T7

Rider--Scrubber
Service Information Manual

The Safe Scrubbing AlternativeR

HygenicR Fully Cleanable Tanks

North America / International 331045

Rev. 01 (09-2008)

www.tennantco.com *331045*
 B
A

FOR REPLACEMENT PARTS

Identify machine model and serial number.
1. (A) Identify the machine model.
2. (B) Identify the machine serial number from the data plate.
Refer to the TENNANT Parts Manual.

NOTE: Only use TENNANT Company supplied or equivalent parts. Parts and supplies may be ordered
online, by phone, by fax or by mail.

Tennant Company
PO Box 1452
Minneapolis, MN 55440
Phone: (800) 553--8033 or (763) 513--2850
www.tennantco.com
FaST--PAK is a US registered and unregistered trademark of Tennant Company.

Specifications and parts are subject to change without notice.

Copyright E 2004 -- 2008 TENNANT Company, Printed in U.S.A.

 T7 SERVICE INFORMATION Table of Contents

Safety Precautions ............................................................... iv Electrical Troubleshooting Information (continued)

General Machine Information ............................................... 1 Tank Level Switches ................................................ 50
Component Locator (Page 1 of 5) ................................. 2 Horn & Hour Meter Systems .................................... 51
Specifications ................................................................. 7 Propel Forward System ........................................... 52
Dimensions/Capacities ............................................ 7 Propel Reverse System ........................................... 53
Machine Performance ..............................................7 Braking System ........................................................54
Power Type .............................................................. 8 Scrub Head & Squeegee Actuator Systems ............ 55
Tires ......................................................................... 8 Scrub Brush Motors System .................................... 57
FaST System ........................................................... 8 Vacuum Fan System ............................................... 58
Dimensions .............................................................. 9 FaST System ........................................................... 59
Maintenance & Repair ................................................... 11 Conventional Solution System ................................. 60
Maintenance Points ................................................. 12 LED Locations & Descriptions ................................. 61
Maintenance Chart .................................................. 13 Operational Modes & Interlocks ...............................62
Batteries ................................................................... 14 Diagnostic & Fault Alarms ....................................... 63
Gel Batteries ..................................................... 14 High Current Faults ............................................63
Lead Acid Batteries ...........................................14 Alarm Codes ...................................................... 63
Charging - Off-Board Charger .......................... 15 Diagnostic & Configuration Modes .......................... 64
Settings - On-Board Charger ............................ 16 Display Software Revision Mode ............................. 65
Charging - On-Board Charger .......................... 17 Self Test Mode .........................................................66
On-Board Charger Error Codes ........................ 17 Input Display Mode .................................................. 67
Electric Motors ......................................................... 18 Manual Mode ........................................................... 68
Belts (Cylindrical Models) ........................................ 18 Propel / Brake Diagnostics ...................................... 69
Scrub Brushes & Pads .............................................19 Propelling System Data ..................................... 69
Disk Brushes .....................................................19 Propel & Brake Pedal Data ................................ 69
Cylindrical Brushes ........................................... 21 Battery Select Mode & Voltage Levels .................... 70
Replacing FaST-PAK ...............................................25 Battery Select Mode .......................................... 70
Squeegee Blades .................................................... 26 Voltage Levels ................................................... 70
Replacing Rear Squeegee Blades ....................26 Reverse Alarm & Propel Speed Select Modes ........ 71
Replacing Side Squeegee Blades .................... 28 Reverse Alarm Select Mode .............................. 71
Adjusting Squeegee Guide Roller .....................28 Propel Speed Select Mode ................................ 71
Leveling Rear Squeegee .................................. 28 Inputs & Outputs Table ............................................ 72
Adjusting Rear Squeegee Deflection ................ 29 Amer Drive Motor ........................................................... 73
Skirts & Seals .......................................................... 30 Drive Motor Exploded View ..................................... 74
Disk Head Floor Skirt ........................................ 30 Performance Specifications ..................................... 74
Recovery Tank Seal ......................................... 30 Commutator Brush Replacement ............................ 75
Solution Tank Seals .......................................... 30 Contact Ring Carbon Brush Access ........................ 75
Tires ......................................................................... 30 Contact Ring Carbon Brushes ................................. 76
Pushing, Towing, & Transporting .............................31 Brake Solenoid ........................................................ 76
Machine Jacking ...................................................... 32 Brake Rotor ..............................................................77
Storage Information ................................................. 32 Drive Motor Disassembly & Repair .......................... 78
Machine Troubleshooting ........................................ 33
Electrical Troubleshooting Information ................................. 35
Commonly Used Electrical Symbols & Terms ............... 36
Electrical Schematic ...................................................... 38
Wire Harness Group (Page 1 of 7)................................. 40
Key OFF, Operator NOT on Seat .................................. 47
Key OFF, Battery Charger Plugged In ........................... 48
Key ON, Operator on Seat ............................................. 49

T7 331045 (9--08) iii

Safety Precautions T7 SERVICE INFORMATION

SAFETY PRECAUTIONS
The following symbols are used throughout this 2. Before starting machine:
manual as indicated in the descriptions: -- Make sure all safety devices are in
place and operate properly.
WARNING: To warn of hazards or -- Check brakes and steering for proper
unsafe practices that could result in operation.
severe personal injury or death.
3. When using machine:
FOR SAFETY: To identify actions that -- Go slow on inclines and slippery
must be followed for safe operation of surfaces.
equipment. -- Use care when backing machine.
-- Report machine damage or faulty
This machine is designed solely for cleaning operation immediately.
smooth flooring in an indoor environment. Tennant -- Follow mixing and handling
does not recommend using this machine in any instructions on chemical containers.
other environment.
4. Before leaving or servicing machine:
The following information signals potentially -- Stop on level surface.
dangerous conditions to the operator or -- Turn off machine and remove key.
equipment. Read this manual carefully. Know
when these conditions can exist. Locate all safety 5. When servicing machine:
devices on the machine. Then, take necessary -- Do not push or tow the machine on
steps to train machine operating personnel. inclines with the brake disabled.
Report machine damage or faulty operation -- Avoid moving parts. Do not wear loose
immediately. Do not use the machine if it is not in jackets, shirts, or sleeves when
proper operating condition. working on machine.
-- Block machine tires before jacking
WARNING: Batteries emit hydrogen gas. machine up.
Explosion or fire can result. Keep -- Jack machine up at designated
sparks and open flame away. Keep locations only. Block machine up with
covers open when charging. jack stands.
-- Use hoist or jack that will support the
WARNING: Flammable materials can weight of the machine.
-- Wear eye and ear protection when
cause an explosion or fire. Do not use
using pressurized air or water.
flammable materials in tank(s).
-- Wear protective gloves when handling
batteries or battery cables.
WARNING: Flammable materials or
-- Disconnect battery connections before
reactive metals can cause an explosion working on machine.
or fire. Do not pick up. -- Avoid contact with battery acid.
-- Do not power spray or hose off
machine. Electrical malfunction may
occur.
FOR SAFETY: -- Use Tennant supplied or equivalent
replacement parts.
1. Do not operate machine:
-- Unless trained and authorized. 6. When loading/unloading machine
-- With brake disabled. onto/off truck or trailer:
-- Unless operation manual is read and -- Drain tanks before loading machine.
understood. -- Turn off machine.
-- In flammable or explosive areas. -- Use truck or trailer that will support
-- In areas with possible falling objects. the weight of the machine.
-- Block machine tires.
-- Lower scrub head and squeegee
before tying down machine.
-- Tie machine down to truck or trailer.

iv T7 331045 (9--08)
T7 SERVICE INFORMATION General Machine Information

GENERAL G

MACHINE
INFORMATION
BEFORE CONDUCTING TESTS:
* Read and Follow ALL Safety Warnings and Precautions as mentioned
at the beginning of this manual
* Always unhook Battery 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.
T7 331045 (9--08) 1
 General Machine Information T7 SERVICE INFORMATION
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Component Locator
(Page 1 of 5)

G Operator Panel Details

Recovery tank Battery charge

full indicator level indicators
Solution tank Fault
empty indicator indicator

Increase Brush
Pressure button
S1 Emergency stop
FaST ON/OFF Increase Solution button (E-stop)
button Flow button S2 Horn
button

Vacuum Fan ON/OFF

& Squeegee Decrease Solution KEYSWITCH1
Raise/Lower button Flow button SW6 Forward/ ON/OFF key switch
Reverse switch
One Step Decrease Brush
Scrub button Pressure button

2 T7 331045 (9--08)
T7 SERVICE INFORMATION General Machine Information
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Component Locator
(Page 2 of 5)

Electrical Panel Details

G

CB2 15A
Circuit Breaker

H1 Hour D1 & D3 Diodes

Meter (below breakers) CB1 5A Circuit
Breaker
Charger Plug &
SW1 Charger
Interlock Switch
M1 Main
Contactor

Standoff 2 U4 Control
Board (See Next
Page for Details)

F1 100A
Fuse

Standoff 1

MTR6 Scrub
Head Actuator Batteries

Shown with seat and battery shroud removed

T7 331045 (9--08) 3
 General Machine Information T7 SERVICE INFORMATION
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Component Locator
(Page 3 of 5)

G Control Board Details

Ribbon Cable
Connector -
To Touch Panel

U4 Control Board

Main Plug
Connector -
Inputs and Low
Power Outputs

Control Board
Fuse – 15 Amp
(Slow Blow)

Battery Positive
Connection from
Battery STANDOFF2
Negative
Connection

Output to Output to Scrub Output to Vacuum

Propel Motor Brush Motors Fan Motor

4 T7 331045 (9--08)
T7 SERVICE INFORMATION General Machine Information
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Component Locator
(Page 4 of 5)

Rear Machine Area Details

G
SW4 Solution Tank
Empty Switch

SW3 Recovery Tank

Full Switch

MTR4 Vacuum
Fan Motor

SHOWN WITH REAR COVER REMOVED

T7 331045 (9--08) 5
 General Machine Information T7 SERVICE INFORMATION
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Component Locator
(Page 5 of 5)

G G

MTR3 Right
Brush Motor

MTR2 Left
Brush Motor MTR7 FaST
Pump

UNDERSIDE VIEW
Brake
MTR1A
Pedal
Propel Motor
Assembly Propel
Pedal
MTR1B Parking
Brake Solenoid

U2 Throttle/
Brake Sensor

SHOWN WITH STEERING

MTR3 Right MTR2 Left COLUMN COVER REMOVED
Brush Motor Brush Motor

6 T7 331045 (9--08)
T7 SERVICE INFORMATION General Machine Information
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SPECIFICATIONS

G
GENERAL MACHINE DIMENSIONS/CAPACITIES

Item Disk Cylinderical Disk Cylinderical 800

650 mm 700 mm 800 mm mm
(26 in) (28 in) (32 in) (32 in)
Length 1520 mm (60 in)
Height 1270 mm (50 in)
Width / frame 740 mm (29 in) 810 mm (31.7 in) 740 mm (29 in) 810 mm (31.7 in)
Width / machine with 800 mm (31.5 in) 830 mm (32.5 in) 910 mm (36 in) 930 mm (36.5 in)
scrub head
Width / rear squeegee 850 mm 850 mm 1000 mm 1000 mm
(roller to roller) (33.25 in) (33.25 in) (39.25 in) (39.25 in)
Brush diameter 330 mm (13 in) 150 mm (6 in) 410 mm (16 in) 150 mm (6 in)
Brush length -- 700 mm (28 in) -- 800 mm (32 in)
Scrubbing path width 650 mm (26 in) 700 mm (28 in) 800 mm (32 in) 800 mm (32 in)
Solution tank capacity 110 L (29 gallons)
Recovery tank capacity 110 L (29 gallons)
Weight/net less batteries 265 Kg (585 lbs) 287 kg (632 lbs) 265 Kg (585 lbs) 296 kg (653 lbs)
Weight/with standard 386 Kg (850 lbs) 407 kg (897 lbs) 386 Kg (850 lbs) 416 kg (918 lbs)
battery package
Weight/with heavy duty 443 Kg (975 lbs) 464 kg (1022 lbs) 443 Kg (975 lbs) 473 kg (1043 lbs)
battery package
GVWR 675 Kg (1485 lbs)
Operating Sound Level
At Operator Ear 67 dB(A) 69 dB(A) 67 dB(A) 69 dB(A)
Vibration level at steering
wheel 0.2 m/s@

