergent pump
on high.
EStBUTTON
Pressing the EStbutton will enable or disable
the EStsystem. The EStsystem will draw
water from the recovery tank, through a filter and
pump it into the solution tank. If the operator has
turned on the EStsystem, and the recovery tank
EStfloat reads a full tank, the EStpump will
begin to run. The EStpump will continue to run
for about 30 seconds after the EStfloat
becomes uncovered.
OVERFLOW FLOAT
In order for the recovery tank float to become
active, it must be consistently in the up position
for at least 10 seconds. If the scrub or vacuum fan
are active and the tank full float becomes active,
the following actions will occur:
1. The overflow light will begin to blink.
2. A one minute delay will pass.
3. The overflow light will stop blinking and stay
on.
4. The Scrub and Squeegee functions will be
canceled.
ELECTRICAL
4-28 7400 MM428 (12--98)
Operating Mode Entry Sequence
(how to activate)
Manual Mode; Manually operate discrete
functions without interlocks.
1. Push and hold the EStbutton
2. Turn on the key
3. Hold the EStbutton until the maintenance
light comes on.
4. Release the EStbutton
MANUAL MODE
The purpose of the manual mode is to allow the
operator to exercise individual functions on the
machine.
NOTE: This mode disregards the effects of
various interlocks. Do not scrub with the
machine in this mode.
FOR SAFETY: When Servicing Machine,
AvoidMovingParts.DoNotWear
Loose Jackets, Shirts, Or Sleeves.
After entering the Manual Mode, the control
buttons assume the following functions:
EStBUTTON
Pressing the EStbutton will toggle the ESt
pump on or off. In the on position, the EStpump
will run regardless of the state of the floats.
SIDE BRUSH BUTTON
Pressing the Side Brush button will turn on and
lower the side brush. If the main brush is off, the
side brush will use the low pressure setting.
SQUEEGEE BUTTON
Pressing the Squeegee button will turn on the
vacuum fan and lower the squeegee. Reverse is
ignored.
ENGINE BUTTON
Pressing the Engine button will toggle the engine
between high and low speed.
SCRUB BUTTON
Pressing the Scrub button will turn on and lower
the main scrub head. Holding the Scrub button
while scrub is active will cause the down pressure
to scroll.
DETERGENT BUTTON
Pressing the Detergent button will cause the
detergent LED’s to scroll. If no LED’s are on, the
detergent pump will be off. If one LED is
illuminated, the detergent pump will run in low
speed. If both LED’s are on, the detergent pump
will run in high speed.
ELECTRICAL
4-29
7400 MM428 (12--98)
Operating Mode Entry Sequence
(how to activate)
Input Display Mode; Display the state of floats,
limit switches, and sensors.
1. Push and hold the Squeegee button
2. Turn on the key
3. Hold the Squeegee button until the maintenance
light comes on.
4. Release the Squeegee button
INPUT DISPLAY MODE
In this mode, the operator can observe whether or
not inputs to the panel are operating as intended.
In the Input Display Mode, the segments of the
gas gauge display the state of each input. If an
input is open, the controller turns off the segment
associated with that input. If an input is shorted to
ground, the controller turns on the segment
associated with that input.
The operation of the Input Display Mode is as
follows:
DSEGMENT 0 -- Rightmost segment of the
gas gauge. This segment displays the state
of the ES float. This segment will illuminate
when this input is shorted to ground.
DSEGMENT 1 -- Second segment from the
right of the gas gauge. This segment
displays the state of the recovery tank float.
This segment will be illuminated when this
input is shorted to ground.
DSEGMENT 2 -- Third segment from the right
of the gas gauge. This segment displays the
state of the reverse input. This segment will
be illuminated when this input is shorted to
ground.
DSEGMENT 3 -- Forth segment from the right
of the gas gauge. This segment displays the
state of the forward input. This segment will
be illuminated when this input is shorted to
ground.
DENGINE TEMPERATURE LIGHT -- In the
Input Display Mode, the engine temperature
light will blink until the engine reaches
operating temperature.
ELECTRICAL
4-30 7400 MM428 (12--98)
Operating Mode Entry Sequence
(how to activate)
Error Display Mode; Display the cause of a
self--test failure.
1. Push and hold the Detergent button
2. Turn on the key
3. Hold the Detergent button until the maintenance
light comes on.
4. Release the Detergent button
ERROR DISPLAY MODE
Each time the operator starts the machine, the
panel will run a self test on each output. If the
panel passes the diagnostic, the “OK” indicator is
illuminated. If the panel fails, a code is stored in a
non volatile (preserved even after power down)
memory. If the machine passes the diagnostic on
the next startup cycle, the panel preserves the
last failed code. In the Error Display Mode, the
operator can obtain the error code stored after the
last startup diagnostic failure. When the machine
is in this mode, the LED’s on the operators panel
will indicate which system experienced the failure.
If the operator pushes the button associated with
an illuminated LED, segments on the gas gauge
will indicate which output failed and what type of
failure occurred.
The operation of the Error Display Mode is as
follows:
EStLED
Problem with the EStoutput. If the operator
pushes the headlight button in this mode, the
panel will display one of the following codes:
DSEGMENT 0 -- Rightmost segment of the gas
gauge. This segment would indicate that the
output was shorted to ground when the
controller was expecting it to be open.
DSEGMENT 0, 1 -- First and second segments
from the right of the gas gauge. These
segments would indicate that the output was
open when the controller was trying to short
it to ground.
ELECTRICAL
4-31
7400 MM428 (12--98)
SIDE BRUSH LED
Problem with the side brush or side brush
actuator outputs. If the operator pushes the side
brush button in this mode, the panel would display
one of the following codes:
DSEGMENT 0 -- Rightmost segment of the gas
gauge. This segment would indicate that the
side brush actuator output was shorted to
ground when the controller was expecting it
to be open.
DSEGMENT 0, 1 -- First and second segments
from the right of the gas gauge. These
segments would indicate that the side brush
actuator output was open when the
controller was trying to short it to ground.
DSEGMENT 2 -- Third segment from the right of
the gas gauge. This segment would indicate
that the side brush motor output was shorted
to ground when the controller was expecting
it to be open.
DSEGMENT 2, 3 -- Third and forth segments
from the right of the gas gauge. These
segments would indicate that the side brush
motor output was open when the controller
was trying to short it to ground.
SQUEEGEE LED
Problem with the squeegee actuator or vacuum
fan motor outputs. If the operator pushes the
squeegee button in this mode, the panel would
display one of the following codes:
DSEGMENT 0 -- Rightmost segment of the gas
gauge. This segment would indicate that the
squeegee actuator output was shorted to
ground when the controller was expecting it
to be open.
