T7 Service Manual Tennant Rider Floor Scrubber
2018-06-20
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T7 Featuring ® The safe scrubbing alternativet HygenictFully Cleanable Tanks Service Information 331045 Rev. 00 *331045* This manual provides service information for the TENNANT Model T7. This machine will provide excellent service. However, the best results will be obtained at minimum costs if: D The machine is operated with reasonable care. D The machine is maintained regularly -- per the maintenance instructions provided. D The machine is maintained with TENNANT supplied or approved parts. Manual Number -- 331045 Revision: 00 Published: 12--04 Tennant Company PO Box 1452 Minneapolis, MN 55440 Phone: (800) 553--8033 or (763) 513--2850 www.tennantco.com FaST Foam Scrubbing Technology logo is a United States registered trademark of Tennant Company. Copyright E 2003 TENNANT, Printed in U.S.A. Table of Contents Electrical Troubleshooting Information ...................................................................................... 1 Commonly Used Electrical Symbols & Terms........................................................................ 2 Ladder Schematic .................................................................................................................. 3 Wire Harness Group............................................................................................................... 5 Key OFF, Operator NOT on Seat........................................................................................... 9 Key OFF, Battery Charger Plugged In ................................................................................. 10 Key ON, Operator on Seat ................................................................................................... 11 Tank Level Sensors.............................................................................................................. 12 Horn & Hour Meter Systems ................................................................................................ 13 Propel Forward System........................................................................................................ 14 Propel Reverse System........................................................................................................ 15 Braking System .................................................................................................................... 16 Scrub Head & Squeegee Actuator Systems ........................................................................ 17 Scrub Brush Motors System................................................................................................. 19 Vacuum Fan System ............................................................................................................ 20 FaST System........................................................................................................................ 21 Conventional Solution System................................................................................................. 22 LED Locations & Descriptions.............................................................................................. 23 Operational Modes & Interlocks ........................................................................................... 24 Diagnostic & Fault Alarms .................................................................................................... 25 Alarm Codes ..................................................................................................................... 25 High Current Faults ........................................................................................................... 25 Diagnostic & Configuration Modes....................................................................................... 26 Display Software Revision Mode ......................................................................................... 27 Self Test Mode ..................................................................................................................... 28 Input Display Mode............................................................................................................... 29 Manual Mode........................................................................................................................ 30 Propel / Brake Diagnostics ................................................................................................... 31 Battery Select Mode & Voltage Levels................................................................................. 32 Battery Select Mode.......................................................................................................... 32 Voltage Levels................................................................................................................... 32 Reverse Alarm & Propel Speed Select Modes .................................................................... 33 Reverse Alarm Select Mode ............................................................................................. 33 Propel Speed Select Mode ............................................................................................... 33 Inputs & Outputs Table......................................................................................................... 34 Torque Standard...................................................................................................................... 35 Inch Fasteners...................................................................................................................... 35 METRIC Fasteners............................................................................................................... 37 Nylon Insert Lock Nuts ......................................................................................................... 39 Nut-Hex Light THIN .............................................................................................................. 39 Wheel Bolt and Nuts............................................................................................................. 40 Wheel Bearing Adjustment................................................................................................... 40 Tightening Nuts on Tapered Shafts ..................................................................................... 41 Shoulder Bolts ...................................................................................................................... 42 Taper Lockr Bushings .......................................................................................................... 43 Sequence Tightening ........................................................................................................... 