GENERAL MACHINE PERFORMANCE

Item Measure
Aisle turnaround width for 650 mm (26 in) scrub head 1730 mm (68.5 in)
Aisle turnaround width for 800 mm (32 in) scrub head 1840 mm (72.5 in)
Travel Speed (maximum) 6.4 Km/h (4 mph)
Maximum rated climb and descent angle with full tanks 6_/10.5%
Maximum rated climb and descent angle with empty tanks 11_/19.25%
Maximum rated climb and descent angle when scrubbing 4_/7%

T7 331045 (9--08) 7
 General Machine Information T7 SERVICE INFORMATION
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G
POWER TYPE

Type Quantity Volts Ah Rating Weight (Each)

Batteries (standard lead acid) 4 6 235 @ 20 hr rate 30.0 kg (66 lb)
Batteries (heavy duty aead acid) 4 6 335 @ 20 hr rate 44.5 kg (97.5 lb)
Batteries (Gel) 4 6 180 @ 20 hr rate 30.0 kg (66 lb)
Batteries (heavy duty Gel) 4 6 220 @ 20 hr rate 30.0 kg (66 lb)

Type Use VDC kW (hp)

Electric Motors Scrub brush (Disk) 24 0.45 kW (0.6 hp)
Scrub brush (Cylinderical) 24 0.50 kW (0.75 hp)
Vacuum fan 24 0.45 kW (0.6 hp)
Propelling 24 0.85 kW (1.1 hp)

Type VDC amp Hz Phase VAC

Chargers (Smart) 24 20 60 1 120
24 25 60 1 120
Chargers (Gel/Agm) 24 20 60? 1 120
24 20 50 / 60 1 240
Chargers (On--Board) 24 25 50 / 60 1 115

TIRES

Location Type Size

Front (1) Solid 90 mm wide x 260 mm OD (3.5 in wide x 10 in OD)
Rear (2) Solid 80 mm wide x 260 mm OD (3.0 in wide x 10 in OD)

FaST SYSTEM (OPTION)

Item Measure
Solution pump 24 Volt DC, 5A, 5.7 LPM (1.5 GPM) open flow,
70 psi bypass setting
Solution flow rate 1.1 LPM (0.30 GPM)
Detergent to water dilution ratio 1:1000
Detergent flow rate 1.35 CC/Minute (0.046 Ounces/Minute)

8 T7 331045 (9--08)
T7 SERVICE INFORMATION General Machine Information
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MACHINE DIMENSIONS

G
For 650 mm (26 in) and 700 mm (28 in) squeegee
800 mm (33.25 in)

For 800 mm (32 in) squeegee

1000 mm (39.25 in)

1270 mm
(50 in)

Frame (Disk)
740 mm (29 in)
1520 mm Frame (Cyl)
(60 in) 810 mm (31.7 in)

T7 331045 (9--08) 9
 T7 SERVICE INFORMATION
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10 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.

MAINTENANCE
& REPAIR
M

BEFORE CONDUCTING TESTS:

* Read and Follow ALL Safety Warnings and Precautions as mentioned
at the beginning of this manual
* Always unhook Battery when removing or replacing electrical
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.

T7 331045 (9--08) 11
 Maintenance T7 SERVICE INFORMATION
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MAINTENANCE POINTS

M
7 3

3 10
2
6 5

10 3 1
4 11

12
14

13 355033

12 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
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MAINTENANCE CHART

No. of
Lubricant/ Service
Interval Key Description Procedure Fluid Points
Daily 1 Side and rear squeegees Check for damage and wear -- 3
Check deflection and leveling -- 6
2 Scrub brushes / pads Check for damage, wear, debris -- 2
8 Recovery tank Clean tank, screen filter, and float -- 1

9 Vacuum fan filter

sensor
Clean -- 1 M
7 FaST--PAK supply hose Clean and connect hose to stor- -- 1
and connector (option) ing plug when not in use
12 Debris tray Clean -- 1
(Cylindrical brushes)
50 Hours 4 Battery cells Check electrolyte level DW 3
(Lead acid batteries)
11 Disk scrub head floor skirt Check for damage and wear -- 2
13 Cylindrical brushes Check taper and rotate front to -- 2
rear
100 Hours 3 Vacuum Fan and tank Check for damage and wear -- 3
seals
14 Cylindrical brush drive Check tension -- 2
belts
200 Hours 4 Battery terminals and Check and clean -- 12
cables
500 Hours 9 Vacuum fan motor(s) Check motor brushes -- 1
5 Scrub brush motors Check motor brushes -- 2
6 Propelling motor Check motor brushes -- 1
10 Tires Check for damage and wear -- 3

LUBRICANT/FLUID
DW . . . . Distilled water

T7 331045 (9--08) 13
 Maintenance T7 SERVICE INFORMATION
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BATTERIES
LEAD ACID BATTERIES
The batteries are designed to hold their power for Check the electrolyte level in each battery cell
long periods of time. The lifetime of the batteries before and after charging, and after every 50
is limited to number of charges the batteries hours of operation. Never add acid to the
receive. To get the most life from the batteries, batteries. Add distilled water only. Always keep
recharge them immediately when the battery the battery caps on, except when adding water or
discharge indicator begins to blink. taking hydrometer readings.

FOR SAFETY: When servicing machine, wear Using a hydrometer, measure the specific gravity
protective gloves when handling batteries or to determine the charge level and condition of the
battery cables. Avoid contact with battery batteries. If one or more of the battery cells test
acid. lower than the other battery cells (0.050 or more),
the cell is damaged, shorted, or is near failure.
After every 200 hours of use check for loose Completely recharge the batteries and then retest.
battery connections and clean the surface of the
batteries, including terminals and cable clamps,
using a strong solution of baking soda and water.
Brush the solution sparingly over the battery tops.
Do not allow any baking soda solution to enter the
batteries. Use a wire brush to clean the terminal
posts and the cable connectors. Wipe off all
cleaning solution residue. 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.

Objects made of metal can potentially short circuit

the batteries. Keep all metallic objects off the 04380
batteries. Replace any worn or damaged wires.
Replace any defective batteries. To dispose of
batteries, contact a battery dealer or your Tennant
Service representative.

GEL BATTERIES
The Gel batteries are maintenance free and do
not need to have the electrolyte level checked.

14 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.

NOTE: Do not take readings immediately after 4. Lead acid batteries: Check the water level in
adding distilled water. If the water and acid are not all battery cells. If the level is low, add just
thoroughly mixed, the readings may not be enough distilled water to cover the plates. DO
accurate. Check the hydrometer readings against NOT OVERFILL. The batteries can overflow
the following chart to determine the remaining during charging due to expansion.
battery charge level:

SPECIFIC GRAVITY BATTERY

at 27_ C (80_F) CHARGE
1.265 100% Charged
1.223 75% Charged
1.185 50% Charged
1.148
1.110
25% Charged
Discharged
M
NOTE: If the readings are taken when the battery
electrolyte is any temperature other than 27_ C
(80_ F), the reading must be temperature NOTE: Make sure the battery caps are in place
corrected. Add or subtract to the specific gravity while charging.
reading 0.004, 4 points, for each 6_ C(10_ F)
above or below 27_C(80_ F). FOR SAFETY: When servicing machine, wear
protective gloves when handling batteries or
CHARGING THE BATTERIES WITH battery cables. Avoid contact with battery
OFF--BOARD CHARGER acid.
1. Drive the machine to a flat, dry surface.
5. Plug the charger connector into the machine
NOTE: Make sure the area is well ventilated. battery charging connector.

2. Turn the machine ON/OFF key switch off. WARNING: Batteries emit hydrogen gas.
Explosion or fire can result. Keep
FOR SAFETY: Before leaving or servicing sparks and open flame away. Keep
machine, stop on level surface, and turn off covers open when charging.
machine.

3. Tilt the operator seat forward and hook the

seat latch into place to hold up the seat

T7 331045 (9--08) 15
 Maintenance T7 SERVICE INFORMATION
.

6. Plug the battery charger into the wall outlet. CHECKING ON--BOARD BATTERY CHARGER
SETTINGS
NOTE: If the red “ABNORMAL CYCLE” lamp
lights when the TENNANT charger is plugged into If your machine is equipped with the on--board
a wall outlet, the charger cannot charge the charger, the charger settings must be set for your
battery and there is something wrong with the battery type before charging. Failure to properly
battery. set will result in battery damage.

To determine your battery type, see battery label.

Contact your battery supplier if not specified.

To verify the setting of the charger, connect the

charger cord into an electrical receptacle. The
charger will display a sequence of codes. One of

M the codes will either read “GEL” or “Acd”.

GEL = Set for sealed/maintenance free batteries.

Acd = Set for wet/lead acid batteries.

07224

7. The TENNANT charger will start

automatically. When the batteries are fully
charged, the TENNANT charger will
automatically turn off.

NOTE: Do not disconnect he charger’s DC cord

from the machine’s battery charging connector
when the charger is operating. Arcing may result.
If the charger must be interrupted during charging,
disconnect the AC power supply cord first.

8. After the charger has turned off, unplug the

charger from the machine battery charging
connector.

9. Lead acid batteries: Check the electrolyte

level in each battery cell after charging. If
needed, add distilled water to raise the
electrolyte level to about 12 mm (0.4 in) below
the bottom of the sight tubes.

10. Unhook the seat latch and lower the operator

seat.

To change the settings to use a different type of

battery, contact your Tennant Service
representative.

16 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.

CHARGING THE BATTERIES WITH THE 5. The charger will display a sequence of codes
ON--BOARD CHARGER once the cord is connected.
Three--digits + the following code:
NOTE: If your machine is equipped with the
on--board battery charger, make sure that the A = Charging current
charger is properly set for your battery type before U = Battery Voltage
charging (See CHECKING ON--BOARD h = Charging time
BATTERY CHARGER SETTINGS). C = Charging ampere--hours [Ah]
E = Energy used [Kwh]
1. Drive the machine to a flat, dry surface. 6. Press the arrow button to review the codes.
NOTE: Make sure the area is well ventilated.

2. Turn the machine ON/OFF key switch off.

FOR SAFETY: Before leaving or servicing

machine, stop on level surface, and turn off
M
machine.

3. Tilt the operator seat forward and hook the

seat latch into place to hold up the seat

WARNING: Batteries emit hydrogen gas.

Explosion or fire can result. Keep
sparks and open flame away. Keep
covers open when charging.
Once the charging cycle begins, the indicator
4. Connect the charger’s AC power supply cord lights will progress from red, yellow to green.
into a properly grounded wall outlet. When the green indicator light comes on, the
charging cycle is done. Unplug the charger cord.

If the charger detects a problem, the charger will

display an error code. See ON--BOARD
BATTERY CHARGER ERROR CODES.