DSEGMENT 0, 1 -- First and second segments
from the right of the gas gauge. These
segments would indicate that the squeegee
actuator output was open when the
controller was trying to short it to ground.
DSEGMENT 2 -- Third segment from the right of
the gas gauge. This segment would indicate
that the vacuum fan motor output was
shorted to ground when the controller was
expecting it to be open.
DSEGMENT 2, 3 -- Third and forth segments
from the right of the gas gauge. These
segments would indicate that the vacuum
fan motor output was open when the
controller was trying to short it to ground.
ELECTRICAL
4-32 7400 MM428 (12--98)
SCRUB LED
Problem with the main brush actuator or motor
outputs. If the operator pushes the scrub button in
this mode, the panel would display one of the
following codes:
DSEGMENT 0 -- Rightmost segment of the gas
gauge. This segment would indicate that the
main brush actuator output was shorted to
ground when the controller was expecting it
to be open.
DSEGMENT 0, 1 -- First and second segments
from the right of the gas gauge. These
segments would indicate that the main brush
actuator output was open when the
controller was trying to short it to ground.
DSEGMENT 2 -- Third segment from the right of
the gas gauge. This segment would indicate
that the main brush motor output was
shorted to ground when the controller was
expecting it to be open.
DSEGMENT 2, 3 -- Third and forth segments
from the right of the gas gauge. These
segments would indicate that the main brush
motor output was open when the controller
was trying to short it to ground.
DETERGENT LED
Problem with the headlight or detergent pump
outputs. If the operator pushes the detergent
button in this mode, the panel would display one
of the following codes:
DSEGMENT 0 -- Rightmost segment of the gas
gauge. This segment would indicate that the
detergent pump output was shorted to
ground when the controller was expecting it
to be open.
DSEGMENT 0, 1 -- First and second segments
from the right of the gas gauge. These
segments would indicate that the detergent
pump output was open when the controller
was trying to short it to ground.
DSEGMENT 2 -- Third segment from the right of
the gas gauge. This segment would indicate
that the headlight output was shorted to
ground when the controller was expecting it
to be open.
DSEGMENT 2, 3 -- Third and forth segments
from the right of the gas gauge. These
segments would indicate that the headlight
pump output was open when the controller
was trying to short it to ground.
ELECTRICAL
4-33
7400 MM428 (12--98)
Operating Mode Entry Sequence
(how to activate)
Pressure Adjust Mode; Adjust the pressure
levels for the three down pressure settings.
1. Push and hold the Side Brush button
2. Turn on the key
3. Hold the Side Brush button until the
maintenance light comes on.
4. Release the Side Brush button
PRESSURE ADJUST MODE
When the machine is in this mode, the operator
can adjust the down pressures for the main and
side brushes. When the operator adjusts down
pressure number 3, pressures 1 and 2 are
automatically calculated and stored. The operator
may make independent adjustments to pressures
1 and 2 after storing number 3. These
adjustments will influence only the currently
displayed setting.
The operator can change the pressure settings by
pressing and holding the scrub button. When the
side brush is inactive and the main brush is
active, the operator can adjust the down pressure
for the main brush. When the side brush and main
brush are active, the operator can adjust the
down pressure for the side brush.
To store the new down pressure settings, turn off
the Side Brush and Scrub Panel LEDs on the
touch panel. Then turn off the key switch.
The operation of the Pressure Adjust Mode is as
follows:
SCRUB BUTTON
Pressing the Scrub button will start the normal
scrub sequence. When scrub is active the
following controls and displays take on alternate
functions.
DGAS GAUGE -- The gas gauge in the pressure
adjust mode displays the relative down
pressure of the main (when the side brush is
inactive) or the side brush (when the side
brush is active).
DSQUEEGEE BUTTON -- Holding the squeegee
button will decrease the down pressure.
DDETERGENT BUTTON -- Holding the
detergent button will increase the down
pressure.
NOTE: To return to the factory brush pressure
settings, run RESET SCRUB PRESSURES from
the Diagnostics menu.
ELECTRICAL
4-34 7400 MM428 (12--98)
Operating Mode Entry Sequence
(how to activate)
Reset Scrub Pressures; Return the down
pressure settings to the factory defaults.
1. Push and hold the Scrub button
2. Turn on the key
3. Hold the Scrub button
4. Wait for the maintenance light
5. While holding the Scrub button, press and hold
the Side Brush button
6. Wait for the maintenance light to go out
7. Release the Scrub and Side Brush buttons
8. Turn the key off
9. Restart the machine
RESET SCRUB PRESSURES
When the machine goes into this mode, the
controller replaces the current brush down
pressure settings with factory defaults. To initiate,
follow the entry sequence (how to activate). The
pressures will automatically reset.
ELECTRICAL
4-35
7400 MM428 (12--98)
TROUBLESHOOTING
The following troubleshooting section is organized
with the section of the electrical schematic that
pertains to that particular problem first, followed
by the flow chart.
ELECTRICAL
4-36 7400 MM428 (12--98)
1/RED
19B/BLU
1
13D/BLK
23/GRY
CB--1
15A
18A/
ORA
18/ORA
8730
5.0A
M3
22/
YEL
8685 M3
1E/
RED
CB--6
19/BLU
IGNITION
SWITCH
S--3
20A/BLU
20/BLU
ELECTRONIC
INSTRUMENT
PANEL
17
50
BATT.
30
19
ACC
13/BLK
BATTERY
22 13S/BLK
INSTRUMENT PANEL
DOES NOT POWER UP
(SCHEMATIC)
OPERATION:
--KEY SWITCH ACTIVATES
M3 AND M4
--M3 CONTACT SUPPLIES
14VDC TO INSTRUMENT
PANEL (PIN 1)
BATTERY
LINE
SWITCHED
LINE
ELECTRICAL
4-37
7400 MM428 (12--98)
INSTRUMENT PANEL
DOES NOT POWER UP
(FLOW CHART)
NO
TURN KEY ON
ENGINE NEED NOT BE RUNNING
REMOVE M3 RELAY
WORKS
PROBLEM
SOLVED
INSTALL NEW M3
RELAY
CHECK FOR BAT.
VOLTAGE AT M3
(PIN 85) 18A/ORA
BATTERY
VOLTAGE
VOLTAGE
CHECK FOR BAT.
VOLTAGE AT KEY
SWITCH 20/BLU
NO
VOLTAGE VOLTAGE
20/BLUE,
18/ORA, OR
CB--1 ARE OPEN
CHECK FOR BAT.
VOLTAGE AT KEY
SWITCH 1D/RED
NO
VOLTAGE
VOLTAGE
DOES NOT
WORK
REPLACE KEY
SWITCH
1D/RED IS OPEN
FROM BATTERY
TO KEY SWITCH
CHECK FOR BAT.