44 i ii T7 ELECTRICAL Troubleshooting Information BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual * Always use an ESD (Electrostatic Discharge) strap when working near the Control Board * Be cautious when working near Control Board – Battery voltage is always present, even with Key OFF * Always unplug Positive Battery Cable when removing or replacing components DURING TESTS: * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action NOTE:Troubleshooting charts may be shown with optional equipment. The optional equipment may not be specified in these charts. Some machines may not be equipped with all components shown. 2005.01.05 T7ETI REV 00 1 Commonly Used Electrical Symbols & Terms NOTE: The term “NORMALLY” refers to the components’ “at rest” or “de-energized” position - + Wires Connected Together Normally Open Switch Wires Not Connected Together Normally Open Limit Switch Plug-in Connection Normally Open Push-Button Switch Normally Closed Limit Switch Normally Open Battery Circuit Breaker Normally Closed Push-Button Switch Fuse Indicates Movement from Normal Position Normally Closed M1 Relay Coil (Part 1 of Relay) Diode Relay Contacts (Part 2 of Relay) Solenoid (Valve or Actuator) Indicates Component in Position Other than Normal X Motor Wiring Standoff (Connection Point) Lamp (Light Bulb) Indicates Component is Energized Horn or Alarm Terms & Abbreviations BDI – Battery Discharge Indicator Dynamic Braking – A method of using the generating nature of an electric motor to slow the machine Hall Effect – A voltage developed as a result of current flow in the presence of a magnetic field LED – Light Emitting Diode PM – Permanent Magnet PWM (Pulse Width Modulation) – A method of using controlled on/off times to regulate the voltage and current supplied to an electrical device Example of Wiring Numbers & Colors: Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number 0 1 2 Color of Wire Tan Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 White 1 RED 25 7 13 BLK T7 – Ladder Schematic (page 1 of 2) 1 2 3 4 5 1021038 3 T7 – Ladder Schematic (page 2 of 2) 1 2 3 4 5 4 1021038 T7 – Wire Harness Group (page 1 of 4) 1 5 T7 – Wire Harness Group (page 2 of 4) 1 6 T7 – Wire Harness Group (page 3 of 4) 1 7 T7 – Wire Harness Group (page 4 of 4) 2 8 T7 - Key OFF, Operator NOT on Seat + 1 RED 6 VDC - + 6 VDC 1 RED - + 1 RED 6 VDC - + 6 VDC - 13 BLK 13 BLK 13 BLK X STANDOFF 4 CHARGER PLUG 1 RED v 1 RED v M1B 2 4 1 RED CB1 5A D3 CONTROL BOARD EMERGENCY STOP SWITCH S1 5 MAIN CONTACTOR 2 4 F1 100 A 5 5 4 M1A PIN J6-17 6 3 4 4 3 50 RED SW1 LOGIC GROUND D1 6 42 PIN J6-5 27 GRN PIN J6-7 26 27 SW2 SEAT SWITCH 26 PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 42 PIN J6-35 PIN J6-13 POST J11 + POS POST J7 NEG - 13 BLK 13 BLK RIBBON CABLE CONNECTOR P6 TOUCH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number 0 1 Color of Wire Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 14 Tan White = Battery Negative or Logic Ground = Battery Positive or Positive Output 9 T7 - Key OFF, Battery Charger Plugged In + 1 RED 6 VDC - + 6 VDC - + 1 RED 1 RED 6 VDC - + 6 VDC - 13 BLK 13 BLK 13 BLK STANDOFF 4 CHARGER PLUG 1 RED v 1 RED v M1B 2 4 1 RED CB1 5A D3 CONTROL BOARD EMERGENCY STOP SWITCH S1 4 5 4 4 4 50 RED 2 M1A 14 6 3 CHARGER SW1 INTERLOCK 26 42 PIN J6-35 14 50 RED 27 GRN SW2 SEAT SWITCH PIN J6-13 POST J11 + POS RIBBON CABLE Wiring Color Codes (Unless otherwise marked) 0 1 Tan Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 White = Battery Negative or Logic Ground = Battery Positive or Positive Output 10 27 PIN J6-6 TOUCH PANEL Color of Wire 32 ORG PIN J6-24 POST J7 NEG - RIBBON CABLE CONNECTOR P6 Right Most Digit of Wire Number LOGIC GROUND 42 PIN J6-5 PIN J6-7 26 CB2 15 A 50 RED PIN J6-17 D1 6 3 KEYSWITCH X STANDOFF 2 5 MAIN CONTACTOR 2 F1 100 A 5 14 13 BLK 13 BLK X T7 - Key ON, Operator on Seat + 1 RED 6 VDC - + 6 VDC - + 1 RED 1 RED 6 VDC - + 6 VDC - 13 BLK 13 BLK 13 BLK X STANDOFF 4 CHARGER PLUG 1 RED v 1 RED v M1B 1 RED 4 CB1 5A D3 2 CONTROL BOARD EMERGENCY STOP SWITCH S1 5 MAIN CONTACTOR 2 4 F1 100 A 5 5 M1A 6 3 4 4 50 RED SW1 LOGIC GROUND 42 PIN J6-5 27 GRN PIN J6-7 26 26 27 SW2 SEAT SWITCH PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 42 PIN J6-35 D1 6 3 4 PIN J6-17 PIN J6-13 POST J11 + POS POST J7 NEG - 13 BLK 13 BLK RIBBON CABLE CONNECTOR P6 TOUCH PANEL Indicates Component is Energized RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number 0 1 Color of Wire KEY SWITCH Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 14 Tan O RIGHT SIDE DASH PANEL I White = Battery Negative or Logic Ground = Battery Positive or Positive Output 11 T7 – Tank Level Switches CONDITIONS: key ON 6 VDC + 1 RED - 6 VDC + - + 1 RED 1 RED 6 VDC - + 6 VDC - 13 BLK 13 BLK 13 BLK STANDOFF 4 CHARGER PLUG 1 RED v 1 RED M1B v 1 RED 4 CB1 5A D3 2 S1 5 5 MAIN CONTACTOR 2 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 M1A 42 PIN J6-17 D1 6 6 RECOVERY TANK FULL SWITCH PIN J6-5 PIN J6-20 3 4 3 LOGIC GROUND PIN J6-35 42 28 SW3 PIN J6-24 KEYSWITCH X STANDOFF 2 SW1 4 4 50 RED 26 26 PIN J6-6 PIN J6-8 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED 29 PIN J6-13 POST J11 POST J7 + POS NEG - 42 SW4 SOLUTION TANK LOW SWITCH 13 BLK 13 BLK RIBBON CABLE CONNECTOR P6 TOUCH PANEL Indicates Component is Energized RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Tan 0 1 Pink 2 Brown 3 Orange 4 Yellow 5 Green Tank Level Switches Logic Chart switch tank full tank empty switch OPEN switch CLOSED Solution Tank Recovery Tank x x x x x Solution Tank Empty LED ON x x x indicator Solution Tank Empty LED OFF Recovery Tank Full LED ON Recovery Tank Full LED OFF 6 Blue 7 Purple 8 Gray Solution Tank Low Switch opens when solution tank is low 9 White Tank Level Switches are ALWAYS in the OPEN position with low or empty tank = Battery Negative or Logic Ground = Battery Positive or Positive Output 12 14 Color of Wire i Recovery Tank Full Switch closes when recovery tank is full Tank Level Switches are ALWAYS in the CLOSED position with full tank X T7 – Horn & Hour Meter Systems CONDITIONS: key ON, operator on seat, in motion OR Vacuum Fan running (for Hour Meter) 1 RED 6 VDC + - + 6 VDC - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 S1 5 5 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 PIN J6-35 6 4 3 50 RED 4 3 SW1 LOGIC GROUND PIN J6-5 PIN J6-24 KEYSWITCH X STANDOFF 2 42 D1 6 M1A PIN J6-17 26 PIN J6-10 26 30 42 S2 HORN SWITCH PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED NOTE: Hour Meter is active only when propelling (forward or reverse), OR anytime Squeegee/ Vacuum Fan is active 14 14 23 23 LS1 HORN 14 14 00000 21 POST J11 + POS POST J7 NEG - 13 BLK 13 BLK PIN J6-15 21 PIN J6-14 H1 HOUR METER RIBBON CABLE CONNECTOR P6 TOUCH PANEL Indicates Component is Energized PIN J6-13 LEFT SIDE DASH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan 0 1 Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 White = Battery Negative or Logic Ground = Battery Positive or Positive Output HORN SWITCH RIGHT SIDE DASH PANEL Horn pulses ON & OFF when Directional Switch is in REVERSE i Hour Meter is ON only when propelling (forward or reverse), or anytime Squeegee/Vacuum Fan is ON Horn pulses when a fault is detected (Directional Switch must be in FORWARD Position) – refer to “Diagnostic/Beep Code” chart 13 T7 – Propel Forward System CONDITIONS: key ON, operator on seat, propel pedal depressed 1 RED 6 VDC + - + 6 VDC - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 S1 5 5 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 M1A PIN J6-17 6 3 3 4 4 50 RED SW1 LOGIC GROUND D1 6 42 PIN J6-5 27 GRN PIN J6-7 26 27 SW2 SEAT SWITCH 26 PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED NOTE: Refer to the “Propel/Brake Diagnostics” page for more information 24 24 WHT 25 BLK MTR1A 14 PIN J6-13 POST J11 + POS PIN J10-2 PROPEL MOTOR 25 NOTE: Brake Solenoid is energized to release parking brake. 