ON--BOARD BATTERY CHARGER ERROR CODES

DISPLAY CODE FAULT SOLUTION

bat Loose or damaged battery cable Check battery cable connections.
Battery exceeded maximum volt- No action necessary.
age level.
E01 Exceeded maximum battery volt- No action necessary.
age allowed.
E02 Safety thermostat exceeded Check if the charger vents are obstructed.
maximum internal temperature.
E03 Exceeded maximum time for Repeat the charging cycle and if the error
charging phase leaving the batter- code E03 reappears check battery or
ies undercharged due to a sulfated replace it.
or faulty battery.
SCt Safety timer exceeded maximum Replace battery.
charging time. Interrupts charging
cycle.
Srt Possible internal short circuit. Contact Service Center.

T7 331045 (9--08) 17
 Maintenance T7 SERVICE INFORMATION
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ELECTRIC MOTORS BELTS (Cylindrical Models)

The carbon brushes on the vacuum fan motor, the The two brush drive belts are located on the
propelling motor, and the scrub brush motors cylindrical brush scrub head. The belts drive the
should be inspected after the initial 500 hours of cylindrical brushes. Proper belt tension is a 6 mm
machine operation and then every 100 hours after (0.25 in) deflection from a force of 2.3 to 2.5 kg
the initial 500 hours. (5.0 to 5.4 lb) at the belt midpoint.

Check and adjust the belt tension every 100 hours

of operation.

18 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.

REPLACING DISK BRUSHES OR PAD DRIVER

SCRUB BRUSHES AND PADS
1. Stop machine on a level surface. Make sure
the scrub head is in the raised position.
The machine can be equipped with either disk or
cylindrical scrub brushes, or cleaning pads. Check 2. Turn the machine ON/OFF key switch off.
scrub brushes daily for wire or string tangled
around the brush or brush drive hub. Also check FOR SAFETY: Before leaving or servicing
for brushes damage and wear. machine, stop on level surface, and turn off
machine.
DISK BRUSHES
3. Pull the pin from the side squeegee retainer
The scrub brushes should be replaced if a large pivot.
number of bristles are missing or if bristle length is
less than 10 mm (0.38 in).

Cleaning pads must be placed on pad drives

M
before they are ready to use. The cleaning pad is
held in place by a pad holder.

Cleaning pads need to be cleaned immediately

after use with soap and water. Do not wash the
pads with a pressure washer. Hang pads, or lie
pads flat to dry.

NOTE: Always replace brushes and pads in sets.

Otherwise one brush or pad will be more
aggressive than the other.

4. Open the side squeegee retainer pivot toward

the front of the machine, then pull the side
squeegee toward the rear of the machine to
access the scrub brushes or pads.

T7 331045 (9--08) 19
 Maintenance T7 SERVICE INFORMATION
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5. Pull the scrub brush/pad driver downward to REPLACING DISK PADS

remove it from the drive hub.
1. Remove the pad driver from the machine.

2. Squeeze the spring clip together to remove

the center disk.

M
6. Place the new scrub brush/pad driver onto the
drive hub. Ensure that it is securely mounted
onto the brush drive hub.
3. Flip or replace the scrub pad, center the scrub
pad on the pad driver. Then reinstall the
center disk to secure the pad in place on the
pad driver.

7. Close the side squeegee and the retainer

pivot, then insert the pin.

NOTE: Be sure the pin is inserted completely

through the bottom.
4. Reinsert the pad driver into the machine.

20 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
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CYLINDRICAL BRUSHES 4. Remove idler plate from the scrub head by

pressing the spring tab downward.
Check the brush taper and rotate the brushes
from front-to-rear every 50 hours of machine
operation for maximum brush life and best
scrubbing performance.

The cylindrical brushes should be replaced if large

amounts of bristles are missing, or if the
remaining bristle length is less than 15 mm
(0.62 in).

NOTE: Replace worn brushes in pairs. Scrubbing

with brushes of unequal bristle length will result in
diminished scrubbing performance.
M
REPLACING OR ROTATING CYLINDRICAL
BRUSHES
1. Stop machine on a level surface. Make sure 5. Pull the old brush out of the scrub head.
the scrub head is in the raised position.
6. Attach the idler plate to the new or rotated
2. Turn the machine ON/OFF key switch off. brush on the end that has the double row of
bristles. Install the brush.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface, and turn off
machine.

3. Remove the cotter pin that holds the side

squeegee in place. Swing the squeegee away
from the scrub head.

7. Push down on the door to catch the door in

the scrub head, then pull up on the door to
latch it into the spring.

8. Repeat for the other brush on the other side

of the scrub head

NOTE: Each side of the scrub head is stamped

with a letter. The idler door of that side of the
scrub head is stamped with the same letter. Make
sure the letter on the door matches the letter on
the scrub head when replacing the doors.

T7 331045 (9--08) 21
 Maintenance T7 SERVICE INFORMATION
.

CHECKING CYLINDRICAL BRUSH PATTERN 7. If the brush patterns are tapered, see
ADJUSTING CYLINDRICAL BRUSH TAPER
1. Apply chalk, or a similar marking material, to section of this manual.
a smooth and level section of the floor.

NOTE: If chalk or other material is not available,

allow the brush to spin on the floor for two
minutes. A polish mark will remain on the floor.

2. Raise the scrub head, then position the

brushes over the chalked area.

3. Block the front or rear wheels to prevent the

machine from moving.

M 4. Lower the scrub head in the chalked area and

slowly press the propel pedal until the scrub
10652
brushes start spinning. Allow the machine to
scrub in the same place for 15 to 20 seconds.
8. If the width of the brushes is not the same,
5. Raise the scrub head and drive the machine
see ADJUSTING CYLINDRICAL BRUSH
away from the chalked area.
WIDTH section of this manual.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface, and turn off
machine.

6. Observe the brush patterns. If the brush

pattern is the same width across the entire
length of each brush and both brushes are the
same width, no adjustment is necessary.

10653

10355

22 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.

ADJUSTING CYLINDRICAL BRUSH TAPER 5. While holding the flat end of the idler shaft
with a wrench, loosen the mounting screw on
FOR SAFETY: Before leaving or servicing the outside of the idler door.
machine, stop on level surface, and turn off
machine.

1. Stop machine on a level surface. Make sure

the scrub head is in the raised position.

2. Turn the machine ON/OFF key switch off.

FOR SAFETY: Before leaving or servicing

machine, stop on level surface, and turn off
machine.

3. Remove the cotter pin that holds the side M

squeegee in place. Swing the squeegee away
from the scrub head.

6. Turn the idler shaft to raise or lower the end of

the brush as needed to straighten the brush
pattern. Tighten the mounting screw.

4. Remove idler plate from the scrub head by

pressing the spring tab downward.

7. Check the brush patterns again and readjust

as necessary until both patterns are the
same.

T7 331045 (9--08) 23
 Maintenance T7 SERVICE INFORMATION
.

ADJUSTING CYLINDRICAL BRUSH WIDTH

1. Stop machine on a level surface. Make sure
the scrub head is in the lowered position.

2. Turn the machine ON/OFF key switch off.

FOR SAFETY: Before leaving or servicing

machine, stop on level surface, and turn off
machine.

3. Loosen the two scrub head mounting screws.

4. Loosen the jam nut, then adjust the brush

width adjustment screw. Tighten the jam nut
and the two scrub head mounting screws
when finished.

5. Check the brush patterns again and readjust

as necessary until both brush patterns are the
same.

24 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.
5. Remove the perforated knock outs from the
REPLACING THE FaST--PAK (FaST Model) new FaST--PAK carton. Do Not remove the
bag from the carton. Pull out the hose
connector located on the bottom of the bag
1. Stop machine on a level surface. and remove the hose cap from the connector.
2. Turn off the machine ON/OFF key switch. NOTE: The FaST--PAK Floor Cleaning
Concentrate is specially designed for use with the
FOR SAFETY: Before leaving or servicing
FaST system scrubbing application. NEVER use
machine, stop on level surface, and turn off a substitute. Other cleaning solutions may cause
machine. FaST system failure.
3. Open the FaST--PAK compartment door and 6. Insert the new FaST--PAK approximately half
slide the empty FaST--PAK approximately half way into the FaST--PAK compartment.
way out from the FaST--PAK compartment
door. 7. Connect the FaST--PAK hose connector to
the FaST supply hose connector, slide the M
FaST--PAK the rest of the way into the
FaST--PAK compartment, and close the
FaST--PAK compartment door.

8. When replacing an empty FaST--PAK carton,

you must scrub with the FaST system for a
few minutes before the detergent will reach its
maximum foaming.

FaST SUPPLY HOSE CONNECTOR

The FaST supply hose connector is located below
the FaST--PAK holder. Soak the connector in
warm water if detergent buildup is visible. When a
FaST--PAK carton is not installed, store the
4. Squeeze the button on the FaST supply hose supply hose connector on the storing plug to
connector, then pull the empty FaST--PAK out prevent the hose from clogging.
from the compartment.

T7 331045 (9--08) 25
 Maintenance T7 SERVICE INFORMATION
.
4. Pull the rear squeegee assembly from the
SQUEEGEE BLADES machine.

5. Loosen the rear squeegee retaining band

The side squeegees control water spray and tension latch and remove the retaining band.
channel water into the path of the rear squeegee.
The side squeegee blades are not adjustable.

The rear squeegee assembly channels water into

the vacuum fan suction. The front blade channels
the water and the rear blade wipes the floor.

Check the squeegee blades daily for damage and

wear. Rotate or replace the squeegee blades if
the leading edge is torn or worn half-way through
the thickness of the blade. Replace the side
M squeegee deflectors if they become worn.

The rear squeegee can be adjusted for leveling

and deflection. The deflection and leveling of the
squeegee blades should be checked daily, or
when scrubbing a different type of floor. 6. Remove rear squeegee blade from the rear
squeegee assembly.
The rear squeegee assembly can be removed
from the squeegee pivot to prevent damage
during transport of the machine.

REPLACING (OR ROTATING) THE REAR

SQUEEGEE BLADES
1. Stop machine on a level surface. Make sure
the scrub head is in the raised position.

2. Turn the machine ON/OFF key switch off.

FOR SAFETY: Before leaving or servicing

machine, stop on level surface, and turn off
machine.

3. Remove the squeegee suction hose from the

rear squeegee assembly. Then loosen both 7. Loosen the two outer knobs on the rear
rear squeegee assembly mounting knobs. squeegee assembly. Remove the front
squeegee blade from the squeegee assembly.

26 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.
8. Install the new front squeegee blade or rotate 12. Tighten the rear squeegee retaining band
the existing blade to the new edge. Be sure tension latch.
the holes in the front squeegee blade are
hooked onto the tabs on the front blade
clamp.

M
13.Reinstall the rear squeegee under the
squeegee mount bracket and tighten all four
knobs.
9. Lightly tighten the two outer knobs.

10. Install the new rear squeegee blade or rotate

the existing blade to the new edge. Be sure
the holes in the squeegee blade are hooked
onto the tabs on the squeegee assembly.

14. Reinstall the squeegee suction hose onto the

rear squeegee assembly.

11. Reinstall the rear squeegee retaining band

onto the squeegee assembly. Be sure each of
the flanges on the retaining band are seated
in the cut outs in the rear squeegee assembly.

T7 331045 (9--08) 27
 Maintenance T7 SERVICE INFORMATION
.
REPLACING SIDE SQUEEGEE BLADES LEVELING THE REAR SQUEEGEE
1. Open the side squeegee. Leveling of the squeegee assures the entire
length of the squeegee is in even contact with the
2. Pull the old side squeegee blade from the surface being scrubbed. Perform this adjustment
side squeegee retainer. Slide the new blade on an even and level floor.
onto the retainer.
1. Lower the squeegee and drive the machine
forward a few feet.