VOLTAGE AT M3
(PIN 30) 22/YEL
NO VOLTAGE
WIRE 22/YEL,
CB--6, OR
1E/RED ARE OPEN
BATTERY
VOLTAGE
OPEN
REPLACE DIODE OR
REPAIR OPEN WIRES
DISCONNECT INSTRUMENT
PANEL
CHECK CONTINUITY OF:
23/GREY FROM M3 (PIN 87)
TO (PIN 1) OF PANEL
13S/BLACK FROM (PIN 22)
OF PANEL TO BAT. NEG.
OK
REPLACE
INSTRUMENT
PANEL
GOOD
CONTINUITY
OPEN WIRE
REPAIR OR REPLACE
OPEN WIRES
OPERATION:
--KEY SWITCH ACTIVATES
M3 AND M4
--M3 CONTACT SUPPLIES
14VDC TO INSTRUMENT
PANEL (PIN 1)
CHECK CONTINUITY OF
WIRES 19/BLU AND 13D/
BLK AND CHECK DIODE
AT M3 (PIN 86) 19/BLU
ELECTRICAL
4-38 7400 MM428 (12--98)
24/
PUR
21/GRY
21B/
GRY 47/BRN
48/GRY
46A/BRN
46A/BRN
46/
BRN
24B/PUR
24B/PUR
24B/PUR
24B/PUR
24B/PUR
SV--7 SCRUB BR.
UP HOLD VALVE
SV--3 SQUEEGEE
DOWN VALVE
CB--7
24B/PUR
21B/GRY
SV--2 VAC FAN
ON VALVE
SV--6 SIDE BR.
ON VALVE
SV--4 SCRUB BR. DN. FORCE
PROP. VALVE
SV--5 SCRUB BR.
DOWN VALVE
45/GRY
46A/BRN
21 (8 SEC
DELAY)
11 (4 SEC
16
19
2
15 AMP
SV--1 SCRUB BR.
ON VALVE
87
30
M4
1F/RED
OPERATION:
--SCRUB IS SELECTED ON
TOUCH PANEL
--SCRUB SOLENOIDS ARE
TURNED ON
--HEAD WILL LOWER,
BRUSHES WILL SPIN
SCRUB BRUSH WILL NOT
TURN ON AND/OR DOWN
(SCHEMATIC)
813R/BLK
36/GRN
FLOW SWITCH
S--15
REVERSE
1/RED
19B/BLU
1
13D/BLK
23/GRY
CB--1
15A
18A/
ORA
18/ORA
8730
5.0A M3
22/
YEL
8685 M3
1E/
RED
CB--6
19/BLU
IGNITION
SWITCH
S--3
20/BLU
ELECTRONIC
INSTRUMENT
PANEL
17
50
BATT.
30
19
ACC
13/BLK
BATTERY
22 13S/BLK
13T/BLK
13U/BLK
13Y/BLK
23
24
DELAY)
8685M4
19A/BLU
ELECTRICAL
4-39
7400 MM428 (12--98)
46/BRN IS OPEN
FROM PANEL PIN TO
SOLENOID WITHOUT
VOLTAGE
OPERATION:
--SCRUB IS SELECTED ON
TOUCH PANEL
--SCRUB SOLENOIDS ARE
TURNED ON
--HEAD WILL LOWER,
BRUSHES WILL SPIN
SCRUB BRUSH WILL NOT
TURN ON AND/OR DOWN
(FLOW CHART)
PANEL IS POWERED UP
KEY IS ON
ENGINE IS OFF
CAN THE SCRUB BUTTON
BE TURNED ON AND OFF ?
NO
REPLACE TOUCH
PANEL FACE
STILL NOT TURNING
ON/OFF
REPLACE INSTRUMENT
PANEL
YES
ENGINE IS ON
ACTIVATE SQ. / VAC BUTTON
DOES THE SQUEEGEE GO DOWN
AND VAC FAN TURN ON ?
YES
NO
IS THE REC TANK
LIGHT ON ? YES
DRAIN THE TANK
NO
ENGINE IS OFF
KEY IS ON
SCRUB SELECTED
ALL 24/PUR WIRES, 21B/GRY
21/GRY, 1F/RED, OR M4
CONTACTS ARE OPEN
DISCONNECT SOLENOIDS
CHECK VOLTAGE AT SV--1,
SV--5, SV--7, AND SV--4
FROM 24/PUR TO GROUND
VOLTAGE
NO
WIRE 24/PUR
FROM CB--7 TO
SOLENOIDS SV--1,
SV--5, SV--7, OR
SV--4 IS OPEN
VOLTAGE
ENGINE IS OFF
KEY IS ON
SCRUB SELECTED
DISCONNECT SOLENOIDS
CHECK VOLTAGE AT SV--1,
SV--5, AND SV--7
FROM 24/PUR TO 46/BRN
VOLTAGE ON AT LEAST
ONE SOLENOID
NO VOLTAGE
AT ALL SOLENOIDS
SOLENOID STILL DISCONNECTED
TURN KEY SW. OFF THEN ON
DOES THE ” OK” LIGHT COME ON ? YES
WIRE 46/BRN IS OPEN
FROM PANEL (PIN 19)
NO
DISCONNECT INST. PANEL
CHECK CONTINUITY OF
WIRE 46/BRN FROM INST.
PANEL HARNESS (PIN 19)
TO GROUND
OPEN
REPLACE INST.
PANEL
CONTINUED ON
NEXT PAGE CONTINUITY
WIRE 46/BRN IS
SHORTED TO
GROUND
ELECTRICAL
4-40 7400 MM428 (12--98)
CONTINUED FROM
PREVIOUS PAGE
KEY ON
ENGINE OFF
SCRUB SELECTED
SV--4 DISCONNECTED
CHECK VOLTAGE AT SV--4
FROM 24/PUR TO 48/BRN
NO VOLTAGE
SOLENOID STILL
DISCONNECTED
TURN KEY OFF, THEN ON
DOES THE ”OK” LIGHT COME ON ?
NO YES
WIRE48/GRYISOPEN
FROM SV--4 TO INST.
PANEL (PIN 16)
KEY IS OFF
DISCONNECT INSTRUMENT PANEL
CHECK CONTINUITY FROM 48/GRY
TO GROUND
OPEN CONTINUITY
REPLACE PANEL WIRE 48/GRY IS
SHORTED TO GROUND
VOLTAGE
CHECK TO SEE IF ALL
FOUR SOLENOIDS ARE
O N -- -- U S E M A G N E T I S M
TEST ON SV--1, SV--5,
SV--7, AND SV--4
ALL ON ONE OR
MORE NOT
ACTIVATED
REPLACE BAD SOLENOID
HYDRAULIC
PROBLEM
>2VOLTS
ELECTRICAL
4-41
7400 MM428 (12--98)
SQUEEGEE AND VACUUM FAN NOT
TURNING ON AND GOING DOWN
(SCHEMATIC)
OPERATION:
--SQ/VAC IS SELECTED ON
TOUCH PANEL
--WITH MACHINE IN FWD
OF NEUT., SV--3 AND SV--2
ARE TURNED ON
--SQ. LOWERS AND VAC
TURNS ON
24/
PUR
21/GRY
21B/
GRY 47/BRN
48/GRY
46A/BRN
46A/BRN
46/
BRN
24B/PUR
24B/PUR
24B/PUR
24B/PUR
24B/PUR
SV--7 SCRUB BR.