14 FORWARD 25 15 15 PIN J6-27 (Unless otherwise marked) 13 BLK 13 BLK PROPEL PEDAL POSITION SENSOR GND 42 U2 HALL PIN J6-34 31 PROPEL EFFECT POWER SIGNAL SENSOR 14 FORWARD X PIN J6-22 42 42 35 REVERSE RIBBON CABLE CONNECTOR P6 TOUCH PANEL Wiring Color Codes SW6 PROPEL DIRECTION SWITCH LEFT SIDE DASH PANEL RIBBON CABLE Color of Wire Tan 0 1 Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 White = Battery Negative or Logic Ground = Battery Positive or Positive Output = Output that can Change Polarity 14 - PIN J10-1 MTR1B BRAKE SOLENOID Right Most Digit of Wire Number POST J7 NEG 14 Indicates Component is Energized 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 42 PIN J6-35 14 14 FOR WA RD DIRECTIONAL SWITCH REV E RS E RIGHT SIDE DASH PANEL Typical Propel Motor Current Draw: 1 to 20 Amps in motion, higher at start-up i Propel Motor Voltage: 0 to 24 VDC - FORWARD Approx. 0 to 17 VDC - REVERSE Propel Motor is controlled by PWM (Pulse Width Modulation) The Propel Pedal Position HALL EFFECT Sensor sends a varying voltage signal (1 to 4 Volts) to control board, based upon position of the propel pedal T7 – Propel Reverse System CONDITIONS: key ON, operator on seat, propel pedal depressed 1 RED 6 VDC + - + 6 VDC - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 S1 5 5 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 M1A PIN J6-17 6 3 3 4 4 50 RED SW1 LOGIC GROUND D1 6 42 PIN J6-5 27 GRN PIN J6-7 26 27 SW2 SEAT SWITCH 26 PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED NOTE: Refer to the “Propel/Brake Diagnostics” page for more information 24 24 WHT 25 BLK MTR1A 14 PIN J6-13 POST J11 + POS PIN J10-2 PROPEL MOTOR 25 NOTE: Brake Solenoid is energized to release parking brake. 14 REVERSE 25 15 15 - PIN J6-27 13 BLK FORWARD X PIN J6-22 Wiring Color Codes (Unless otherwise marked) 42 42 35 REVERSE RIBBON CABLE CONNECTOR P6 TOUCH PANEL 13 BLK PROPEL PEDAL POSITION SENSOR GND 42 U2 HALL PIN J6-34 31 PROPEL EFFECT POWER SIGNAL SENSOR 14 PIN J10-1 MTR1B BRAKE SOLENOID Right Most Digit of Wire Number POST J7 NEG 14 Indicates Component is Energized 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 42 PIN J6-35 SW6 PROPEL DIRECTION SWITCH LEFT SIDE DASH PANEL RIBBON CABLE Color of Wire Tan 0 1 Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 White = Battery Negative or Logic Ground = Battery Positive or Positive Output = Output that can Change Polarity 14 14 FOR WA RD DIRECTIONAL SWITCH REV E RS E RIGHT SIDE DASH PANEL Typical Propel Motor Current Draw: 1 to 20 Amps in motion, higher at start-up i Propel Motor Voltage: 0 to 24 VDC - FORWARD Approx. 0 to 17 VDC - REVERSE Propel Motor is controlled by PWM (Pulse Width Modulation) The Propel Pedal Position HALL EFFECT Sensor sends a varying voltage signal (1 to 4 Volts) to control board, based upon position of the propel pedal 15 T7 – Braking System CONDITIONS: key ON, operator on seat, brake pedal depressed 1 RED 6 VDC + - + 6 VDC - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 S1 5 5 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 M1A 42 PIN J6-17 PIN J6-35 D1 6 6 3 3 42 PIN J6-5 27 GRN 4 4 50 RED SW1 PIN J6-7 26 27 SW2 SEAT SWITCH 26 PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED NOTE: Refer to the “Propel/Brake Diagnostics” page for more information 14 24 WHT MTR1A 25 BLK 24 PIN J6-13 POST J11 + POS POST J7 NEG PIN J10-2 PROPEL MOTOR NOTE: Brake Solenoid is DEenergized to apply parking brake. Dynamic Braking will occur before Brake Solenoid is de-energized. 25 25 15 14 15 - 13 BLK 13 BLK BRAKE PEDAL POSITION SENSOR GND 42 U2 HALL PIN J6-33 32 BRAKE EFFECT POWER SIGNAL SENSOR 14 PIN J10-1 PIN J6-27 14 MTR1B BRAKE SOLENOID RIBBON CABLE CONNECTOR P6 TOUCH PANEL Indicates Component is Energized 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 LOGIC GROUND LEFT SIDE DASH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan 0 1 Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 White = Battery Negative or Logic Ground = Battery Positive or Positive Output 16 14 i 14 The brake pedal position HALL EFFECT sensor sends a varying voltage signal (1 to 4 Volts) to control board, based upon position of the brake pedal Brake Solenoid is DE-energized to apply brake. Dynamic Braking will occur before Brake Solenoid is de-energized. T7 – Scrub Head & Squeegee Actuator Systems (page 1 of 2) CONDITIONS: key ON, operator on seat, forward travel, propel pedal depressed, One Step Scrub Button pressed 1 RED 6 VDC + - 6 VDC + - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 5 5 PIN J6-17 PIN J6-35 S1 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 6 3 3 42 PIN J6-5 27 GRN 4 4 50 RED SW1 26 PIN J6-7 26 27 SW2 SEAT SWITCH PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED 18 17 17 MTR5 SQUEEGEE ACTUATOR NOTE: Actuator voltage switches polarity when direction of actuator travel changes (see next page for more information) 19 20 18 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 LOGIC GROUND D1 6 M1A 42 PIN J6-13 POST J11 + POS POST J7 NEG - 13 BLK 13 BLK PIN J6-12 PIN J6-9 19 PIN J6-23 MTR6 SCRUB HEAD ACTUATOR 20 PIN J6-21 RIBBON CABLE CONNECTOR P6 Indicates Component is Energized Vacuum Fan/ Squeegee Button One Step Scrub Button Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number 0 1 TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE Color of Wire Tan Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 White = Battery Negative or Logic Ground = Battery Positive or Positive Output = Output that can Change Polarity Pressing the “One Step Scrub Button” will lower the squeegee and scrub head i Only one actuator will be energized at any given time – squeegee is lowered first, then the scrub head Squeegee actuator uses internal limit switches to stop travel in upward and downward travel Scrub head actuator travel is controlled by monitoring actuator current in upward travel and brush motor current in downward travel Squeegee actuator can also be operated by pressing the “Vacuum Fan/ Squeegee Button”, without operating scrub brushes 17 T7 – Scrub Head & Squeegee Actuator Systems (page 2 of 2) Actuator Voltage Data Actuator Travel Direction Wire # DOWN Squeegee UP DOWN Scrub Head UP Color Polarity 17 Purple 18 Gray 17 Purple 18 Gray 19 White 20 Tan 19 White 20 Tan − "+" "+" − − "+" "+" − Notes Voltage at actuator connector will be approx. 24 VDC for 2 seconds, then approx. 12 VDC for 2 seconds for both UP & DOWN travel Voltage at actuator connector will be approx. 24 VDC for 4 seconds Voltage at actuator connector will be approx. 