2. Turn off the machine ON/OFF key switch.

FOR SAFETY: Before leaving or servicing

machine, stop on level surface, and turn off
machine.
M 3. Look at the deflection of the squeegee over
the full length of the squeegee blade.

4. If the deflection is not the same over the full

length of the blade, turn the squeegee
leveling bolt to make adjustments.

3. Close the side squeegee. The squeegee leveling bolt is located directly
behind the squeegee suction hose. DO NOT
ADJUSTING THE SQUEEGEE GUIDE ROLLER disconnect the suction hose from the
squeegee frame when leveling squeegee.
The squeegee guide rollers are located on both
ends of the rear squeegee. The rollers guide the
squeegee blade end along a wall. Loosen the nut
located at the top of the guide roller and move the
roller in or out to adjust how close the end of the
squeegee blade is to the wall. The squeegee
blade end should be further away from the wall
when the floor curves up into the wall.

Turn the squeegee leveling bolt

counter-clockwise to increase the deflection at
the ends of the squeegee.

Turn the squeegee leveling bolt clockwise to

decrease the deflection at the ends of the
squeegee blade.

5. Drive the machine forward with the squeegee

down to recheck the squeegee blade
deflection if adjustments were made.

6. Readjust the squeegee blade deflection if

necessary.

28 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.

ADJUSTING REAR SQUEEGEE BLADE 4. If the overall squeegee blade deflection needs
DEFLECTION to be adjusted, loosen the jam nuts on the
squeegee casters and adjust the height.
Deflection is the amount of curl the overall
squeegee blade has when the machine moves
forward. The best deflection is when the
squeegee wipes the floor dry with a minimal
amount of deflection.

1. Lower the squeegee and drive the machine

forward a few meters (feet).

2. Turn off the machine ON/OFF key switch.

FOR SAFETY: Before leaving or servicing

machine, stop on level surface, and turn off
machine.
M
3. Look at the amount of deflection or “curl” of
the squeegee blade. The correct amount of 5. Drive the machine forward again to recheck
deflection is 12 mm (0.50 in) for scrubbing the squeegee blade deflection after
smooth floors and 15 mm (0.62 in) for rough adjustments are made.
floors.
6. Readjust the squeegee blade deflection if
necessary.
12 mm
(0.50 in)

03719

T7 331045 (9--08) 29
 Maintenance T7 SERVICE INFORMATION
.
SOLUTION TANK SEALS
SKIRTS AND SEALS
There are two solution tank seals. Check the seal
for damage and wear after every 100 hours of
DISK SCRUB HEAD FLOOR SKIRT operation.
The skirt is located in front of the disc brush scrub A front seal is located on the bottom of the
heads. Check the skirt for damage and wear after solution tank cover. A rear seal is located on the
every 50 hours of operation. bottom of the recovery tank.

The skirts should clear the floor by 0 to 6 mm

(0 to .25 in) when the scrub brushes are new and TIRES
the scrub head is down.

RECOVERY TANK SEAL The machine has three solid rubber tires: one tire
is front and two are in the rear. Check the tires for
The recovery tank seal is located on the bottom of damage and wear after every 500 hours of
the recovery tank cover. Check the seal for operation.
damage and wear after every 100 hours of
operation.

30 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.
Immediately after pushing the machine, remove
PUSHING, TOWING, AND TRANSPORTING the screw driver to enable the parking brake and
THE MACHINE reconnect the propel motor harness. Never
operate the machine with the brake disabled.
PUSHING OR TOWING THE MACHINE FOR SAFETY: Do not operate machine with
If the machine becomes disabled, it can be the brake disabled.
pushed from the front or rear, but only tow it from
the front. TRANSPORTING THE MACHINE
When transporting the machine by trailer or truck,
FOR SAFETY: When servicing machine, do be certain to follow the tie--down procedure below:
not push or tow the machine on inclines with
the brake disabled. 1. Raise the squeegee and scrub head.

Before attempting to push or tow the machine, 2. Load the machine using a recommended
disconnect the propel motor harness and
disengage the brake.
loading ramp.
M
FOR SAFETY: When transporting machine,
ATTENTION! Do not push or tow machine use a recommended ramp when loading/
with the motor harness connected or the unloading into/off truck or trailer.
control board may fail.
3. Position the front of machine against the front
of the trailer or truck.

4. Lower the scrub head and squeegee after the

machine is positioned on the trailer or truck.

5. Place a block behind each wheel to prevent

the machine from rolling.

6. Route the front tie--down straps through the

stabilizer arms and then secure the tie--downs
to the trailer or truck to prevent the machine
from tipping.

To disengage the brake, insert the tip of a small

screw driver between the electronic brake lever
and the hub.

NOTE: It may be necessary to install tie-down

brackets to the floor of the trailer or truck.

FOR SAFETY: When transporting machine,

use tie--down straps to secure machine to
truck or trailer.
Only push or tow the machine on a level surface.
Do not exceed 3.2 kp/h (2 mph). It is NOT 7. Route the rear tie--down straps through the
intended to be pushed or towed at a high speed. opening at the center part of the rear axle.

T7 331045 (9--08) 31
 Maintenance T7 SERVICE INFORMATION
.

MACHINE JACKING STORAGE INFORMATION

Empty the recovery and solution tanks before The following steps should be taken when storing
jacking the machine. Jack up the machine for the machine for extended periods of time.
service at the designated locations. Use a hoist or
jack capable of supporting the weight of the 1. Drain and clean the solution and recovery
machine. Always stop the machine on a flat, level tanks. Open the recovery tank cover to
surface and block the tires before jacking up the promote air circulation.
machine.
2. Park the machine in a cool, dry area. Do not
Front jacking locations are located on both sides expose the machine to rain. Store indoors.
of the machine.
3. Remove the batteries, or charge them every
M three months.

FREEZE PROTECTION
1. Be sure the solution tank is empty.

2. Pour 3.8 L (1 gal) of pre-mixed

automotive-type windshield washer solution
into the solution tank.

3. FaST models: Remove the FaST--PAK and

store in temperatures above freezing.

4. Turn the machine power on.

5. Run the solution flow for about 15 seconds in

Rear jacking locations are located on both sides
the conventional mode and about 30 seconds
of the machine at the axles.
in the FaST mode.
FOR SAFETY: Before leaving or servicing
6. The washer solution does not need to be
machine, stop on level surface. drained from the solution tank.
FOR SAFETY: When servicing machine, block
machine tires before jacking machine up. Use
a hoist or jack that will support the weight of
the machine. Jack machine up at designated
locations only. Block machine up with jack
stands.

32 T7 331045 (9--08)
T7 SERVICE INFORMATION Maintenance
.

MACHINE TROUBLESHOOTING

Problem Cause Remedy

Trailing water--poor or no Vacuum fan turned off Turn vacuum fan on
water pickup Worn squeegee blades Rotate or replace squeegee blades
Squeegee out of adjustment Adjust squeegee
Vacuum hose clogged Flush vacuum hoses
Vacuum fan filter dirty Clean vacuum fan filter
Vacuum fan cover seals worn Replace seals
Debris caught on squeegee Remove debris
Vacuum hose to squeegee or
recovery tank disconnected or
Reconnect or replace vacuum hose
M
damaged
Recovery tank cover not Check for obstructions and close
completely closed cover
Vacuum fan will not turn on Vacuum fan switch turned off Turn vacuum switch on
Recovery tank full Drain recovery tank
Foam filling recovery tank Empty recovery tank
Use less detergent
Recovery tank sensor dirty or stuck Clean or replace sensor
Little or no solution flow to Solution tank empty Fill solution tank
the floor (Conventional Solution flow turned off Turn solution flow on
Scrubbing Mode)
Solution supply lines plugged Flush solution supply lines

T7 331045 (9--08) 33
 Maintenance T7 SERVICE INFORMATION
.

Problem Cause Remedy

Poor scrubbing performance One Step Scrub button not on Turn One Step Scrub button on
Improper detergent or brushes Contact Tennant service
used representative
Recovery tank full Empty recovery tank
Solution tank empty Fill solution tank
Debris caught on scrub brushes or Remove debris
pads
Worn scrub brush Replace scrub brush
Broken or loose brush drive belt Replace or tighten belt
(Cylindrical models)

M Brush pressure set too light

Low battery charge
Increase brush pressure
Charge batteries until the charger
automatically turns off
FaST System does not FaST switch is turned off Turn on the FaST switch
operate
Accessory circuit breaker tripped Reset circuit breaker
Clogged FaST--PAK supply hose Soak connector and hose in warm
and/or connector water and clean
FaST--PAK carton is empty or not Replace FaST--PAK carton and/or
connected connect supply hose
FaST system is not primed To prime, operate the FaST solu-
tion system for a few minutes
Clogged filter screen Drain solution tank, remove and
clean filter screen
Faulty solution pump Replace solution pump

34 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting

ELECTRICAL
Troubleshooting Information

BEFORE CONDUCTING TESTS:

* Read and Follow ALL Safety Warnings and Precautions as mentioned

E
at the beginning of this 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 unhook Battery 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.
T7 331045 (9--08) 35
 Electrical Troubleshooting T7 SERVICE INFORMATION
..

Commonly Used Electrical Symbols & Terms

NOTE: The term “NORMALLY” refers to the components’ “at rest” or “de-energized” position

+ -

Wires Connected Wires Not Plug-in

Connected Together Battery Circuit Breaker Fuse
Together Connection

Normally Open Normally Open Normally Closed Normally Open Normally Closed Indicates Movement
Switch Limit Switch Limit Switch Push-Button Switch Push-Button Switch from Normal Position

Normally Open Normally Closed

M1

Relay Coil Solenoid (Valve Indicates Component in

(Part 1 of Relay) Diode or Actuator) Position Other than Normal
Relay Contacts (Part 2 of Relay)

E X
Wiring Standoff Lamp Indicates Component
Motor (Connection Point) Horn or Alarm
(Light Bulb) is Energized

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
Color of Wire
of Wire Number

0 Tan
1 Pink
2 Brown
3 Orange 1 RED 25 7 13 BLK
4 Yellow
5 Green
6 Blue
7 Purple
8 Gray
9 White

36 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
.