UP HOLD VALVE
SV--3 SQUEEGEE
DOWN VALVE
CB--7
24B/PUR
21B/GRY
SV--2 VAC FAN
ON VALVE
SV--4 SCRUB BR. DN. FORCE
PROP. VALVE
SV--5 SCRUB BR.
DOWN VALVE
45/GRY
46A/BRN
21 (8 SEC
DELAY)
16
19
2
15 AMP
SV--1 SCRUB BR.
ON VALVE
87
30
M4
1F/RED
813R/BLK
36/GRN
FLOW SWITCH
S--15
REVERSE
1/RED
19B/BLU
1
13D/BLK
23/GRY
CB--1
15A
18A/
ORA
18/ORA
8730
5.0A M3
22/
YEL
8685 M3
1E/
RED
CB--6
19/BLU
IGNITION
SWITCH
S--3
20/BLU
ELECTRONIC
INSTRUMENT
PANEL
17
50
BATT.
30
19
ACC
13/BLK
BATTERY
22 13S/BLK
13T/BLK
13U/BLK
13Y/BLK
23
24
11 (4 SEC
DELAY)
8685M4
19A/BLU
ELECTRICAL
4-42 7400 MM428 (12--98)
CHECK REVERSE INPUT
--DISCONNECT INSTRUMENT
PANEL
--TURN ENGINE ON, MACHINE
IN REVERSE
--CHECK CONTINUITY AT THE
INSTR. PANEL (PIN 8) FROM
36/GRN TO GROUND
ELECTRONICS OK
SEE HYDRAULIC
TROUBLESHOOTING
DOES THE SQ. AND/OR
VAC TURN ON/OFF WITH THE
SQ/VAC BUTTON NOW ?
CAN THE SQ/VAC TOUCH
PANEL BUTTON
BE TURNED ON AND OFF?
SQUEEGEE AND VACUUM FAN NOT
TURNING ON AND GOING DOWN
(FLOW CHART)
OPERATION:
--SQ/VAC IS SELECTED ON
TOUCH PANEL
--WITH MACHINE IN FWD
OF NEUT., SV--3 AND SV--2
ARE TURNED ON
--SQ. LOWERS AND VAC
TURNS ON
PANEL IS POWERED UP
KEY IS ON
ENGINE IS RUNNING
NO
YES
REPLACE TOUCH
PANEL FACE
STILL DOES
NOT WORK
REPLACE INST.
PANEL
GO INTO ”MANUAL MODE
THE OUTPUTS WILL TURN
ON REGARDLESS OF THE
INPUTS
--TURN KEY OFF
--PUSH AND HOLD ”ES”
BUTTON
--TURN KEY ON
--KEEP HOLDING ES” BUT-
TON UNTIL THE MAINTE-
NANCE LIGHT COMES ON
--RELEASE ”ES” BUTTON
NO
CHECK VOLTAGE AT SV--3
FROM 24P/PUR TO GRND. AND
SV--2 FROM 24/PUR TO GRND.
VOLTAGE
NO
VOLTAGE
--MANUAL MODE
--ENGINE OFF
--KEY ON
--SQ/VAC SELECTED
”ON”
ARE SV--2 AND SV--3
TURNED ON ? (USE
MAGNETIZED TEST)
NO
YES
DISCONNECT HYD.
COILS
CHECK VOLTAGE
ACROSS BOTH COILS,
SV--2 FROM 24/PUR TO
45/GRY AND SV--3 FROM
24/PUR TO 47/BRN
VOLTAGE
NO
VOLTAGE
CONTINUED ON
NEXT PAGE
REPLACE HYD. COIL
THAT WILL NOT TURN
ON----RE--TEST SYSTEM
24/PUR, 21/GRY,
CB--7, OR M--4
CONTACTS ARE
OPEN
YES
IS THE REC TANK
FULL LIGHT ON ?
YES
DRAIN TANK AND
RE--TEST
NO
OPEN
CONTINUITY
REPLACE THE
PANEL
36/GRN, 13R/BLK, OR
S--15 ARE OPEN
NOTE: S--15 IS
CLOSED IN REVERSE
ELECTRICAL
4-43
7400 MM428 (12--98)
REMOVE THE SHORT
TO GROUND ON
47/BRN AND/OR
45/GRY
COILS STILL
DISCONNECTED
CONTINUED FROM
PREVIOUS PAGE
--TURN KEY OFF THEN ON
IS THE ”OK” LIGHT ON ?
NO
YES
WIRE 47/BRN OR
WIRE 45/GRY
ARE OPEN
KEY OFF
PANEL
DISCONNECTED
CHECK CONTINUITY OF
47/BRN AND 45/GRY TO
GROUND
OPEN
CONTINUITY
--RECONNECT PANEL
--KEY OFF THEN ON
DOES THE ”OK” PANEL
LIGHT COME ON ?
YESNO
RE--TEST
SYSTEM
REPLACE
INSTRUMENT PANEL
ELECTRICAL
4-44 7400 MM428 (12--98)
CIRCUIT 1
CIRCUIT 2
S10
46C/BRN
46B/BRN
25/
GRY
21/GRY
51A/PUR
51A/PUR
51/PUR51C/PUR
S10
97/YEL
25B/GRY
25B/GRY
25B/GRY
25B/GRY
SV--11 SIDE BR.
UP HOLD VALVE
SV--12 LOW
WATER VALVE
SV--13 HIGH
WATER VALVE
95/BLU
96/GRY
21A/
GRY
15 AMP
CB--8
51B/PUR
SV--14 SIDE BR.
WATER VALVE
SV--10 SIDE BR. DN. FORCE
PROP. VALVE
25C/GRY
SV--9 SIDE BR.
OUT VALVE
SV--8 SIDE BR.
DOWN VALVE
SV--6 SIDE BR.