24 VDC for 4 seconds, then approx. 11 to 12 VDC for 2 to 4 seconds Pressing the “One Step Scrub Button” will lower the squeegee and scrub head i Only one actuator will be energized at any given time – squeegee is lowered first, then the scrub head Squeegee actuator uses internal limit switches to stop travel in upward and downward travel Scrub head actuator travel is controlled by monitoring actuator current in upward travel and brush motor current in downward travel Squeegee actuator can also be operated by pressing the “Vacuum Fan/ Squeegee Button”, without operating scrub brushes 18 T7 – Scrub Brush Motors System CONDITIONS: key ON, operator on seat, forward travel, propel pedal depressed, One Step Scrub Button pressed 1 RED 6 VDC + - 6 VDC + - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 5 5 PIN J6-17 PIN J6-35 S1 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 6 3 3 42 PIN J6-5 27 GRN 4 4 50 RED SW1 26 PIN J6-7 26 27 SW2 SEAT SWITCH PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED 8 MTR2 7 7 LEFT SCRUB BRUSH MOTOR 10 9 8 9 MTR3 RIGHT SCRUB BRUSH MOTOR 10 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 LOGIC GROUND D1 6 M1A 42 PIN J6-13 POST J11 + POS POST J7 NEG - 13 BLK 13 BLK PIN J8-1 PIN J8-2 PIN J8-3 PIN J8-4 RIBBON CABLE CONNECTOR P6 Brush Pressure Buttons Indicates Component is Energized One Step Scrub Button TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number 0 1 Color of Wire Tan Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray 9 White = Battery Negative or Logic Ground i Brush Motor Current Draw: Approx. 10 to 20 Amps per motor, varying upon selected brush pressure setting Brush Motor Voltage: Approx. 18 VDC in Economy Mode Approx. 21.5 VDC in All Other Modes Scrub Brush Motors are controlled by PWM (Pulse Width Modulation) Pressing the “One Step Scrub Button” will turn on the Scrub Brush Motors (after lowering squeegee and scrub head) Scrub Brush Motors will function only when propelling either forward or reverse Scrub Brush Pressure is controlled by monitoring brush motor current = Battery Positive or Positive Output 19 T7 – Vacuum Fan System CONDITIONS: key ON, operator on seat, forward travel, One Step Scrub Button pressed 1 RED 6 VDC + - 6 VDC + - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 5 5 PIN J6-17 PIN J6-35 S1 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 6 3 3 42 PIN J6-5 27 GRN 4 4 50 RED SW1 26 PIN J6-7 26 27 SW2 SEAT SWITCH PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 50 RED 50 RED 12 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 LOGIC GROUND D1 6 M1A 42 PIN J6-13 POST J11 + POS POST J7 NEG - 13 BLK 13 BLK 11 11 PIN J9-1 MTR4 VACUUM FAN 12 PIN J9-2 RIBBON CABLE CONNECTOR P6 Vacuum Fan/ Squeegee Button Indicates Component is Energized One Step Scrub Button TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number 0 1 Color of Wire Tan Pink 2 Brown 3 Orange 4 Yellow 5 Green Vacuum Fan Motor Current Draw: Approx. 18 to 21 Amps Vacuum Fan Motor Voltage: Approx. 18 VDC in Economy Mode Approx. 21.5 VDC in All Other Modes 6 Blue 7 Purple 8 Gray Pressing the “One Step Scrub Button” will activate Vacuum Fan 9 White Vacuum Fan can also be operated by pressing the “Vacuum Fan/Squeegee Button”, without operating scrub brushes = Battery Negative or Logic Ground = Battery Positive or Positive Output 20 i Vacuum Fan Motor is controlled by PWM (Pulse Width Modulation) T7 – FaST System CONDITIONS: key ON, operator on seat, forward travel, propel pedal depressed, One Step Scrub Button pressed 1 RED 6 VDC + - 6 VDC + - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 5 5 PIN J6-17 PIN J6-35 S1 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 6 3 3 42 PIN J6-5 27 GRN 4 4 50 RED SW1 26 PIN J6-7 26 27 SW2 SEAT SWITCH PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 LOGIC GROUND D1 6 M1A 42 PIN J6-13 14 50 RED 50 RED 14 MTR7 22 22 POST J11 + POS POST J7 NEG - 13 BLK 13 BLK PIN J6-25 FaST PUMP MOTOR RIBBON CABLE CONNECTOR P6 FaST Button Indicates Component is Energized One Step Scrub Button TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number 0 1 Color of Wire Tan Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray FaST system will operate ONLY if FaST LED is ON 9 White Solution Volume Control Buttons will NOT operate & Solution Volume Control LED’s will be OFF during FaST scrubbing = Battery Negative or Logic Ground i Pressing the “One Step Scrub Button” will activate FaST Pump Motor OR Solution Solenoid Valve as Scrub Brush Motors engage Pressing the FaST button will toggle from FaST scrubbing to Conventional scrubbing = Battery Positive or Positive Output 21 T7 – Conventional Solution System CONDITIONS: key ON, operator on seat, forward travel, propel pedal depressed, One Step Scrub Button pressed 1 RED 6 VDC + - + 6 VDC - + 6 VDC - + 6 VDC - 13 BLK STANDOFF 4 X v 1 RED M1B 2 v 1 RED 4 CB1 5A D3 2 5 5 PIN J6-17 PIN J6-35 S1 MAIN CONTACTOR 4 F1 100 A CONTROL BOARD EMERGENCY STOP SWITCH 5 4 M1A 6 3 3 4 4 50 RED SW1 LOGIC GROUND D1 6 42 PIN J6-5 27 GRN 26 PIN J6-7 26 27 SW2 SEAT SWITCH PIN J6-6 CHARGER INTERLOCK 2 14 14 CB2 15 A 32 ORG PIN J6-24 KEYSWITCH X STANDOFF 2 42 PIN J6-13 14 50 RED 50 RED POST J11 + POS POST J7 NEG - 13 BLK 13 BLK SOL2 14 16 16 PIN J6-4 SOLUTION SOLENOID VALVE RIBBON CABLE CONNECTOR P6 Solution Volume Control Buttons Indicates Component is Energized One Step Scrub Button TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number 0 1 Color of Wire Tan Pink 2 Brown 3 Orange 4 Yellow 5 Green 6 Blue 7 Purple 8 Gray Conventional Solution system will operate ONLY if FaST LED is OFF 9 White Solution Volume Control Buttons & LED’s will operate ONLY during Conventional scrubbing = Battery Negative or Logic Ground = Battery Positive or Positive Output 22 i Pressing the “One Step Scrub Button” will activate FaST Pump Motor OR Solution Solenoid Valve as Scrub Brush Motors engage Pressing the FaST button will toggle from FaST scrubbing to Conventional scrubbing T7 – LED Locations & Descriptions 23 T7 – Operational Modes & Interlocks Mode Entry Sequence Indicator Function −Directional Switch Forward −Directional Switch in Forward position Forward Forward movement of machine −Propel Pedal Depressed −Directional Switch Reverse −Directional Switch in Reverse position −Propel Pedal Depressed −Horn Sounding continuously ON & OFF (except in "Hospital" mode) Reverse Scrub Mode FaST Mode −Press One Step Scrub Button −One Step Scrub LED ON (ON) −Press One Step Scrub Button −One Step Scrub & FaST LED's ON (ON) −Press FaST Button (ON) −Press One Step Scrub Button Conventional (ON) Solution Mode −Press FaST Button (OFF) −One Step Scrub & Solution Flow LED(s) ON −FaST LED OFF Double Scrub (no water pickup) −Press One Step Scrub Button −One Step Scrub LED ON (ON) −Press Vacuum Fan/Squeegee −Vacuum Fan/Squeege LED OFF Button (OFF) Water pickup (no Scrub) −Press Vacuum Fan/Squeegee Button (ON) Low Power Mode −Press Brush Pressure Decrease (-) to one LED −Press Solution Flow Decrease (-) to one LED −Press Brush Pressure Low Power Decrease (-) to one LED Mode w/ FaST −Press FaST Button (ON) Solution Tank −Solution Tank Empty (Float Switch Open) Empty Recovery Tank −Recovery Tank Full (Float Switch Closed) Full Battery Discharged Accessory Motor High Current Fault 24 −Solution Flow LED's OFF −One Step Scrub LED OFF −Vacuum Fan/Squeegee LED ON −Lower Brush Pressure (#1) LED ON; Middle (#2) & Upper (#3) LED's OFF −Lower Solution Flow (#1) LED ON; Middle (#2) & Upper (#3) LED's OFF −Lower Brush Pressure (#1) LED ON; Middle (#2) & Upper (#3) LED's OFF −FaST LED ON (Solution Flow LED's OFF) Reverse movement of machine Activate Scrub Brush, Squeegee, Vacuum Fan & Solution Flow operations Activate FaST foam solution flow when scrub and propel are engaged Activate Conventional solution flow when scrub and propel are engaged Apply cleaning solution with no water pickup Collect solution on floor with squeegee, without scrubbing floor Reduce Scrub Brush and Fan speeds (to prolong battery life, reduce noise, lower water usage) Reduce Scrub Brush and Fan speeds (to prolong battery life, reduce noise, lower water usage) −Solution Tank Empty LED ON Disable Scrub function (Operator can get an additional minute of operation by re-engaging scrub system with One Step button) −Recovery Tank Full LED ON Disable Scrub function (Operator can get an additional minute of operation by re-engaging scrub system with One Step button) −Battery voltage at or below full −Red LED (on Battery Gauge) blinking discharge voltage Disable Scrub function (Operator can get an additional minute of operation by re-engaging scrub system with One Step button) −Fault LED ON and any one or more of the −Controller sensed an Over following: Prevent damage to Scrub Brush Current condition in the Lower Brush Pressure (#1) LED ON (Right Motor) Motors or Vacuum Fan Motor – Scrub Brush Motors or Scrub function shuts off Upper Brush Pressure (#3) LED ON (Left Motor) Vacuum Fan Motor Upper Solution Flow (#3) LED ON (Vacuum Fan) T7 – Diagnostic & Fault Alarms Alarm Codes Directional Switch Mode Back-Up Alarm REVERSE Propel Interlock: Seat Switch Released FORWARD Propel interlock: High Pedal Disable Propel Interlock: Throttle Fault Propel Interlock: Parking Brake Fault Entry Sequence Alarm Sequence Directional switch placed in REVERSE Propel Pedal depressed with operator NOT on seat Key switch turned ON FORWARD with Propel Pedal engaged Controller sensed FORWARD an out-of range Throttle signal FORWARD Function Horn sounds 1 beep cycle (repeats) Alerts nearby persons of machine backward movement (Note: Backup alarm will not sound when machine is placed in "Hospital" mode) Horn sounds 2 beep cycle (repeats) Prevents movement of machine when operator not in place Horn sounds 4 beep cycle (repeats) Horn sounds 5 beep cycle (repeats) (Also FAULT and FaST LED's blink) Controller sensed an out- Horn sounds 6 beep cycle (repeats) of range (Also FAULT and Vacuum Fan/ Brake signal Squeegee LED's blink) Prevents movement of machine when key switched ON while throttle depressed Prevents movement of machine with invalid throttle voltage. Scrub function shuts off. Prevents movement of machine with invalid brake voltage. Scrub function shuts off. Propel Interlock: FORWARD Parking Brake Unplugged Controller sensed open Horn sounds 7 beep cycle (repeats) circuit on parking brake (Also FAULT and Lower Solution Flow LED's blink) Prevents movement of machine with ineffective parking brake. Scrub function shuts off. Propel Interlock: FORWARD E-STOP Switch Activated Controller sensed open Horn sounds 8 beep cycle (repeats) circuit on Emergency (When in Input Display Mode, FAULT Stop Switch circuit LED will also blink) Disables all functions (Note: To reset, key switch must be cycled OFF and ON after the E-STOP switch has closed) Battery charger plugged into machine with Horn sounds 9 beep cycle (repeats) Key Switch ON Prevents movement of the machine with charger plugged in Propel Interlock: Charger Plugged In FORWARD High Current Faults Fault Entry Sequence Indicator Excessive Propel Motor Current Propel Motor Current Higher than 40 Amps for 15 min. OR Higher than 55 Amps for 6 min. OR Higher than 68 Amps for 4 min. Blinking FAULT LED, Propel disabled Excessive Left Brush Motor Current Left brush motor current higher than 30 Amps Blinking FAULT LED, Blinking Brush Pressure LED #3 Excessive Right Brush Motor Current Right brush motor current higher than 30 Amps Blinking FAULT LED, Blinking Brush Pressure LED #1 Excessive Vacuum Fan Motor Current Vacuum Fan Motor current higher than 27 Amps Blinking FAULT LED, Blinking Vacuum Fan/Squeegee LED 25 T7 – Diagnostic & Configuration Modes Mode 26 Entry Sequence Indicator Function Upper Brush Pressure LED blinks Tens of days of month, Upper Solution Flow LED blinks Single day of month Display Software Revision Mode Press and hold One Step Button, turn key switch ON, wait 10 seconds, release One Step Button Self Test Mode Press and hold FaST and Vacuum Fan/Squeegee Buttons, turn key switch ON, wait 10 seconds, release buttons Start of test - Left Scrub Brush turns ON End of test - Horn sounds Solid lit One Step LED indicates OK, A Flashing LED indicates an OPEN Fault, A Solid lit LED (other than One Step) indicates a SHORT Fault Input Display Mode Press and hold Decrease Solution Flow (-) Button, turn key switch ON, release button after forth battery LED starts to blink Fourth battery LED blinks Shows state of control board inputs from various switches and sensors Manual Mode Press and hold Decrease Brush Pressure (-) Button, turn key switch ON, release after Lowest Brush Pressure LED starts to blink. Lowest down pressure LED will blink Allows operation of individual functions without the safety interlocks affecting or controlling them Propel/Brake Diagnostic Mode FaST LED ON if in Forward OR Vacuum Press and hold FaST Fan/Squeegee LED ON if in Reverse and Increase Brush Solution Flow LED's display position of Pressure (+) Buttons, turn Propel Pedal, Brush Pressure LED's display key switch ON, release after position of Brake Pedal, Battery LED's battery LED's are OFF display Propel Motor current level Provides information regarding brake pedal signal, propel pedal signal, and propel motor current Battery Select Mode Press and hold the Increase Solution Flow (+) Button, turn key switch ON, release after one Battery LED starts to blink Any one of lower 4 battery LED’s blinks Allows selection of battery type. See “Battery Select Mode Settings” table. Reverse Alarm Select Mode Put directional switch in Reverse, press & hold Horn Button, turn key switch ON Horn sounds or is silent Allows enable/disable of Backup alarm (Hospital Mode) Propel Speed Selection Mode Press and hold FaST Button, turn key switch ON, Brush Pressure Lower, Middle, and Upper release after selecting LED’s represents LOW, MEDIUM and HIGH desired Brush Pressure LED maximum Forward Propel Speed selection setting Middle Brush Pressure LED blinks Tens of month, Middle Solution Flow LED blinks Single month Blinking Brush Pressure and Solution Flow LED’s indicate revision date Lower Brush Pressure LED blinks Tens of