T7 331045 (9--08) 37
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
Electrical Schematic (page 1 of 2)
1

E
4

1021038

38 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
..
Electrical Schematic (page 2 of 2)
1

1021038
T7 331045 (9--08) 39
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
Wire Harness Group (page 1 of 7)

40 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
..
Wire Harness Group (page 2 of 7)

T7 331045 (9--08) 41
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
Wire Harness Group (page 3 of 7)

42 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
..
Wire Harness Group (page 4 of 7)

T7 331045 (9--08) 43
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
Wire Harness Group (page 5 of 7)

44 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
..
Wire Harness Group (page 6 of 7)

T7 331045 (9--08) 45
 Electrical Troubleshooting T7 SERVICE INFORMATION
.
.
Wire Harness Group (page 7 of 7)

46 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
.
.
Key OFF, Operator NOT on Seat

6 VDC 6 VDC 6 VDC 6 VDC

1 RED + - + - + - + - 13 BLK

1 RED 1 RED 13 BLK 13 BLK

X
X
CHARGER STANDOFF 1
PLUG

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v PIN J6-17 42 LOGIC GROUND
CB1 PIN J6-35
5A S1
M1B D3 MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 32
27
F1 ORG
GRN
100 A 4 3 3
PIN J6-24
KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7

E
4 4 SW1 26 26 SW2
PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -
RIBBON CABLE CONNECTOR P6

TOUCH
PANEL

RIBBON CABLE

Wiring Color Codes

(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number 14
0 Tan
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
T7 331045 (9--08) 47
 Electrical Troubleshooting T7 SERVICE INFORMATION
.
.
Key OFF, Battery Charger Plugged In

6 VDC 6 VDC 6 VDC 6 VDC

1 RED + - + - + - + - 13 BLK

1 RED 1 RED 13 BLK 13 BLK

X
X
CHARGER STANDOFF 1
PLUG

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v PIN J6-17 42 LOGIC GROUND
CB1 PIN J6-35
5A S1
M1B D3 MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 32
27
F1 ORG
GRN
100 A 4 3 3
PIN J6-24
KEYSWITCH CHARGER 27
X
X STANDOFF 2 PIN J6-7

E
SW1 INTERLOCK
4 4 26 26 SW2
PIN J6-18 SEAT
SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -
RIBBON CABLE CONNECTOR P6

TOUCH
PANEL

RIBBON CABLE

Wiring Color Codes

(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number 14
0 Tan
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

48 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
.
.
Key ON, Operator on Seat

6 VDC 6 VDC 6 VDC 6 VDC

1 RED + - + - + - + - 13 BLK

1 RED 1 RED 13 BLK 13 BLK

X
X
CHARGER STANDOFF 1
PLUG

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v PIN J6-17 42 LOGIC GROUND
CB1 PIN J6-35
5A S1
M1B D3 MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 32
27
F1 ORG
GRN
100 A 4 3 3
PIN J6-24
KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7

E
4 4 SW1 26 26 SW2
PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -
RIBBON CABLE CONNECTOR P6

TOUCH
PANEL

RIBBON CABLE

Wiring Color Codes

(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number 14
0 Tan
1 Pink
2 Brown
3 Orange KEY
SWITCH
4 Yellow
5 Green
6 Blue
O
7 Purple
RIGHT SIDE I
8 Gray DASH PANEL
9 White
= Battery Negative
or Logic Ground
= Battery Positive
or Positive Output
T7 331045 (9--08) 49
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
Tank Level Switches
CONDITIONS: key ON

6 VDC 6 VDC 6 VDC 6 VDC

1 RED + - + - + - + - 13 BLK

1 RED 1 RED 13 BLK 13 BLK

X
X
CHARGER STANDOFF 1
PLUG

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v PIN J6-17 42 LOGIC GROUND
CB1 PIN J6-35
5A S1
M1B D3 MAIN
2 2 CONTACTOR D1
4 RECOVERY TANK
5 6 6 FULL SWITCH
M1A PIN J6-5
F1 28 42
PIN J6-20
100 A 4 3 3 SW3
PIN J6-24
KEYSWITCH
X
X STANDOFF 2
SW1

E
4 4 26 26
PIN J6-18 29 42
PIN J6-8
CHARGER INTERLOCK SW4
2 14 14 SOLUTION TANK
CB2 PIN J6-13
LOW SWITCH
15 A
POST J11 POST J7
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -
RIBBON CABLE CONNECTOR P6

TOUCH
PANEL

RIBBON CABLE

Wiring Color Codes

(Unless otherwise marked)
Right Most Digit 14
Color of Wire
of Wire Number

0 Tan Tank Level Switches Logic Chart

1 Pink
2 Brown
3 Orange
4 Yellow
5 Green
6 Blue
7 Purple i Recovery Tank Full Switch closes when recovery tank is full

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
= Battery Negative empty tank
or Logic Ground Tank Level Switches are ALWAYS in the CLOSED position with full tank
= Battery Positive
or Positive Output

50 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
..
Horn & Hour Meter Systems
CONDITIONS: key ON, operator on seat, in motion OR Vacuum Fan running (for Hour Meter)

6 VDC 6 VDC 6 VDC 6 VDC

1 RED + - + - + - + - 13 BLK

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5 42 LOGIC GROUND
v v CB1
PIN J6-17 PIN J6-35
5A S1
M1B D3 MAIN
2 2 CONTACTOR D1
4 5 6 6
M1A PIN J6-5
F1
100 A 4 3 3
PIN J6-24
KEYSWITCH 30 42
X
X STANDOFF 2 PIN J6-10
SW1 26 26 S2
4 4
PIN J6-18 HORN
SWITCH
CHARGER INTERLOCK
2 14 14
CB2 PIN J6-13
15 A

E
POST J11 POST J7
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -
NOTE: Hour Meter is active
only when propelling 14 14 23 23
PIN J6-15
(forward or reverse), OR LS1
anytime Squeegee/ HORN
Vacuum Fan is active

14 14 21 21 RIBBON CABLE
00000 PIN J6-14 CONNECTOR P6

H1
HOUR METER

TOUCH
PANEL LEFT SIDE
DASH PANEL

RIBBON CABLE

Wiring Color Codes

(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number

0 Tan HORN
1 Pink SWITCH

2 Brown
3 Orange
RIGHT SIDE
4 Yellow DASH PANEL
5 Green
6 Blue
7 Purple i Horn pulses ON & OFF when Directional Switch is in REVERSE

8 Gray Hour Meter is ON only when propelling (forward or reverse), or anytime

Squeegee/Vacuum Fan is ON
9 White
= Battery Negative Horn pulses when a fault is detected (Directional Switch must be in FORWARD
or Logic Ground Position) – refer to “Diagnostic/Beep Code” chart
= Battery Positive
or Positive Output
T7 331045 (9--08) 51
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
Propel Forward System
CONDITIONS: key ON, operator on seat, propel pedal depressed

1 RED 6 VDC 6 VDC 6 VDC 6 VDC

+ - + - + - + - 13 BLK

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v PIN J6-17 42 LOGIC GROUND
CB1 PIN J6-35
5A S1
M1B D3 MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 27 32
F1 GRN ORG
100 A 4 3 3
PIN J6-24
X KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7
4 4 SW1 26 26 SW2
50 RED PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7

E
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG - PROPEL PEDAL
POSITION SENSOR
25 BLK 24 WHT 24 U2 GND 42
PIN J10-2 HALL
MTR1A PIN J6-34 31 PROPEL
14 EFFECT POWER
SIGNAL
PROPEL MOTOR SENSOR
NOTE: Brake Solenoid 14
is energized to release 25 FORWARD 25
PIN J10-1
FORWARD
X
parking brake. 42 42
15 15 35
PIN J6-27 PIN J6-22
REVERSE
14 14
SW6
MTR1B RIBBON CABLE CONNECTOR P6 PROPEL
NOTE: Refer to the BRAKE
DIRECTION
“Propel/Brake Diagnostics” SOLENOID
SWITCH
page for more information
TOUCH
PANEL LEFT SIDE
DASH PANEL
Wiring Color Codes
(Unless otherwise marked) RIBBON CABLE
Right Most Digit
Color of Wire
of Wire Number

0 Tan
1 Pink
14 14
2 Brown
3 Orange
FOR
WA
4 Yellow RD

5 Green
REV
DIRECTIONAL E RS
6 Blue E
SWITCH RIGHT SIDE
7 Purple DASH PANEL
8 Gray
Typical Propel Motor Current Draw: 1 to 20 Amps in motion, higher at start-up
9 White i Propel Motor Voltage: 0 to 24 VDC - FORWARD
= Battery Negative
Approx. 0 to 17 VDC - REVERSE
or Logic Ground
= Battery Positive Propel Motor is controlled by PWM (Pulse Width Modulation)
or Positive Output
= Output that can The Propel Pedal Position HALL EFFECT Sensor sends a varying voltage
Change Polarity signal (1 to 4 Volts) to control board, based upon position of the propel pedal
52 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
..
Propel Reverse System
CONDITIONS: key ON, operator on seat, propel pedal depressed

1 RED 6 VDC 6 VDC 6 VDC 6 VDC

+ - + - + - + - 13 BLK

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v PIN J6-17 42 LOGIC GROUND
CB1 PIN J6-35
5A S1
M1B D3 MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 27 32
F1 GRN ORG
100 A 4 3 3
PIN J6-24
X KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7
4 4 SW1 26 26 SW2
50 RED PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7

E
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG - PROPEL PEDAL
POSITION SENSOR
25 BLK 24 WHT 24 U2 GND 42
PIN J10-2 HALL
MTR1A PIN J6-34 31 PROPEL
14 EFFECT POWER
SIGNAL
PROPEL MOTOR SENSOR
NOTE: Brake Solenoid 14
is energized to release 25 REVERSE 25
PIN J10-1
FORWARD
X
parking brake. 42 42
15 15 35
PIN J6-27 PIN J6-22
14 14 REVERSE
SW6
MTR1B RIBBON CABLE CONNECTOR P6 PROPEL
NOTE: Refer to the BRAKE
DIRECTION
“Propel/Brake Diagnostics” SOLENOID
SWITCH
page for more information
TOUCH
PANEL LEFT SIDE
DASH PANEL
Wiring Color Codes
(Unless otherwise marked) RIBBON CABLE
Right Most Digit
Color of Wire
of Wire Number

0 Tan
1 Pink
14 14
2 Brown
3 Orange
FOR
W AR
4 Yellow D

5 Green
DIRECTIONAL REV
E RS
6 Blue E
SWITCH
RIGHT SIDE
7 Purple DASH PANEL
8 Gray
Typical Propel Motor Current Draw: 1 to 20 Amps in motion, higher at start-up
9 White i Propel Motor Voltage: 0 to 24 VDC - FORWARD
= Battery Negative
Approx. 0 to 17 VDC - REVERSE
or Logic Ground
= Battery Positive Propel Motor is controlled by PWM (Pulse Width Modulation)
or Positive Output
= Output that can The Propel Pedal Position HALL EFFECT Sensor sends a varying voltage
Change Polarity signal (1 to 4 Volts) to control board, based upon position of the propel pedal
T7 331045 (9--08) 53
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
Braking System
CONDITIONS: key ON, operator on seat, brake pedal depressed

1 RED 6 VDC 6 VDC 6 VDC 6 VDC

+ - + - + - + - 13 BLK

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v PIN J6-17 42 LOGIC GROUND
CB1 PIN J6-35
5A S1
M1B D3 MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 27 32
F1 GRN ORG
100 A 4 3 3
PIN J6-24
X KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7
4 4 SW1 26 26 SW2
50 RED PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7

E
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG - BRAKE PEDAL
POSITION SENSOR
14 24 WHT 24 U2 GND 42
MTR1A PIN J10-2 HALL
25 BLK 32 BRAKE
NOTE: Brake Solenoid is DE- PIN J6-33 EFFECT POWER
SIGNAL
energized to apply parking PROPEL MOTOR SENSOR
brake. Dynamic Braking will 14
25 25
occur before Brake Solenoid is PIN J10-1
de-energized.
15 15
PIN J6-27
14 14
MTR1B RIBBON CABLE CONNECTOR P6
NOTE: Refer to the BRAKE
“Propel/Brake Diagnostics” SOLENOID
page for more information
TOUCH
PANEL LEFT SIDE
DASH PANEL

RIBBON CABLE
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number

0 Tan 14 14
1 Pink
2 Brown
3 Orange
4 Yellow
The brake pedal position HALL EFFECT sensor sends a varying voltage
5
6
Green
Blue
i signal (1 to 4 Volts) to control board, based upon position of the brake pedal
Brake Solenoid is DE-energized to apply brake.
7 Purple
8 Gray Dynamic Braking will occur before Brake Solenoid is de-energized.
9 White
= Battery Negative
or Logic Ground
= Battery Positive
or Positive Output

54 T7 331045 (9--08)
 T7 SERVICE INFORMATION Electrical Troubleshooting
..
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

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v CB1
PIN J6-17 42 LOGIC GROUND
S1 PIN J6-35
M1B D3 5A MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 32
27
F1 ORG
GRN
100 A 4 3 3
PIN J6-24
KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7
4 4 SW1 26 26 SW2
50 RED PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7