ON VALVE
52/YEL
51A/PUR
6 (3 SEC. DELAY)
12
87
30
M4
1F/RED
SIDE BRUSH WILL NOT TURN ON
AND GO DOWN
(SCHEMATIC)
OPERATION:
--MACHINE MUST BE IN
SCRUB MODE
--SIDE BRUSH BUTTON IS
ACTIVATED AND WILL
TURN ON AND LOWER
SIDE BRUSH
-- S V -- 6 , S V -- 9 , S V -- 8 , S V -- 1 0 ,
AND SV--11 WILL BE ON
813R/BLK
36/GRN
FLOW SWITCH
S--15
REVERSE
1/RED
19B/BLU
1
13D/BLK
23/GRY
CB--1
15A
18A/
ORA
18/ORA
8730
5.0A M3
22/
YEL
8685 M3
1E/
RED
CB--6
19/BLU
IGNITION
SWITCH
S--3
20/BLU
ELECTRONIC
INSTRUMENT
PANEL
17
50
BATT.
30
19
ACC
13/BLK
BATTERY
22 13S/BLK
13T/BLK
13U/BLK
13Y/BLK
19
23
24
8685M4
19A/BLU
ELECTRICAL
4-45
7400 MM428 (12--98)
51/PUR IS OPEN
FROM PANEL (PIN
12) TO SOLENOID
WITHOUT VOLTAGE
25/GRY, 21A/GRY, OR
CB--8 IS OPEN FROM
SOLENOID TO M--4
(PIN 87)
GO TO SCRUB
TROUBLESHOOTING
FLOW CHART FIRST
REPLACE TOUCH
PANEL FACE
CAN THE SCRUB AND SIDE
BRUSH BUTTONS BE TURNED
ON AND OFF
SIDE BRUSH WILL NOT TURN ON
AND GO DOWN
(FLOW CHART)
OPERATION:
--MACHINE MUST BE IN
SCRUB MODE
--SIDE BRUSH BUTTON IS
ACTIVATED AND WILL
TURN ON AND LOWER
SIDE BRUSH
-- S V -- 6 , S V -- 9 , S V -- 8 , S V -- 1 0 ,
AND SV--11 WILL BE ON
PANEL IS POWERED UP
KEY IS ON
ENGINE IS RUNNING
NO
YES
STILL DOES
NOT WORK
REPLACE INST.
PANEL
--ENGINE ON
ACTIVATE THE SCRUB BUTTON
DO THE SCRUB FUNCTIONS TURN ON ?
YESNO
--ENGINE OFF
--KEY ON
--SCRUB SELECTED
--SIDE BRUSH SELECTED
CHECK VOLTAGE AT SV--6, SV--8, SV--9,
SV--10, AND SV--11 FROM 25/GRY TO
GROUND
VOLTAGE
NO VOLTAGE
ON ANY OR
ALL
--ENGINE OFF
--KEY ON
--SCRUB SELECTED
--SIDE BRUSH SELECTED
--ALL FOUR SOLENOIDS DISCONNECTED
CHECK VOLTAGE ACROSS SOLENOIDS
SV--6, 8, 9, AND 11 FROM 25/GRY TO 51 PUR
CONTINUED ON
NEXT PAGE
VOLTAGE ACROSS
ALL FOUR SOLENOIDS
VOLTAGE ACROSS
AT LEAST ONE SOLENOID
NO VOLTAGE
ON ALL FOUR
--SOLENOIDS STILL DISCONNECTED
--TURN KEY OFF, THEN ON
DOES THE ”OK” LIGHT COME ON ? YES
NO
51/PUR IS OPEN
FROM PANEL TO ALL
FOUR SOLENOID
--DISCONNECT INSTRUMENT PANEL
CHECK CONTINUITY OF 51/PUR FROM
INSTR. PANEL (PIN 12) TO GROUND
OPEN
CONTINUITY
REPLACE INST.
PANEL
WIRE 51/PUR IS
SHORTED TO
GROUND
ELECTRICAL
4-46 7400 MM428 (12--98)
--KEY OFF
PANEL DISCONNECTED
CHECK CONTINUITY FROM
52/YEL TO GROUND
WIRE 52/YEL IS OPEN
FROM SV--10 TO
INSTR. PANEL (PIN 6)
--KEY ON
--ENGINE OFF
--SCRUB AND SIDE BRUSH ON
--SV--10 DISCONNECTED
CHECK VOLTAGE AT SV--10 FROM
25/GRY TO 52/YEL
CONTINUED FROM
PREVIOUS PAGE
NO VOLTAGE
VOLTAGE
WITH SOLENOID STILL DISCONNECTED----
TURN KEY OFF, THEN ON
DOES THE :OK” LIGHT COME ON ?
NO YES
WIRE 52/YEL
IS SHORTED
TO GROUND
CONTINUITYOPEN
REPLACE INSTRUMENT
PANEL
CHECK TO SEE IF ALL SOLENOIDS
ARE TURNING ON
USE THE MAGNETIC TEST
ONE OR
MORE OFF
REPLACE BAD
SOLENOIDS
ALL SOLENOIDS
ON
HYDRAULIC PROBLEM
SEE TROUBLESHOOTING
>2VOLTS
ELECTRICAL
4-47
7400 MM428 (12--98)
WATER VALVES NOT OPERATING
(SCHEMATIC) OPERATION:
--SCRUB FUNCTIONS MUST
BE ON
--WATERSWITCHINPOSITION#1
TURNS ON SV--12 LOW WATER
VALVE AND SV--14 SIDE BRUSH
VALVE
--WATERSWITCHINPOSITION#2
TURNS ON SV--12, SV--14, AND
SV--13 (HIGH WATER VALVE)
CIRCUIT 1
CIRCUIT 2
S10
46C/BRN
46B/BRN
25/
GRY
21/GRY
51A/PUR
51A/PUR
51/PUR51C/PUR
S10
97/YEL
25B/GRY
25B/GRY
25B/GRY
25B/GRY
SV--11 SIDE BR.
UP HOLD VALVE
SV--12 LOW
WATER VALVE
SV--13 HIGH
WATER VALVE
95/BLU
96/GRY
21A/
GRY
15 AMP
CB--8
51B/PUR
SV--14 SIDE BR.
WATER VALVE
SV--10 SIDE BR. DN. FORCE
PROP. VALVE
25C/GRY
SV--9 SIDE BR.
OUT VALVE
SV--8 SIDE BR.
DOWN VALVE
SV--6 SIDE BR.
ON VALVE
52/YEL
51A/PUR
6 (3 SEC. DELAY)
12
87
30
M4
1F/RED
813R/BLK
36/GRN
FLOW SWITCH
S--15
REVERSE
1/RED
19B/BLU
1
13D/BLK
23/GRY
CB--1
15A
18A/
ORA
18/ORA
8730
5.0A M3
22/
YEL
8685 M3
1E/
RED
CB--6
19/BLU
IGNITION
SWITCH
S--3
20/BLU
ELECTRONIC
INSTRUMENT
PANEL
17
50
BATT.