year, Lower Solution Flow LED blinks out Single year Allows selection of maximum forward speed during scrubbing LOWER (#1) LED = 2.0 mph / 3.2 kph MIDDLE (#2) LED = 2.7 mph / 4.3 kph UPPER (#3) LED = 3.5 mph / 5.5 kph T7 – Display Software Revision Mode TO ENTER: • Press and hold One Step Button • Turn key switch ON, wait 10 seconds • Release One Step Button READING THE SOFTWARE REVISION: •Upper Brush Pressure LED blinks TENS of DAYS of MONTH, Upper Solution Flow LED blinks SINGLE DAY of MONTH •Middle Brush Pressure LED blinks TENS of MONTH, Middle Solution Flow LED blinks SINGLE MONTH •Lower Brush Pressure LED blinks TENS of YEAR, Lower Solution Flow LED blinks SINGLE YEAR Brush Pressure LED's # of Blinks Solution Flow LED's # of Blinks Day # 3 (Upper) 2 # 3 (Upper) 6 Month # 2 (Middle) 1 # 2 (Middle) 1 Year # 1 (Lower) 0 (LED OFF) # 1 (Lower) 4 TOUCH PANEL One Step Scrub Button Revision Date 26th November 2004 LEFT SIDE DASH PANEL NOTE: An LED that does NOT blink is the digit ZERO (0) Brush Pressure Increase Button LED 2 MONTH LED 2 LED 1 YEAR LED 1 Solution Flow Increase Button LED 3 DAY LED 3 Brush Pressure Decrease Button + + Solution Flow Decrease Button ONES TENS - - = BLINKING (except if zero) 27 T7 – Self Test Mode TO ENTER: • Press and hold FaST & Vacuum Fan/Squeegee Buttons • Turn key switch ON, wait 10 seconds • Release Buttons • The entire Self Test takes approximately 40 seconds AFTER THE SELF TEST IS COMPLETE: • If the One Step LED is lit solid, NO FAULTS were found • If any LED is blinking, an OPEN FAULT was found – refer to table below • If any LED (other than One Step) is lit solid, a SHORT FAULT was found – refer to table below Self Test Results 28 LED (Flashing = OPEN, Solid = SHORT) System at Fault One Step LED FaST LED Vacuum Fan/Squeegee LED # 3 (Upper) Brush Pressure LED # 2 (Middle) Brush Pressure LED # 1 (Lower) Brush Pressure LED # 3 (Upper) Solution Flow LED # 2 (Middle) Solution Flow LED # 1 (Lower) Solution Flow LED Recovery Tank Full LED No Faults Found Fast Pump Vacuum-Fan Right Brush Left Brush Head Actuator Water Valve Squeegee Actuator Brake Horn/Back-up Alarm Solution Tank Empty LED Solution Tank Float Switch # 1 (Lower) Solution Flow LED # 2 (Middle) Solution Flow LED # 3 (Upper) Solution Flow LED Right Scrub Brush Low Pressure Medium Pressure High Pressure LOW scrub brush current sensed MEDIUM scrub brush current sensed HIGH scrub brush current sensed Scrub system IS NOT ACTIVATED Scrub system IS NOT ACTIVATED Battery has sufficient charge level Battery needs charging (LED is BLINKING) LOW scrub brush current sensed MEDIUM scrub brush current sensed HIGH scrub brush current sensed Vacuum Fan & Squeegee ARE NOT ACTIVATED Scrub system IS NOT ACTIVATED Vacuum Fan & Squeegee ARE ACTIVATED Scrub system IS ACTIVATED NOTE: For Propel & Brake signal troubleshooting, refer to the Propel Diagnostics Mode page # 1 (Lower) Brush Pressure LED # 2 (Middle) Brush Pressure LED # 3 (Upper) Brush Pressure LED # 1 (Red) Battery LED Vacuum Fan/Squeegee LED One Step LED Left Scrub Brush Low Pressure Medium Pressure High Pressure Battery Voltage Vacuum Fan/Squeegee Button One Step Button NOTES FaST system will still operate, but without indicator Operator IS NOT sitting on seat (switch Operator IS sitting on Seat (switch is is OPEN) CLOSED) Recovery tank IS FULL (switch must be Recovery tank IS NOT FULL (switch Opening switch and pushing the the One Step CLOSED for 5 to 7 seconds after One is OPEN) Button turns LED off again Step Button is activated) Solution tank IS EMPTY (switch must be Solution tank IS NOT EMPTY Closing switch and pushing the the One Step OPEN for 5 to 7 seconds after One Step (switch is CLOSED) Button turns LED off again Button is activated) Emergency Stop Switch IS ACTIVATED Emergency Stop Switch IS NOT Horn will repeat 8 beep cycle when Emergency (switch is OPEN) ACTIVATED (switch is CLOSED) Stop Switch is activated LED IS OFF WHEN: Battery charger IS plugged in (switch is OPEN) LED IS ON WHEN: Battery charger IS NOT plugged in (switch is CLOSED) • Press and hold the Decrease Solution Flow (-) Button • Turn key switch ON • Release Button after the # 4 Battery LED blinks Fault Indicator LED (Blinking) Recovery Tank Full LED Recovery Tank Float Switch Emergency Stop Switch # 5 (Green) Battery LED FaST LED Charger Interlock Switch Seat Switch ASSOCIATED LED INPUT TO ENTER: The purpose of the Input Display Mode is to show the condition of various control board inputs T7 – Input Display Mode 29 30 One Step LED ON INDICATOR NOTES Scrub head will continue to lower as long as button is held Press & Release Press & Release Release button after lowering scrub head Scrub head raises to to top of stroke and stops In this mode, pressing the One Step Button during lowering of the squeegee will stop squeegee travel Vacuum Fan/ Squeegee LED ON Scrub head stops lowering after One Step Button is released One Step LED OFF One Step LED ON Press & Release Press & Release Press & Release Press & Release Press & Release ADDITIONAL NOTES Solution Flow LED's Solution Flow LED's FaST LED OFF FaST LED ON Vacuum Fan/ Squeegee LED OFF In this mode, the Solution Flow automatic ON/OFF interlock is disabled In this mode, the Solution Flow automatic ON/OFF interlock is disabled In this mode, pressing the One Step Button during raising of the squeegee will stop squeegee travel • For safety considerations, the "High Pedal Disable" and "Seat Switch Disable" interlocks & alarms are still active in Manual Mode • With the Directional Switch in REVERSE, the Back-up Alarm will sound but automatic raising of the squeegee is disabled • If the Recovery Full LED or the Solution Empty LED is ON, and the Scrub System or Vacuum Fan/Squeegee system is activated, the Recovery Full LED and Solution Empty LED will turn OFF and the sensing of both switches will be disabled for about a minute • When the Solution Empty switch is un-grounded for a short time, the Solution Empty LED will light • When the Recovery Full switch is grounded for a short time, the Recovery Full LED will light Decrease Solution Flow (-) Decrease Solution Flow Rate FaST Turn OFF FaST pump Increase Solution Flow (+) FaST Turn ON FaST pump Increase Solution Flow Rate Vacuum Fan/ Squeegee Turn OFF Vacuum Fan and Raise Squeegee CAUTION : In this mode, automatic raising of the squeegee when in REVERSE is disabled Vacuum Fan/ Squeegee One Step Turn OFF Scrub Brushes and Raise Scrub Head Turn ON Vacuum Fan and Lower Squeegee One Step Operate Scrub Brushes ! Press & Hold ACTION CAUTION : Do not hold One Step Button down too long - actuator stall will occur, possibly damaging actuator or control board One Step Lower Scrub Head ! BUTTON • Press and hold the Decrease Brush Pressure (-) Button • Turn key switch ON • Release Button after # 1 (Lower) Brush Pressure LED blinks FUNCTION TO ENTER: The purpose of the Manual Mode is to allow functioning of the individual systems on the machine without regard of most safety interlocks T7 – Manual Mode T7 – Propel/Brake Diagnostics TO ENTER: • Press and hold FaST & Increase Brush Pressure (+) Buttons • Turn key switch ON • Release Buttons after FaST LED (if in Forward) or Vacuum Fan/Squeegee LED (if in Reverse) is lit TEST ACTION INDICATOR NOTES Directional Switch Forward Place Directional Switch in Forward Propel position FaST LED ON LED will be illuminated if the controller senses the Directional Switch in Forward Position - Machine will not propel if any of the Brake LED’s are illuminated Directional Switch Reverse Place Directional Switch in Vacuum Fan/ Reverse Propel position Squeegee LED ON LED will be illuminated if the controller senses the Directional Switch in Reverse Position - Machine will not propel if any of the Brake LED’s are illuminated Depress Brake Pedal Brush Pressure LED's LED’s will display the sensed position of the brake pedal - No LED’s indicate pedal is released, 3 LED’s indicate that the pedal is fully depressed Depress Accelerator Pedal Solution Flow LED's LED’s will display the sensed position of the accelerator pedal - No LED’s indicate the pedal is released, 3 LED’s indicate that the pedal is fully depressed Propel Motor Current Depress Accelerator Pedal Battery LED's Battery gauge LED’s display the current level being drawn by the Propel Motor - Each LED represents 7 Amps of current (ex: 3 LED's = 21 Amps) Brake Pedal Accelerator Pedal Propelling System Data Direction Forward Reverse Wire # Color Polarity Notes 25 Green 24 Yellow 25 Green 24 Yellow − "+" "+" − Voltage during FORWARD travel will vary Releasing the Propel Pedal will initiate between 0 to 24 VDC Dynamic Braking; As machine slows to a halt, the Brake solenoid is De-energized, Voltage during REVERSE travel will vary applying the Parking Brake between approximately 0 to 17 VDC Propel & Brake Pedal Data Pedal LED group Propel Solution Flow Brake Brush Pressure Lit LED's 0 1 2 3 0 1 2 3 Pedal Position Released Slightly Depressed Halfway Depressed Fully Depressed Released Slightly Depressed Halfway Depressed Fully Depressed Input Voltage Level below 1.35 VDC 1.35 to 1.89 VDC 1.89 to 2.27 VDC 2.27 to 4.0 VDC below 1.5 VDC 1.5 to 1.89 VDC 1.89 to 2.27 VDC 2.27 to 4.0 VDC Notes Machine must be in Propel Diagnostic Mode when testing; LED's will display the sensed position of the pedal; No LED's indicate pedal is released; 3 LED's indicate pedal is fully depressed 31 T7 – Battery Select Mode & Voltage Levels Battery Select Mode TO ENTER: • Press and hold Increase Solution Flow (+) Button • Turn key switch ON • Release Button after one of the Battery LED’s begins blinking BDI Indicator LED's Location / Type Worldwide / Wet R x x x x Europe** / Wet x Y x x x TNV** / Wet x x G x x Worldwide / Gel x x x G x LED's: R=RED Y=YELLOW G=GREEN x =OFF =BLINKING **Used only under instruction of battery manufacturer Voltage Levels* Battery Level Worldwide European** TNV** Worldwide Voltage (Wet) Voltage (Wet) Voltage (Wet) Voltage (Gel) BDI Indicator LED's Full Battery Voltage 24.5 24.5 24.5 24.5 R Y G G G Level 4 23.8 23.9 23.9 24.0 R Y G G x Level 3 23.1 23.2 23.3 23.5 R Y G x x Level 2 22.4 22.6 22.7 23.0 R Y x x x Level 1 21.7 21.9 22.1 22.6 R x x x x Full discharge 21.0 21.3 21.6 22.2 R x x x x LED's: R=RED Y=YELLOW G=GREEN x =OFF =BLINKING *Voltage measured at circuit board - Assume 0.5 Volts higher at batteries (under load) **Used only under instruction of battery manufacturer 32 T7 – Reverse Alarm & Propel Speed Select Modes Reverse Alarm Select Mode Reverse Alarm Select Mode allows enabling or disabling of the Backup Alarm TO ENTER: • Put directional switch in Reverse • Press & Hold Horn Button • Turn key switch ON • If Back-up Alarm is silent, Hospital (Quiet) Mode has been selected • If Back-up Alarm is sounding, Normal mode has been selected • Cycle key switch OFF, then ON again • Verify correct mode has been chosen Propel Speed Select Mode Propel Speed Select Mode allows selection of maximum forward speed during scrubbing TO ENTER: • Press and hold FaST Button • Turn key switch ON • Release Buttons after selecting desired Brush Pressure LED • Refer to table below for speed selection BRUSH PRESSURE LED MAXIMUM SCRUB SPEED # 1 (Lower) LED # 2 (Middle) LED # 3 (Upper) LED 2.0 mph / 3.2 kph 2.7 mph / 4.3 kph 3.5 mph / 5.5 kph 33 34 Outputs E Dynamic Braking Force - Increase D D D E E E E E Squeegee Down FaST System Solution Solenoid Hour Meter Operation Horn D D D D D D E D D D D E E E E E E* E E D D D D D D D D D D E** E D E E = Input that will ENABLE Output D = Input that will DISABLE Output * Activating Vacuum Fan OR Propelling machine will enable the Hour Meter ** Horn will sound when Directional Switch is selected for Reverse (except in Hospital Mode) *** Parking Brake activated after timer has expired E D E Vacuum Motor Battery Gauge Reset D E D E Scrub Head Pressure Control Scrub Motors E E E Propel Reverse E D E E Propel Forward D D E Parking Brake Inputs Charger Solution Recovery Vacuum Switch Directional Seat Switch Emergency Key Switch Tank Full Tank Empty One Step FaST Switch Fan/ Switch (Operator on (Charger Stop Switch (ON) Switch (ON) (ON) Squeegee Switch (Tank Switch (Tank plugged in to (Pressed) Forward seat) Full) Empty) Switch (ON) machine) Main Contactor Inputs and the Outputs they Control D E** D Directional Switch Reverse E* E E E D E E D D D E*** E D D E Throttle Brake Input Horn Button Input (Pedal (Pedal (Pressed) pressed) pressed) T7 – Inputs & Outputs Table Torque Standard Inch Fasteners Thread Size SAE Grade 1 SAE Grade 2 Carriage Bolts Thread Cutting Thread Rolling SAE Grade 5 Socket and Stainless Steel SAE Grade 8 Headless Socket Set Screws Square Head Set Screws 4 (.112) (5) -- (6.5) (4) -- (6) 5 (.125) (6) -- (8) (9) -- (11) 6 (.138) (7) -- (9) (20) -- (24) (9) -- (11) 8 (.164) (12) -- (16) (40) -- (47) (17) -- (23) 10 (.190) (20) -- (26) (50) -- (60) (31) -- (41) 1/4 (.250) 4-- 5 5-- 6 7-- 10 7-- 10 10-- 13 6-- 8 17-- 19 5/16 (.312) 7-- 9 9-- 12 15-- 20 15-- 20 20-- 26 13-- 15 32-- 38 3/8 (.375) 13-- 17 16-- 21 27-- 35 36-- 47 22-- 26 65-- 75 7/16 (.438) 20-- 26 26-- 34 43-- 56 53-- 76 33-- 39 106-- 124 1/2 (.500) 27-- 35 39-- 51 65-- 85 89-- 116 48-- 56 162-- 188 5/8 (.625) 80-- 104 130-- 170 171-- 265 228-- 383 3/4 (.750) 129-- 168 215-- 280 313-- 407 592-- 688 1 (1.000) 258-- 335 500-- 650 757-- 984 1281-- 1489 I N C H P O N U D S F O O T P O U N D S Torque Foot Pounds (Inch Pounds) Zinc Plated Fasteners and Torque Control (10---90) 35 Torque Standard Inch Fasteners Mechanical Properties Fastener Identification Type Material SAE Grade 1 Machine Screws Low or Medium Carbon Steel SAE Grade 2 Carriage Bolts Low or Medium Carbon Steel Stainless Steel 18-- 8 Austenitic Stainless Steel SAE Grade 5 Socket Screws SAE Grade 8 Medium Carbon Steel Quenched Tempered Medium Carbon Alloy Quenched Tempered Proof Load (PSI) Yield Strength Min (PSI) #2 Thru #10 Tensile Strength Min (PSI) 55,000 1/4 Thru 1 1/2 33,000 36,000 60,000 1/4 Thru 3/4 55,000 57,000 74,000 Over 3/4 Thru 1 1/2 33,000 36,000 60,000 50,000 90,000 1/4 Thru 1 85,000 92,000 120,000 Over 1 to 1 1/2 74,000 81,000 105,000 High Carbon Alloy Steel Quenched Tempered Fasteners and Torque Control (10---90) 36 