E
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -
18 17 17
MTR5 PIN J6-12

SQUEEGEE ACTUATOR 18
PIN J6-9
NOTE: Actuator voltage switches
polarity when direction of actuator 20 19 19
travel changes (see next page for MTR6 PIN J6-23
more information)
SCRUB HEAD ACTUATOR 20
PIN J6-21
RIBBON CABLE CONNECTOR P6

Vacuum Fan/
Squeegee Button
TOUCH
One Step LEFT SIDE
Scrub Button PANEL
DASH PANEL
Wiring Color Codes
(Unless otherwise marked) RIBBON CABLE
Right Most Digit
Color of Wire
of Wire Number

0 Tan
1 Pink
2 Brown
3 Orange
4 Yellow Pressing the “One Step Scrub Button” will lower the squeegee and scrub head
5 Green i Only one actuator will be energized at any given time – squeegee is lowered
6 Blue first, then the scrub head
7 Purple Squeegee actuator uses internal limit switches to stop travel in upward and
8 Gray downward travel
9 White Scrub head actuator travel is controlled by monitoring actuator current in
= Battery Negative upward travel and brush motor current in downward travel
or Logic Ground
= Battery Positive
Squeegee actuator can also be operated by pressing the “Vacuum Fan/
or Positive Output Squeegee Button”, without operating scrub brushes
= Output that can
Change Polarity
T7 331045 (9--08) 55
 Electrical Troubleshooting T7 SERVICE INFORMATION
.
..
Scrub Head & Squeegee Actuator Systems
(page 2 of 2)

Actuator Voltage Data

Actuator Travel Direction Wire # Color Polarity Notes

DOWN
17 Purple í Voltage at actuator connector will be
Squeegee
18 Gray "+" approx. 24 VDC for 2 seconds, then
17 Purple "+" approx. 12 VDC for 2 seconds for both UP
UP & DOWN travel
18 Gray í
DOWN
19 White í Voltage at actuator connector will be
20 Tan "+" approx. 24 VDC for 4 seconds
Scrub
Head 19 White "+" Voltage at actuator connector will be

E
UP approx. 24 VDC for 4 seconds, then
20 Tan í 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

56 T7 331045 (9--08)
 T7 SERVICE INFORMATION Electrical Troubleshooting
..
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

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v CB1
PIN J6-17 42 LOGIC GROUND
S1 PIN J6-35
M1B D3 5A MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 32
27
F1 ORG
GRN
100 A 4 3 3
PIN J6-24
KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7
4 4 SW1 26 26 SW2
50 RED PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7

E
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -
8 7 7
MTR2 PIN J8-1
LEFT OR FRONT
SCRUB BRUSH
MOTOR 8
PIN J8-2

10 9 9
RIGHT OR REAR MTR3 PIN J8-3
SCRUB BRUSH
MOTOR 10
PIN J8-4
RIBBON CABLE CONNECTOR P6
Brush Pressure
Buttons

TOUCH
One Step LEFT SIDE
Scrub Button PANEL
DASH PANEL

RIBBON CABLE
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number

0 Tan
1 Pink
2 Brown
Brush Motor Current Draw: Approx. 10 to 20 Amps per motor, varying upon
3 Orange
4 Yellow
i selected brush pressure setting

Green
Brush Motor Voltage: Approx. 18 VDC in Economy Mode
5
Approx. 21.5 VDC in All Other Modes
6 Blue
Scrub Brush Motors are controlled by PWM (Pulse Width Modulation)
7 Purple
8 Gray Pressing the “One Step Scrub Button” will turn on the Scrub Brush Motors
(after lowering squeegee and scrub head)
9 White
= Battery Negative Scrub Brush Motors will function only when propelling either forward or reverse
or Logic Ground Scrub Brush Pressure is controlled by monitoring brush motor current
= Battery Positive
or Positive Output
T7 331045 (9--08) 57
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
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

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v CB1
PIN J6-17 42 LOGIC GROUND
S1 PIN J6-35
M1B D3 5A MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 32
27
F1 ORG
GRN
100 A 4 3 3
PIN J6-24
KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7
4 4 SW1 26 26 SW2
50 RED PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
15 A
POST J11 POST J7

E
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -
12 11 11
MTR4 PIN J9-1

VACUUM FAN

12
PIN J9-2

RIBBON CABLE CONNECTOR P6

Vacuum Fan/
Squeegee Button
TOUCH
One Step LEFT SIDE
Scrub Button PANEL
DASH PANEL

RIBBON CABLE
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number

0 Tan
1 Pink
2 Brown
3 Orange
Vacuum Fan Motor Current Draw: Approx. 18 to 21 Amps
4 Yellow i Vacuum Fan Motor Voltage: Approx. 18 VDC in Economy Mode
5 Green
Approx. 21.5 VDC in All Other Modes
6 Blue
Vacuum Fan Motor is controlled by PWM (Pulse Width Modulation)
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
= Battery Negative Button”, without operating scrub brushes
or Logic Ground
= Battery Positive
or Positive Output

58 T7 331045 (9--08)
 T7 SERVICE INFORMATION Electrical Troubleshooting
..
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

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v CB1
PIN J6-17 42 LOGIC GROUND
S1 PIN J6-35
M1B D3 5A MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 32
27
F1 ORG
GRN
100 A 4 3 3
PIN J6-24
KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7
4 4 SW1 26 26 SW2
50 RED PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
14
15 A
POST J11 POST J7

E
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -

14 22 22
MTR7 PIN J6-25

FaST PUMP MOTOR

RIBBON CABLE CONNECTOR P6

FaST Button

TOUCH
One Step LEFT SIDE
Scrub Button PANEL
DASH PANEL

RIBBON CABLE
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number

0 Tan
1 Pink
2 Brown
3 Orange
4 Yellow Pressing the “One Step Scrub Button” will activate FaST Pump Motor OR
5 Green i Solution Solenoid Valve as Scrub Brush Motors engage

6 Blue Pressing the FaST button will toggle from FaST scrubbing to Conventional
scrubbing
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
= Battery Negative Control LED’s will be OFF during FaST scrubbing
or Logic Ground
= Battery Positive
or Positive Output
T7 331045 (9--08) 59
 Electrical Troubleshooting T7 SERVICE INFORMATION
.
..
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

EMERGENCY
CONTROL BOARD
1 RED 1 RED 4 STOP SWITCH 5 5
v v CB1
PIN J6-17 42 LOGIC GROUND
S1 PIN J6-35
M1B D3 5A MAIN
2 2 CONTACTOR D1
4 5 6 6 42
M1A PIN J6-5 32
27
F1 ORG
GRN
100 A 4 3 3
PIN J6-24
KEYSWITCH 27
X
X STANDOFF 2 PIN J6-7
4 4 SW1 26 26 SW2
50 RED PIN J6-18 SEAT
CHARGER INTERLOCK SWITCH
2 14 14
CB2 PIN J6-13
14
15 A
POST J11 POST J7

E
50 RED 50 RED 13 BLK 13 BLK
+ POS NEG -

SOL2

14 16 16
PIN J6-4

SOLUTION SOLENOID VALVE

RIBBON CABLE CONNECTOR P6

Solution Volume
Control Buttons

TOUCH
One Step LEFT SIDE
Scrub Button PANEL
DASH PANEL

RIBBON CABLE
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
Color of Wire
of Wire Number

0 Tan
1 Pink
2 Brown
3 Orange
4 Yellow Pressing the “One Step Scrub Button” will activate FaST Pump Motor OR
5 Green i Solution Solenoid Valve as Scrub Brush Motors engage

6 Blue Pressing the FaST button will toggle from FaST scrubbing to Conventional
scrubbing
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
= Battery Negative Conventional scrubbing
or Logic Ground
= Battery Positive
or Positive Output

60 T7 331045 (9--08)
T7 331045 (9--08)
Fault Indicator
LED
Solution Tank
Empty LED
Solution Flow
LED’s’s
T7 SERVICE INFORMATION

FaST LED

One Step 1 2 3 4 5
LED
RED
GREEN
GREEN

GREEN
YELLOW

#3
#3 #2
#1
. .

#2
.

#1

Battery
Recovery Tank LED’s
Full LED

Brush Pressure
LED’s’s
LED Locations & Descriptions

Vacuum Fan/
Squeegee LED
Electrical Troubleshooting

61
E
 Electrical Troubleshooting T7 SERVICE INFORMATION
.
. ..
Operational Modes & Interlocks

Mode Entry Sequence Indicator Function

íDirectional Switch Forward

Forward íDirectional Switch in Forward position Forward movement of machine
íPropel Pedal Depressed

íDirectional Switch in Reverse position

íDirectional Switch Reverse
Reverse íHorn Sounding continuously ON & OFF (except in Reverse movement of machine
íPropel Pedal Depressed
"Hospital" mode)

Activate Scrub Brush, Squeegee,

íPress One Step Scrub
Scrub Mode íOne Step Scrub LED ON Vacuum Fan & Solution Flow
Button (ON)
operations

íPress One Step Scrub

íOne Step Scrub & FaST LED's ON Activate FaST foam solution flow when
FaST Mode Button (ON)
íSolution Flow LED's OFF scrub and propel are engaged
íPress FaST Button (ON)

Conventional íPress One Step Scrub

íOne Step Scrub & Solution Flow LED(s) ON Activate Conventional solution flow
Solution Button (ON)
íFaST LED OFF when scrub and propel are engaged
Mode íPress FaST Button (OFF)

E Double Scrub
(no water
pickup)
íPress One Step Scrub
Button (ON)
íPress Vacuum Fan/
Squeegee Button (OFF)
íOne Step Scrub LED ON
íVacuum Fan/Squeege LED OFF
Apply cleaning solution with no water
pickup

Water pickup íPress Vacuum Fan/ íOne Step Scrub LED OFF Collect solution on floor with squeegee,
(no Scrub) Squeegee Button (ON) íVacuum Fan/Squeegee LED ON without scrubbing floor

íPress Brush Pressure íLower Brush Pressure (#1) LED ON;

Reduce Scrub Brush and Fan speeds
Low Power Decrease (-) to one LED Middle (#2) & Upper (#3) LED's OFF
(to prolong battery life, reduce noise,
Mode íPress Solution Flow íLower Solution Flow (#1) LED ON;
lower water usage)
Decrease (-) to one LED Middle (#2) & Upper (#3) LED's OFF

íPress Brush Pressure íLower Brush Pressure (#1) LED ON; Reduce Scrub Brush and Fan speeds
Low Power
Decrease (-) to one LED Middle (#2) & Upper (#3) LED's OFF (to prolong battery life, reduce noise,
Mode w/ FaST
íPress FaST Button (ON) íFaST LED ON (Solution Flow LED's OFF) lower water usage)

Disable Scrub function (Operator can

Solution íSolution Tank Empty (Float get an additional minute of operation by
íSolution Tank Empty LED ON
Tank Empty Switch Open) re-engaging scrub system with One
Step button)
Disable Scrub function (Operator can
Recovery íRecovery Tank Full (Float get an additional minute of operation by
íRecovery Tank Full LED ON
Tank Full Switch Closed) re-engaging scrub system with One
Step button)
Disable Scrub function (Operator can
Battery íBattery voltage at or below get an additional minute of operation by
íRed LED (on Battery Gauge) blinking
Discharged full discharge voltage re-engaging scrub system with One
Step button)
íController sensed an Over
Accessory Prevent damage to Scrub Brush Motors
Current condition in the
Motor High íRefer to "High Current Faults" chart on next page or Vacuum Fan Motor – Scrub function
Scrub Brush Motors or
Current Fault shuts off
Vacuum Fan Motor