30
19
ACC
13/BLK
BATTERY
22 13S/BLK
13T/BLK
13U/BLK
13Y/BLK
19
23
24
8685M4
19A/BLU
ELECTRICAL
4-48 7400 MM428 (12--98)
TROUBLESHOOT THE
SCRUB FUNCTION
AND SIDE BRUSH
FUNCTION FIRST
ACTIVATE SCRUB AND SIDE BRUSH
DO THEY BOTH TURN ON AND COME DOWN ?
WATER VALVES NOT OPERATING
(FLOW CHART) OPERATION:
--SCRUB FUNCTIONS MUST
BE ON
--WATERSWITCHINPOSITION#1
TURNS ON SV--12 LOW WATER
VALVE AND SV--14 SIDE BRUSH
VALVE
--WATERSWITCHINPOSITION#2
TURNS ON SV--12, SV--14, AND
SV--13 (HIGH WATER VALVE)
PANEL IS POWERED UP
KEY IS ON
ENGINE IS RUNNING
YES NO
--ENGINE RUNNING
--SCRUB AND SIDE BRUSH ON
--WATERSWITCHONPOSITION#2
--SV--14, SV--12, AND SV--13 DISCONNECTED
CHECK FOR VOLTAGE AT SV--14 FROM
97/YEL TO GROUND
CHECK FOR VOLTAGE AT SV--12 FROM
96/GRY TO GROUND
CHECK FOR VOLTAGE AT SV--13 FROM
95/BLU TO GROUND
NO VOLTAGE ON ANY
WIRES 97/YEL, 96/GRY, 95/BLU
25/GRY, OR SWITCH S--10 ARE
OPEN FROM CB--8 TO SOLENOID
WITH NO VOLTAGE
VOLTAGE ON
ALL SOLENOIDS
--KEY ON, ENGINE OFF
--SOLENOIDS STILL DISCONNECTED
--SCRUB AND SIDE BRUSH ON
CHECK VOLTAGE AT SV--14 FROM
97/YEL TO 51B/PUR
CHECK VOLTAGE AT SV--12 FROM
96/GRY TO 46B/BRN
CHECK VOLTAGE AT SV--13 FROM
95/BLU TO 46C/BRN
NO VOLTAGE ON ANY
VOLTAGE ON
ALL SOLENOIDS
REPLACE ANY VALVE
NOT OPERATING
--IF SV--14 IS NO VOLTAGE
WIRE 51B/PUR FROM SV--14 TO
(PIN 12) IS OPEN
--IF SV--12 IS NO VOLTAGE
WIRE 46B/BRN FROM SV--12 TO
(PIN 19) IS OPEN
--IF SV--13 IS NO VOLTAGE
WIRE 46C/BRN FROM SV--13 TO
(PIN 19) IS OPEN
ELECTRICAL
4-49
7400 MM428 (12--98)
13S/BLK
13T/BLK
13Y/BLK
62E/BRN
62D/BRN
62B/YEL
62A/YEL
59A/BRN
59/
BRN
20B/
BLU
62C/YEL
ELECTRONIC
INSTRUMENT
PANEL
M6
8730
BRAKE SWITCH
S--11
REV/FLSH LIGHT LRC
89/ORG
CB--3
13HH/
BLK
13II/
BLK
13DD/BLK
13CC/BLK
13KK/BLK
62/YEL
89A/ORA
89B/ORA
15 AMP
TAIL LHT L.H.
TAIL LHT R.H.
HEADLIGHT L.H.
HEADLIGHT R.H.
15
20
23C/GRY 60/GRN
M6
LIGHTS
85 86
CB--1
15A
IGNITION
SWITCH
S--3 20A/BLU
20/BLU
17
50
BATT.
30
19
ACC
START
15B/BLU
15/BLU
14/GRN
18A/ORA 13P/BLK
13B/BLK
S--4 OIL SWITCH
15A/BLU
FUEL PUMP
10A/GRY
M2
HEAD LIGHTS WILL NOT TURN ON
(SCHEMATIC) OPERATION:
--(PIN 15) TO GROUND BY OIL
PRESSURE SWITCH TURNS ON M6
1/RED 13/BLK
BATTERY
22
13U/BLK
23
24
18A/ORA
1
23/GRY
18A/
ORA
8730
5.0A
M3
22/
YEL
8685 M3
1E/
RED
CB--6
19/BLU 13D/BLK
1E/
RED
1D/RED
ELECTRICAL
4-50 7400 MM428 (12--98)
-- P O W E R O F F
--DISCONNECT PANEL
IS 60/GRN SHORTED
TO GROUND ?
WIRES 15/BLU, 13B/BLK, OR S--4 ARE
OPEN, OR ENGINE OIL PRESSURE
IS LOW
DISCONNECT M6 AND CHECK
CONTINUITY OF 60/GRN
FROM M6 (PIN 86) TO INSTR.
PANEL (PIN 20)
CHECK VOLTAGE ON M6 AT
(PIN 30) FROM 59/BRN TO
GROUND
REMOVE M6 RELAY
CHECK VOLTAGE AT M6
(PIN 85) FROM 23C/GRY
TO GROUND
HEAD LIGHTS WILL NOT TURN ON
(FLOW CHART) OPERATION:
--(PIN 15) TO GROUND BY OIL
PRESSURE SWITCH TURNS ON M6
PANEL IS POWERED UP
KEY IS ON
ENGINE IS RUNNING
VOLTAGE
NO VOLTAGE
CHECK VOLTAGE AT M6 (PIN 87)
FROM 59/BRN TO GROUND VOLTAGE
NO VOLTAGE
WIRE 20B/BLU IS OPEN FROM
KEY SWITCH TO CB--3
CHECK VOLTAGE AT HEAD LIGHTS
FROM 62/YEL TO 13CC/BLK OR
FROM 62A/YEL TO 13DD/BLK
HEAD LIGHT IS BAD
62/YEL, 62A/YEL,
13CC/BLK, OR 13DD/
BLK ARE OPEN
VOLTAGENO VOLTAGE
REPLACE M6 RELAY
WORKS
PROBLEM SOLVED
NO LIGHTS
VOLTAGE
WIRE 23C/GRY IS OPEN
FROM M6 (PIN 85) TO
M3 (PIN 87)
IS THE ENGINE OIL PRESSURE
WARNING LIGHT ”ON” ON THE
INSTRUMENT PANEL ?
NO VOLTAGE
NO
YES
CONTINUITY
OPEN
REPAIR 60/GRN DOES ”OK” LIGHT COME
ON WHEN KEY IS
TURNED ON ?
NO
YES
GROUND AT (PIN 15)
REPLACE INSTR.
PANEL
--DISCONNECT THE INSTR. PANEL
--START ENGINE
CHECK FOR GROUND ON 15/BLU
AT INSTR. PANEL ON (PIN 15)
NO
15/BLU, S--4, OR 13B/BLK
IS OPEN
REPLACE INSTR.