Nominal Size 136,000 1/4 Thru 1 1/2 120,000 160,000 130,000 150,000 Torque Standard METRIC Fasteners Thread Size M3 M4 M5 4.8/5.6 8.8 Stainless Steel 10.9 Set Screws 12.9 N 43-- 56 Ncm 99-- 128 Ncm 139-- 180 Ncm 166-- 215 Ncm 61-- 79 Ncm E W T 99-- 128 Ncm 223-- 290 Ncm 316-- 410 Ncm 381-- 495 Ncm 219-- 285 Ncm O N 193-- 250 Ncm 443-- 575 Ncm 624-- 810 Ncm 747-- 970 Ncm 427-- 554 Ncm M6 3.3-- 4.3 Nm 7.6-- 9.9 Nm 10.8-- 14 Nm 12.7-- 16.5 Nm 7.5-- 9.8 Nm M8 8.1-- 10.5 Nm 18.5-- 24 Nm 26.2-- 34 Nm 31-- 40 Nm M10 16-- 21 Nm 37-- 48 Nm 52-- 67 Nm 63-- 81 Nm M12 28-- 36 Nm 64-- 83 Nm 90-- 117 Nm 108-- 140 Nm M14 45-- 58 Nm 102-- 132 Nm 142-- 185 Nm 169-- 220 Nm M16 68-- 88 Nm 154-- 200 Nm 219-- 285 Nm 262-- 340 Nm M20 132-- 171 Nm 300-- 390 Nm 424-- 550 Nm 508-- 660 Nm M22 177-- 230 Nm 409-- 530 Nm 574-- 745 Nm 686-- 890 Nm M24 227-- 295 Nm 520-- 675 Nm 732-- 950 Nm 879-- 1140 Nm 18.3-- 23.7 Nm C E N T I M E T E R S N E W T O N M E T E R S Zinc Plated Conversion Tables Ncm to Inch Pound x 0.08851 Nm to Foot Pound x 0.7376 Inch Pound to Ncm x 11.2982 Foot Pound to Nm x 1.3558 Fasteners and Torque Control (10---90) 37 Torque Standard METRIC Fasteners Mechanical Properties Fastener Identification Type 8.8 A 10.9 Material 3.6/4.6 Carriage Bolts Low or Medium Carbon Steel 190 (27,550 PSI) 240 (34,800 PSI) 330 (47,850 PSI) 400 (58,000 PSI) 4.8 Pan Head Machine Screws Low or Medium Carbon Steel 340 (49,300 PSI) 420 (60,900 PSI) Austenitic Stainless Steel 450 (65,300 PSI) 700 (101,000 PSI) Stainless Steel 8.8 Hex Head (Grade 5) Medium Carbon Steel Quenched Tempered 10.9 Hex Head Flat Head (Grade 8) Medium Carbon Steel Quenched Tempered 12.9 Socket Head Alloy Steel < M16 640 800 (92,800 PSI) (116,000 PSI) > M16 660 830 (95,700 PSI) (120,350 PSI) 12.9 Conversion Table Mega Pascals to Pounds per Square Inch x 145.138 Fasteners and Torque Control (1---01) 38 Tensile Strength (Min) MPa Class A2-- 70 A2--- 70 Yield Point .2% Elongati (Min) MPa Nominal Yield Stress Size (Min) MPa 940 1040 (136,300 PSI) (150,800 PSI) 1100 1220 (159,500 PSI) (176,900 PSI) Torque Standard Nylon Insert Lock Nuts Nut-Hex Light THIN (Cad or Zinc Plated) Size Grade 2 Bolt Grade 5 Bolt 1/4---20 5---8 7---8 1/4---28 4---6 5---6 5/16---18 8---14 13---14 5/16---24 9---14 13---14 3/8---16 12---18 15---18 3/8---24 12---18 16---18 1/2---13 26---40 37---40 1/2---20 27---42 41---42 5/8---11 58---89 73---89 5/8---18 60---92 82---92 Torque in Foot Pounds Fasteners and Torque Control (10---90) 39 Torque Standard Wheel Bolt and Nuts Stud or Bolt Size and Thread Recommended Torque in Foot Pounds 7/16---20 75---85 1/2---20 75---85 9/16---18 80---90 5/8---18 140---170 Wheel Bearing Adjustment 1. Tighten the spindle nut to 12 ft lbs while turning the wheel assembly forward by hand to fully seat the bearings. 2. Back off the nut to the “just loose” position. 3. Hand tighten the spindle nut. Loosen the spindle nut until either hole in the spindle lines up with a slot in the nut. (Not more than 1/2 flat.) 4. Install the cotter pin. Bend the ends of the cotter pin against the nut, cut off extra length to ensure ends will not interfere with the dust cap. Fasteners and Torque Control (10---90) 40 Tightening Nuts on Tapered Shafts Example of recommended torque. +.0010 +0,025 .3730 -- .00000 /9,474 -- 0 1”-- 20 UNEF-- 2B SLOTTED KEY WIDTH HEX LOCKNUT PER SAE J-- 501 (EXCEPT 1.50/38,1 ACROSS FLATS). RECOMMENDED TOQUE TO 175 FT LB PLUS TORQUE REQUIRED TO ALIGN SLOTTED NUT TO SHAFT HOLE 2.27/57,7 CLEARANCE DIA. .156 3,96 P SHAFT DIA. DIA. THRU 1.500 + .002 TAPER PER FOOT/125 + 0,17 MM TAPER PER METER .750 + .010 19,05 + 0,25 1.890 48,01 3.00 76,2 Check with the manufacturer to see what the recommended maximum torque is. Tighten the slotted nut to a lower torque, and then tighten the nut to align the cotter pin hole with the slot on the nut. Do not exceed the recommended torque. Do not back off the nut to align the holes. Motor Tapered Shaft Nut Info. Torque Specification Recommendations A&H Series 1.00 dia. .75--16 UNF 1.107 Hex 150 ft lb dry 125 ft lb lubricated Plus torque to align for pin 2000 Series 1.25 dia. 1--20 UNEF 1.44 Hex 225 ft lb dry 225 ft lb lubricated PLUS torque to align for pin 4000 Series 1.625 dia. 1.25--18 UNEF 2.187 Hex 475 ft lb dry 375 ft lb lubricated PLUS torque to align for pin 6000 Series 1.75 dia. 1.25--18 UNEF 2.187 Hex 475 ft lb dry 375 ft lb lubricated PLUS torque to align for pin Fasteners and Torque Control (10---90) 41 Torque Standard Shoulder Bolts Nominal Diameter Thread Size Recommended Seating Torque .250 10 -- 24 45 In Lbs .312 1/4-- 20 9 Ft Lbs .375 5/16-- 18 19 Ft lbs .500 3/8-- 16 32 Ft Lbs .625 1/2-- 13 82 Ft Lbs .750 5/8 -- 11 164 Ft Lbs Metric Nominal Diameter Thread Size Recommended Seating Torque 6 M5x0.8 7 Nm 8 M6x1.0 12 Nm 10 M8x1.25 29 Nm 12 M10x1.5 57 Nm 16 M12x1.75 100 Nm Fasteners and Torque Control (10---90) 42 Taper Lockr Bushings IMPORTANT: Follow all these instructions carefully. This is necessary to insure satisfactory performance. C C 1008 to 3030 To Install 1. Clean shaft, bore and outside of bushing, and hub bore of all oil, lacquer, and dirt. 2. Insert bushing in hub. Match the hole pattern, not threaded holes (each hole will be threaded on one side only). 3. Oil setscrews and thread into those half threaded holes indicated by C on above diagram. 4. Alternately torque setscrews to recommended torque setting in chart below. 5. Using a block, sleeve, or drift, hammer large end of bushing (do not hammer bushing directly). 6. Repeat steps 4 and 5 until torque wrench reading after hammering is the same as before hammering. 7. Fill all unoccupied holes with grease. To Remove 1. Remove all setscrews. 2. Insert setscrews in holes indicated by D on the diagram. Loosen bushing by alternately tightening setscrews. 3. To reinstall, complete all seven (7) steps installation steps. Recommended Wrench Torque Wrench Torque Bushing No. Screws (Pound-Inch) 1008, 1108 1210, 1215, 1310 1610, 1615 2012 2517, 2525 3020, 3030 1/4” Setscrews 3/8” Setscrews 3/8” Setscrews 7/16” Setscrews 1/2” Setscrews 5/8” Setscrews 55 175 175 280 430 800 Hammer Size 6 lb 6 lb 6 lb 6 lb 6 lb 6 lb If two bushings are used on same component and shaft, fully tighten one bushing before working on the other. Fasteners and Torque Control (10---90) 43 Sequence Tightening On some assemblies, it is advisable to use a crisscross pattern. Always avoid starting in one spot and tightening one after another in a row. Remember that the object is to tighten the parts in such a manner that even stress is set up throughout, at the same time allowing the parts to be drawn together so that their mating surfaces will contact. 5 1 3 3 5 1 4 2 5 6 3 2 6 1 2 4 4 6 Torque in Steps 1. Run each fastener, in proper sequence, up to the recommended torque. 2. Repeat the process of running up each fastener, in proper sequence, up to the recommended torque. 3. If necessary, repeat step two until all the fasteners are tightened to the recommended torque. Fasteners and Torque Control (10---90) 44
Source Exif Data:
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