62 T7 331045 (9--08)
 T7 SERVICE INFORMATION Electrical Troubleshooting
. ..
Diagnostic & Fault Alarms

High Current Faults

Fault Entry Sequence Indicator
Propel Motor Current Higher than 40 Amps
Excessive Propel Blinking FAULT LED,
for 15 min. OR Higher than 55 Amps for 6 min.
Motor Current Propel disabled
OR Higher than 68 Amps for 4 min.
Disk Scrub Head: RIGHT brush motor <OR>
Excessive Brush Blinking FAULT LED,
Cylindrical Scrub Head: REAR brush motor
Motor Current Blinking Brush Pressure LED #3
Current Higher than 30 Amps
Disk Scrub Head: LEFT brush motor <OR>
Excessive Brush Blinking FAULT LED,
Cylindrical Scrub Head: FRONT brush motor
Motor Current Blinking Brush Pressure LED #1
Current Higher than 30 Amps

Excessive Vacuum Fan Blinking FAULT LED,

Vacuum Fan Motor current higher than 27 Amps
Motor Current Blinking Vacuum Fan/Squeegee LED

Alarm Codes
Mode
Directional
Switch
Entry Sequence Alarm Sequence Function

Alerts nearby persons of machine

backward movement (Note: Back-
E
Directional switch
Back-Up Alarm REVERSE
placed in REVERSE Horn sounds 1 beep cycle (repeats) up alarm will not sound when
machine is placed in "Hospital"
mode)
Propel Pedal depressed
Propel Interlock: Prevents movement of machine
Seat Switch Released
FORWARD with operator NOT on Horn sounds 2 beep cycle (repeats) when operator not in place
seat
Key switch turned ON Prevents movement of machine
Propel interlock:
High Pedal Disable
FORWARD with Propel Horn sounds 4 beep cycle (repeats) when key switched ON while
Pedal engaged throttle depressed
Controller sensed Prevents movement of machine
Propel Interlock:
FORWARD an out-of range Horn sounds 5 beep cycle (repeats) with invalid throttle voltage. Scrub
Throttle Fault Throttle signal (Also FAULT and FaST LED's blink) function shuts off.
Controller sensed an out- Horn sounds 6 beep cycle (repeats) Prevents movement of machine
Propel Interlock:
FORWARD of range (Also FAULT and Vacuum Fan/ with invalid brake voltage. Scrub
Parking Brake Fault Brake signal function shuts off.
Squeegee LED's blink)

Controller sensed open Horn sounds 7 beep cycle (repeats)

Prevents movement of machine
Propel Interlock:
FORWARD with ineffective parking brake.
Parking Brake Unplugged circuit on parking brake (Also FAULT and Lower Solution Flow
LED's blink) Scrub function shuts off.
Disables all functions
Controller sensed open Horn sounds 8 beep cycle (repeats)
Propel Interlock: (Note: To reset, key switch must be
FORWARD circuit on Emergency (When in Input Display Mode, FAULT
E-STOP Switch Activated cycled OFF and ON after the
Stop Switch circuit LED will also blink) E-STOP switch has closed)

Battery charger plugged

Propel Interlock: Prevents movement of the machine
Charger Plugged In
FORWARD into machine with Horn sounds 9 beep cycle (repeats) with charger plugged in
Key Switch ON

T7 331045 (9--08) 63
 Electrical Troubleshooting T7 SERVICE INFORMATION
..

Diagnostic & Configuration Modes

Mode Entry Sequence Indicator Function

Upper Brush Pressure LED blinks Tens of days, Upper

Display Solution Flow LED blinks Single day
Software Press and hold One Step
Button, turn key switch ON, wait Middle Brush Pressure LED blinks Tens of months, Blinking Brush Pressure and Solution
Revision
10 seconds, release One Step Middle Solution Flow LED blinks Single month Flow LED’s indicate revision date
Mode Button
Lower Brush Pressure LED blinks Tens of years,
(REFER TO PAGE 65)
Lower Solution Flow LED blinks out Single year

Self Test Press and hold FaST and Solid lit One Step LED indicates OK, A
Vacuum Fan/Squeegee Buttons, Start of test - Left Scrub Brush turns ON Flashing LED indicates an OPEN Fault,
Mode
turn key switch ON, wait 10 End of test - Horn sounds A Solid lit LED (other than One Step)
(REFER TO PAGE 66) seconds, release buttons indicates a SHORT Fault

Press and hold Decrease

Input Display Mode Solution Flow (-) Button, turn
Shows state of control board inputs from
key switch ON, release button Battery LED #4 (green) blinks
(REFER TO PAGE 67) various switches and sensors
after forth battery LED starts to
blink
Press and hold Decrease Brush
Manual Mode Pressure (-) Button, turn key Allows operation of individual functions
switch ON, release after Lowest Lowest down pressure LED will blink without the safety interlocks affecting or
(REFER TO PAGE 68) Brush Pressure LED starts to controlling them
blink.

E
Press and hold FaST FaST LED ON if in Forward OR Vacuum
Propel/Brake and Increase Brush Pressure (+) Fan/Squeegee LED ON if in Reverse - Solution Flow Provides information regarding brake
Diagnostic Mode Buttons, turn key switch ON, LED's display position of Propel Pedal, Brush Pressure pedal signal, propel pedal signal, and
release after battery LED's are LED's display position of Brake Pedal, Battery LED's propel motor current
(REFER TO PAGE 69)
OFF display Propel Motor current level

Press and hold the Increase

Battery Select Mode Solution Flow (+) Button, turn Allows selection of battery type. See
Any one of lower 4 battery LED’s blinks
(REFER TO PAGE 70) key switch ON, release after one “Battery Select Mode Settings” table.
Battery LED starts to blink

Reverse Alarm Put directional switch in

Allows enable/disable of
Select Mode Reverse, press & hold Horn Horn sounds or is silent
Backup alarm (Hospital Mode)
Button, turn key switch ON
(REFER TO PAGE 71)

Allows selection of maximum forward

Propel Speed Press and hold FaST Button,
Brush Pressure Lower, Middle, and Upper LED’s speed during scrubbing
turn key switch ON, release after
Selection Mode represents LOW, MEDIUM and HIGH maximum LOWER (#1) LED = 2.0 mph / 3.2 kph
selecting desired Brush
Forward Propel Speed selection MIDDLE (#2) LED = 2.7 mph / 4.3 kph
(REFER TO PAGE 71) Pressure LED setting
UPPER (#3) LED = 3.5 mph / 5.5 kph

64 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
. ..
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,
Upper Solution Flow LED blinks SINGLE DAY
•Middle Brush Pressure LED blinks TENS of MONTHS,
Middle Solution Flow LED blinks SINGLE MONTH
•Lower Brush Pressure LED blinks TENS of YEARS,
Lower Solution Flow LED blinks SINGLE YEAR

Brush Pressure # of Solution Flow # of Revision

LED's Blinks LED's Blinks Date
Day # 3 (Upper) 2 # 3 (Upper) 6 26th
Month # 2 (Middle) 1 # 2 (Middle) 1 November
Year # 1 (Lower) 0 (LED OFF) # 1 (Lower) 4 2004
E
TOUCH
One Step PANEL LEFT SIDE
DASH PANEL
Scrub Button

NOTE: An LED that does NOT

blink is the digit ZERO (0)

+ + Solution Flow
Increase Button
Brush Pressure
Increase Button LED 3
LED 3 DAY

LED 2
LED 2 MONTH
Solution Flow
LED 1 Decrease Button
YEAR
Brush Pressure LED 1
ONES
Decrease Button
TENS

- - = BLINKING (except if zero)

T7 331045 (9--08) 65
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
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 –

E 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

LED (Flashing = OPEN, Solid = SHORT) System at Fault
One Step LED No Faults Found
FaST LED Fast Pump
Vacuum Fan/Squeegee LED Vacuum-Fan
# 3 (Upper) Brush Pressure LED Right Brush
# 2 (Middle) Brush Pressure LED Left Brush
# 1 (Lower) Brush Pressure LED Head Actuator
# 3 (Upper) Solution Flow LED Water Valve
# 2 (Middle) Solution Flow LED Squeegee Actuator
# 1 (Lower) Solution Flow LED Brake
Recovery Tank Full LED Horn/Back-up Alarm

66 T7 331045 (9--08)
 The purpose of the Input Display Mode is to show the condition of various control board inputs

T7 331045 (9--08)
TO ENTER:
• Press and hold the Decrease Solution Flow (-) Button
• Turn key switch ON
• Release Button after the # 4 Battery LED blinks
• Turn key switch OFF when testing is complete.
T7 SERVICE INFORMATION

INPUT ASSOCIATED LED LED IS ON WHEN: LED IS OFF WHEN: NOTES

Battery charger IS NOT plugged in Battery charger IS plugged in FaST system will still operate, but without
Charger Interlock Switch FaST LED
(switch is CLOSED) (switch is OPEN) indicator
Operator IS NOT sitting on seat (switch Operator IS sitting on Seat (switch is
Seat Switch # 5 (Green) Battery LED
is OPEN) CLOSED)

Recovery Tank Float Recovery tank IS FULL (switch must be Recovery tank IS NOT FULL (switch Opening switch and pushing the the One Step
Recovery Tank Full LED
Switch CLOSED for 5 to 7 seconds) is OPEN) Button turns LED off again

Solution Tank Float Solution tank IS EMPTY (switch must be Solution tank IS NOT EMPTY Closing switch and pushing the the One Step
Solution Tank Empty LED
. ..

Switch OPEN for 5 to 7 seconds) (switch is CLOSED) Button turns LED off again

Emergency Stop Switch IS ACTIVATED Emergency Stop Switch IS NOT Horn will repeat 8 beep cycle when Emergency
Emergency Stop Switch Fault Indicator LED (Blinking)
(switch is OPEN) ACTIVATED (switch is CLOSED) Stop Switch is activated

One Step Button One Step LED Scrub system IS ACTIVATED Scrub system IS NOT ACTIVATED
Input Display Mode

Vacuum Fan/Squeegee Vacuum Fan & Squeegee ARE Vacuum Fan & Squeegee ARE NOT
Vacuum Fan/Squeegee LED
Button ACTIVATED ACTIVATED
Battery needs charging (LED is
Battery Voltage # 1 (Red) Battery LED Battery has sufficient charge level
BLINKING)

Left Scrub Brush

Low Pressure # 1 (Lower) Brush Pressure LED LOW scrub brush current sensed
Medium Pressure # 2 (Middle) Brush Pressure LED MEDIUM scrub brush current sensed Scrub system IS NOT ACTIVATED
High Pressure # 3 (Upper) Brush Pressure LED HIGH scrub brush current sensed

Right Scrub Brush

Low Pressure # 1 (Lower) Solution Flow LED LOW scrub brush current sensed
Medium Pressure # 2 (Middle) Solution Flow LED MEDIUM scrub brush current sensed Scrub system IS NOT ACTIVATED
High Pressure # 3 (Upper) Solution Flow LED HIGH scrub brush current sensed

NOTE: For Propel & Brake signal troubleshooting, refer to the Propel Diagnostics Mode page
Electrical Troubleshooting

67
E
 E
The purpose of the Manual Mode is to allow functioning of the individual systems on the machine without regard of most safety interlocks

68
TO ENTER:
• Press and hold the Decrease Brush Pressure (-) Button
• Turn key switch ON
• Release Button after # 1 (Lower) Brush Pressure LED blinks
• Turn key switch OFF when testing is complete.
FUNCTION BUTTON ACTION INDICATOR NOTES

Lower Scrub Head One Step Press & Hold One Step LED ON Scrub head will continue to lower as long as button is held
Electrical Troubleshooting

CAUTION : Do not hold One Step Button down too long - actuator stall will occur, possibly damaging actuator or control board
!
Release button after
Operate Scrub Brushes One Step One Step LED ON Scrub head stops lowering after One Step Button is released
lowering scrub head

Turn OFF Scrub Brushes

One Step Press & Release One Step LED OFF Scrub head raises to to top of stroke and stops
and Raise Scrub Head

Turn ON Vacuum Fan Vacuum Fan/ Vacuum Fan/ In this mode, pressing the One Step Button during lowering of
Press & Release
and Lower Squeegee Squeegee Squeegee LED ON the squeegee will stop squeegee travel
...