PANEL
NO
YES
REPAIR 60/GRN
ELECTRICAL
4-51
7400 MM428 (12--98)
5 SEC. DELAY
ES PUMP RUNS
30 SEC.
5 SEC. DELAY
1MIN.TOVAC
FAN SHUT--OFF
3
10
4
13K/BLK
23C/GRY
27/PUR
26/BRN
RECOVERY
TANK
SOLUTION
TANK
S--18 N.C.H.O.
S--17 N.O.H.C.
N.C.H.O.
28/YEL
M5
57/GRN
ES PUMP
85 86
RECOVERY TANK
S--8
IGNITION
SWITCH
S--3
13J/BLK
1D/RED
20A/BLU
20/BLU
ELECTRONIC
INSTRUMENT
PANEL
17
50
BATT.
30
19
ACC
START
66/BRN 13PP/BLK
AUTO FILL
65/GRY
CB--2
ES PUMP
M5
20A/
BLU 8730
15 AMP
MTR
EStPUMP NOT WORKING
(SCHEMATIC) OPERATION:
-- I F E S tIS SELECTED ON PANEL AND
--S--17 AND S--18 CLOSE FOR 5 SECONDS
--M5 RELAY WILL ACTIVATE, TURNING ON
PUMP
13T/BLK
13Y/BLK
15
CB--1
15A
15B/BLU
15/BLU
14/GRN
18A/ORA 13P/BLK
13B/BLK
S--4 OIL SWITCH
15A/BLU
FUEL PUMP
10A/GRY
M2
1/RED 13/BLK
BATTERY
22
13U/BLK
23
24
18A/ORA
1
23/GRY
18A/
ORA
87
30 M3
22/
YEL
8685 M3
1E/
RED
19/BLU 13D/BLK
13S/BLK
23/GRY
15/BLU
ELECTRICAL
4-52 7400 MM428 (12--98)
DISCONNECT INSTR. PANEL
--CHECK FOR CONTINUITY
AT INSTR. PANEL FROM
26/BRN (PIN 3) TO GROUND STILL NOT
WORKING IN
MANUAL MODE
CAN THE ES PUMP TOUCH
PANEL BUTTON BE
TURNED ON/OFF
EStPUMP NOT WORKING
(FLOW CHART) OPERATION:
-- I F E S tIS SELECTED ON PANEL AND
--S--17 AND S--18 CLOSE FOR 5 SECONDS
--M5 RELAY WILL ACTIVATE, TURNING ON
PUMP
PANEL IS POWERED UP
KEY IS ON
ENGINE IS RUNNING
NO
YES REPLACE TOUCH
PANEL FACE
STILL DOES
NOT WORK
REPLACE INST.
PANEL
GO INTO ”MANUAL MODE
THE OUTPUTS WILL TURN ON
REGARDLESS OF THE INPUTS
--TURN KEY OFF
--PUSH AND HOLD ”ES” BUTTON
--TURN KEY ON
--KEEP HOLDING ES” BUTTON
UNTIL THE MAINTENANCE LIGHT
COMES ON
--RELEASE ”ES” BUTTON
NO
YES DOES THE ES PUMP TURN
ON AND OFF WITH THE ES
BUTTON NOW ?
INPUT OUTPUT
REPLACE M5
CHECK VOLTAGE AT
M5 (PIN 30) FROM 65/GRY
TO GROUND
NO VOLTAGE
CHECK VOLTAGE AT M5
(PIN 85) FROM 23C/GRY
TO GROUND
VOLTAGE
20A/BLU, CB--2, OR 65/GRY
ARE OPEN FROM M5 (PIN 30)
TO KEY SWITCH
CONTINUED ON
NEXT PAGE
23C/GRY IS OPEN FROM
M5 (PIN 85) TO M3 (PIN 87)
CHECK FLOAT
INPUT
KEY
OFF
NO
YES
26/BRN, S--17, 27/PUR,
S--18, OR 13K/BLK
OPEN
KEY ON
PANEL CONNECTED
GO TO INPUT MODE
APPLY AND RE-
MOVE GROUND TO
(PIN 3) BY CLOSING
S--17 AND S--18
YES
NO
REPLACE PANEL
SYSTEM O.K.
VOLTAGE
NO VOLTAGE
ELECTRICAL
4-53
7400 MM428 (12--98)
WIRE 66/BRN OR
13PP/BLK ARE
OPEN
57/GRN IS OPEN FROM
(PIN 4) ON INSTR. PAN-
EL TO (PIN 86)
CONTINUED FROM
PREVIOUS PAGE
VOLTAGE
NO VOLTAGE
WITH ES ON AND
MACHINE IN
MANUAL MODE
CHECK VOLTAGE AT M5 (PIN 87)
FROM WIRE 66/BRN TO GROUND
WITH ES ON AND
MACHINE IN
MANUAL MODE
CHECK VOLTAGE AT ES PUMP
FROM 66/BRN TO 13PP/BLK
NO VOLTAGE VOLTAGE
MOTOR BAD
WITH M5 REMOVED
TURN KEY ON, THEN OFF
IS ”OK” LIGHT ON ?
NO YES
PANEL DISCONNECTED
POWER OFF
M5 REMOVED
REPLACE PANEL
NO
YES
REMOVE SHORT TO
GROUND ON 57/GRN
CHECK CONTINUITY
FROM 57/GRN TO
GROUND
ELECTRICAL
4-54 7400 MM428 (12--98)
23C/GRY
8
18
13R/BLK
58/BLU
M7
REVERSE
85 86
36/GRN
18A/
ORA
87
30
FLOW SWITCH
5.0A
S--15 REVERSE
M3
22/
YEL
86
85
M3
CB--6
13RR/BLK
13JJ/BLK
93A/ORA
93/ORA
20C/
BLU 92/PUR M7
8730
CB--4 94/YEL
93B/ORA
15 AMP
BACK--UP ALARM UNIT
FLASHER
REVERSE LIGHT OR ALARM
NOT WORKING
(SCHEMATIC)
OPERATION:
--GROUND AT (PIN 8) WHEN
MACHINE IS IN REVERSE
--TURNS ON M7
--SUPPLIES POWER TO BACK--UP
ALARM/LIGHT
ELECTRONIC
INSTRUMENT
PANEL
ES PUMP
MTR
13T/BLK
13Y/BLK
22
13U/BLK
23
24
13S/BLK
IGNITION
SWITCH
S--3
1D/RED
20A/BLU
20/BLU
17
50
BATT.
30
19
ACC CB--1
15A
1/RED 13/BLK
BATTERY
1
23/GRY
19/BLU 13D/BLK
ELECTRICAL
4-55
7400 MM428 (12--98)
M7 STILL REMOVED
TURN KEY OFF THEN
ON, IS ”OK LIGHT ON?