CAUTION : In this mode, automatic raising of the squeegee when in REVERSE is disabled
!
Turn OFF Vacuum Fan Vacuum Fan/ Vacuum Fan/ In this mode, pressing the One Step Button during raising of
Press & Release
Manual Mode

and Raise Squeegee Squeegee Squeegee LED OFF the squeegee will stop squeegee travel

Turn ON FaST pump FaST Press & Release FaST LED ON

Turn OFF FaST pump FaST Press & Release FaST LED OFF

Increase Solution Increase Solution In this mode, the Solution Flow automatic
Press & Release Solution Flow LED's
Flow Rate Flow (+) ON/OFF interlock is disabled
Decrease Solution Decrease Solution In this mode, the Solution Flow automatic
Press & Release Solution Flow LED's
Flow Rate Flow (-) ON/OFF interlock is disabled
ADDITIONAL NOTES
• When the Recovery Full switch is CLOSED for 5 to 7 seconds, the Recovery Full LED will light
• When the Solution Empty switch is OPEN for 5 to 7 seconds, the Solution Empty LED will light
• 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
• With the Directional Switch in REVERSE, the Back-up Alarm will sound but automatic raising of the squeegee is disabled
• For safety considerations, the "High Pedal Disable" and "Seat Switch Disable" interlocks & alarms are still active in Manual Mode
T7 SERVICE INFORMATION

T7 331045 (9--08)
 T7 SERVICE INFORMATION Electrical Troubleshooting
..
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

LED will be illuminated if the controller senses the
Directional Switch - Place Directional Switch in
FaST LED ON Directional Switch in Forward Position - Machine will not
Forward Forward Propel position propel if any of the Brake LED’s are illuminated

LED will be illuminated if the controller senses the

Directional Switch - Place Directional Switch in Vacuum Fan/
Directional Switch in Reverse Position - Machine will not
Reverse Reverse Propel position Squeegee LED ON propel if any of the Brake LED’s are illuminated

LED’s will display the sensed position of the brake

Brush Pressure
Brake Pedal Depress Brake Pedal pedal - No LED’s indicate pedal is released, 3 LED’s indicate
LED's that the pedal is fully depressed

LED’s will display the sensed position of the accelerator

Solution Flow
Accelerator Pedal Depress Accelerator Pedal pedal - No LED’s indicate the pedal is released, 3 LED’s
LED's indicate that the pedal is fully depressed

E
Battery gauge LED’s display the current level being drawn by
Propel Motor Current Depress Accelerator Pedal Battery LED's the Propel Motor - Each LED represents
7 Amps of current (ex: 3 LED's = 21 Amps)

Propelling System Data

Direction Wire # Color Polarity Notes

Forward
25 Green í Voltage during FORWARD travel will vary
Releasing the Propel Pedal will initiate
24 Yellow "+" between 0 to 24 VDC
Dynamic Braking; As machine slows to a
25 Green "+" halt, the Brake solenoid is De-energized,
Voltage during REVERSE travel will vary
Reverse applying the Parking Brake
24 Yellow í between approximately 0 to 17 VDC

Propel & Brake Pedal Data

Pedal LED group Lit LED's Pedal Position Input Voltage Level Notes
0 Released below 1.35 VDC
Machine must be in Propel
1 Slightly Depressed 1.35 to 1.89 VDC
Propel Solution Flow Diagnostic Mode when testing;
2 Halfway Depressed 1.89 to 2.27 VDC
LED's will display the sensed
3 Fully Depressed 2.27 to 4.0 VDC
position of the pedal; No LED's
0 Released below 1.5 VDC
indicate pedal is released; 3
1 Slightly Depressed 1.5 to 1.89 VDC
Brake Brush Pressure LED's indicate pedal is fully
2 Halfway Depressed 1.89 to 2.27 VDC
depressed
3 Fully Depressed 2.27 to 4.0 VDC

T7 331045 (9--08) 69
 Electrical Troubleshooting T7 SERVICE INFORMATION
..
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
• Battery Location/Type can be changed by pressing the Solution Flow (-) until the
desired setting is selected.
• Turn key switch OFF to save setting.

Location / Type BDI Indicator LED's

Worldwide / Wet R x x x x

Europe** / Wet x Y x x x

E 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*
Worldwide European** TNV** Worldwide BDI Indicator
Battery Level
Voltage (Wet) Voltage (Wet) Voltage (Wet) Voltage (Gel) 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

70 T7 331045 (9--08)
T7 SERVICE INFORMATION Electrical Troubleshooting
.
.
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

E
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
• Turn key switch OFF to save setting.

BRUSH PRESSURE LED(s) LIT MAXIMUM SCRUB SPEED

# 1 (Lower) LED 2.0 mph / 3.2 kph
#1 & # 2 LEDs 2.7 mph / 4.3 kph
#1, #2, & # 3 LEDs 3.5 mph / 5.5 kph

T7 331045 (9--08) 71
 E

72
Inputs
Inputs and the Charger Solution
Vacuum Recovery
Outputs they Seat Switch Switch Emergency Tank Empty Directional Directional Throttle Brake Input
Key Switch One Step FaST Switch Fan/ Tank Full Horn Button
(Operator on (Charger Stop Switch Switch Switch Switch Input (Pedal (Pedal
Control (ON) Switch (ON) (ON) Squeegee Switch (Pressed)
seat) plugged in to (Pressed) (Tank Forward Reverse pressed) pressed)
Switch (ON) (Tank Full)
machine) Empty)

Main Contactor E D D
Propel Forward E E D D E D E D
Propel Reverse
Electrical Troubleshooting

E E D D D E** E D
Dynamic Braking
Force - Increase E E D E
Parking Brake E E D E***
Scrub Motors E D D E D D E D
Scrub Head
Pressure Control E D D E D D E D
Vacuum Motor E D D E D D
...

Outputs
Squeegee Down E D D E D D E D
FaST System E D D E E D D E D
Solution Solenoid E D D E
Inputs & Outputs Table

Hour Meter
Operation E E* E*
Horn E E** E
Battery Gauge
Reset 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
T7 SERVICE INFORMATION

T7 331045 (9--08)
T7 SERVICE INFORMATION Amer Drive Motor
.

AMER DRIVE
MOTOR

BEFORE CONDUCTING TESTS:

* Read and Follow ALL Safety Warnings and Precautions as mentioned
at the beginning of this manual
* Always unhook Battery when removing or replacing electrical
components

DURING TESTS: A
* 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.

T7 331045 (9--08) 73
 Amer Drive Motor T7 SERVICE INFORMATION
.

Drive Motor Exploded View

Performance Specifications
Watts
Speed Nominal
Volts Values
A Amps
Tennant Part Number
Gear Ratio
Duty Cycle
Date Made
Serial Number

Amp draw with drive wheel off

of the floor should not exceed:
24volt 7.5 amps
36volt 6.5 amps

74 T7 331045 (9--08)
T7 SERVICE INFORMATION Amer Drive Motor
.
.

&RPPXWDWRU %UXVK5HSODFHPHQW

•Clean using high pressure air to remove dust and dirt.

•Check brushes at least every 500 Hours.
•Change brushes when they reach a length of 12/13 mm (0.50 inches).
•Do not allow sleeve to come out when brush is removed. Two of the
four brush sleeves use brass nuts as spacers which may drop into
assembly.

&RQWDFW5LQJ&DUERQ%UXVK$FFHVV

Always remove the complete box to

service the contact ring carbon
brushes.

T7 331045 (9--08) 75
 Amer Drive Motor T7 SERVICE INFORMATION
.

&RQWDFW5LQJ&DUERQ%UXVKHV
First style:
•Square carbon brush
•Loose backing nut

Second style:
•Curved carbon brush
•Loose backing nut

Third style:
•Curved carbon brush
•Fixed backing nut

Brake Solenoid
The air gap should be
.31mm(.012in) to.019mm(.008in).
A Measurement is taken from three different angles
while the brake is mounted to the drive motor.

76 T7 331045 (9--08)
T7 SERVICE INFORMATION Amer Drive Motor
.

Brake Solenoid (continued)

Original spacer length set at
35mm (1.3779in). Tighten 3 mounting allen screws to 3N/m

Gap adjustment is made with the brake

assembly removed by turning each
Three Adjustable Spacers
adjustable spacer an equal amount

%UDNH5RWRU

A new brake rotor is

6.35mm (0.25in) thick.
A
It is lined with braking material 2mm deep
on both sides.

Measuring total thickness, replace when

worn to
4mm (0.1718in), or 1mm or less on each
side .

Brake dragging may be caused by:

Air gap too narrow
Intermittent electrical connection
Debris in air gap

T7 331045 (9--08) 77
 Amer Drive Motor T7 SERVICE INFORMATION
.

Drive Motor Disassembly & Repair

IMPORTANT: before removing the

brush holder assembly mark with a
marking pen a point of reference
A between the rubber wheel and the
brush holder, in order to make easier
the correct reassembly and avoid the
mounting with the wrong rotation of
the motor wheel.

To make the reassembly of the brush

holder assembly easier unscrew the
caps and remove the carbon
brushes.

78 T7 331045 (9--08)
T7 SERVICE INFORMATION Amer Drive Motor
.

Drive Motor Disassembly & Repair (continued)

IMPORTANT: during this phase do not

remove the stator from the original
position.

Keep the gearbox side bracket on the

table and remove the armature. Pay
attention: the oil must not come out
from the gearbox otherwise it will
damage the o ring.

T7 331045 (9--08) 79
 T7 SERVICE INFORMATION
.

80 T7 331045 (9--08)
We Need Your Help...
As part of Tennant’s Zero Defects Program, we want to know about errors you have
found or suggestions you may have regarding our machine manuals. If you find an
error or have a suggestion, please complete this postage-paid form and mail it to us.
Thank you for helping us make zero defects a way of life at Tennant.

Manual No. Rev. No. Publish Date Page

Machine - Report Error - Suggestion

Name Date
Customer Number
Company
Address
City/State/Zip Code
Fold along dotted lines Tape here
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED SATES
BUSINESS REPLY MAIL
FIRST CLASS MAIL PERMIT NO. 94 MINNEAPOLIS, MN
POSTAGE WILL BE PAID BY ADDRESSEE
TENNANT COMPANY
Technical Publications #15
701 North Lilac Drive
P.O. Box 1452
Minneapolis, MN 55440--9947
We Need Your Help...
As part of Tennant’s Zero Defects Program, we want to know about errors you have
found or suggestions you may have regarding our machine manuals. If you find an
error or have a suggestion, please complete this postage-paid form and mail it to us.
Thank you for helping us make zero defects a way of life at Tennant.

Manual No. Rev. No. Publish Date Page

Machine - Report Error - Suggestion

Name Date
Customer Number
Company
Address
City/State/Zip Code
Fold along dotted lines Tape here
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED SATES
BUSINESS REPLY MAIL
FIRST CLASS MAIL PERMIT NO. 94 MINNEAPOLIS, MN
POSTAGE WILL BE PAID BY ADDRESSEE
TENNANT COMPANY
Technical Publications #15
701 North Lilac Drive
P.O. Box 1452
Minneapolis, MN 55440--9947