REPAIR OR REPLACE WIRES
93A/ORA, 93B/ORA, OR
94/YEL
CHECK VOLTAGE AT M7
(PIN 85) FROM 23C/GRY
TO GROUND
CHECK CONTINUITY OF WIRES
93/ORA, 93A/ORA, 93B/ORA,
AND 94/YEL
CHECK FOR VOLTAGE FROM
ALARM OR LIGHTS WORK-
ING WIRE OR 13JJ BLK,
13RR/BLK TO BATT POSITIVE
CHECK THE VOLTAGE
FROM THE ALARM OR
LIGHT NOT WORKING TO
GROUND
REVERSE LIGHT OR ALARM
NOT WORKING
(FLOW CHART)
OPERATION:
--GROUND AT (PIN 8) WHEN
MACHINE IS IN REVERSE
--TURNS ON M7
--SUPPLIES POWER TO BACK--UP
ALARM/LIGHT
PANEL IS POWERED UP
KEY IS ON
ENGINE IS RUNNING
NO
YES
DOES THE BACK--UP ALARM
OR LIGHT WORK
VOLTAGE
NO VOLTAGE
93/ORA, 93B/ORA, 94/YEL
OR FLASHER ARE OPEN
KEY ON
REPLACE M7
STILL NOT
WORKING
REMOVE M7 AND CHECK
VOLTAGE AT M7 (PIN 30)
FROM 92/PUR TO GROUND
NO VOLTAGE
VOLTAGE
92/PUR, 20C/BLU, OR
CB--4 ARE OPEN
NO VOLTAGE
23C/GRY IS OPEN VOLTAGE
VOLTAGE
REPLACE BAD ALARM
OR FLASHER LIGHT
NO VOLTAGE
REPAIR OR REPLACE
13JJ/BLK OR 13RR/BLK
OPEN
CONTINUED ON
NEXT PAGE
OK
YES
NO
POWER OFF
DISCONNECT PANEL
CHECK CONTINUITY ON
WIRE 58/BLU TO GROUND
NOYES
REPLACE
PANEL
58/BLU IS SHORTED
TO GROUND, RE-
PAIR AND REPLACE
ELECTRICAL
4-56 7400 MM428 (12--98)
REPLACE INSTR.
PANEL
36/GRN, 13R/BLK, OR S--15
ARE OPEN AND IN REVERSE
GO INTO ”INPUT” MODE
IS THE 3RD SEGMENT FROM
THE RIGHT TURNING ON WITH
THE MACHINE RUNNING AND IN
REVERSE ?
CONTINUED FROM
PREVIOUS PAGE
DISCONNECT INSTR. PANEL WITH ENGINE
RUNNING AND MACHINE IN REVERSE
CHECK CONTINUITY AT INSTR. PANEL
CONNECTOR (PIN 8) FROM 36/GRN TO
GROUND WHEN MACHINE IS RUNNING
CONTINUITY
NO CONTINUITY
YES
NO
--DISCONNECT PANEL
-- P O W E R O F F
CHECK CONTINUITY
OF 58/BLU
REPLACE INSTR.
PANEL
CONTINUITY OPEN
REPAIR 58/BLU
ELECTRICAL
4-57
7400 MM428 (12--98)
56/ORA 9
23A/GRY MTR
DETERGENT METERING
DETERGENT METERING
PUMP IS NOT OPERATING
(SCHEMATIC)
OPERATION:
--PANEL DETERGENT BUTTON IS
ACTIVE IN LOW OR HIGH POSITION
--MACHINE IS IN SCRUB MODE
--DETERGENT PUMP WILL BE TURNED
ON WITH A PULSE WIDTH MODULATED
SIGNAL
18A/
ORA
87
30
5.0A
M3
22/
YEL
86
85 M3
CB--6
ELECTRONIC
INSTRUMENT
PANEL
13T/BLK
13Y/BLK
22
13U/BLK
23
24
13S/BLK
IGNITION
SWITCH
S--3
1D/RED
20/BLU
17
50
BATT.
30
19
ACC CB--1
15A
1/RED 13/BLK
BATTERY
1
23/GRY
19/BLU 13D/BLK
ELECTRICAL
4-58 7400 MM428 (12--98)
REPAIR AND
REPLACE
56/ORA
23A/GRY IS OPEN
FROM PUMP TO
M3 (PIN 87)
VERIFY THAT THE SCRUBBING
SYSTEM IS FUNCTIONING
IS 46/BRN AT INSTR. PANEL (PIN 19)
GOING LOW AND TURNING ON
SV--1, SV--5, AND SV--7 ?
--IN MANUAL MODE
--KEY ON, ENGINE OFF
CHECK VOLTAGE AT
PUMP FROM WIRE 23A/
GRY TO 56/ORA
GO INTO ”MANUAL MODE
THE OUTPUTS WILL TURN ON
REGARDLESS OF THE INPUTS
--TURN KEY OFF
--PUSH AND HOLD ”ES” BUTTON
--TURN KEY ON
--KEEP HOLDING ES” BUTTON
UNTIL THE MAINTENANCE LIGHT
COMES ON
--RELEASE ”ES” BUTTON
ENGINE DOES NOT HAVE TO BE
RUNNING
DETERGENT METERING
PUMP IS NOT OPERATING
(FLOW CHART)
OPERATION:
--PANEL DETERGENT BUTTON IS
ACTIVE IN LOW OR HIGH POSITION
--MACHINE IS IN SCRUB MODE
--DETERGENT PUMP WILL BE TURNED
ON WITH A PULSE WIDTH MODULATED
SIGNAL
PANEL IS POWERED UP
KEY IS ON
ENGINE IS RUNNING
REPLACE TOUCH
PANEL FACE
STILL DOES
NOT WORK
REPLACE INST.
PANEL
NO
CAN THE DETERGENT
METERING AND TOUCH
PANEL SWITCHES BE
TURNED ON AND OFF ?
YES
DOES THE DETERGENT METERING
PUMP TURN ON AND OFF WITH
THE TOUCH PANEL SWITCH ?
NO
YES
SCRUB
INPUTS DISCONNECT DETERGENT
PUMP
CHECK VOLTAGE AT DETERGENT
PUMP FROM 23A/GRY TO GROUND
VOLTAGE
NO VOLTAGE
YES
NO
TROUBLESHOOT
SCRUB BRUSH
SYSTEM FIRST
NO VOLTAGE
VOLTAGE
REPLACE
PUMP
-- P O W E R O F F
--PANEL DISCONNECTED
CHECK CONTINUITY OF 56/ORA
FROM PANEL (PIN 9) TO PUMP
OPEN
CONTINUITY