T5
Service Information Manual
NOTE: Refer to page iv for important
information for machines with serial number
date codes below DC1006 (October, 2006).
The Safe Scrubbing AlternativeR
HygenicR Fully Cleanable Tanks
QA Controlst
North America / International
www.tennantco.com
9002333
Rev. 02 (11-2007)
*9002333*
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 2006 TENNANT Company, Printed in U.S.A.
ii
T5 9002333 REV.02 (07-06)
T5 Service Information Manual
Table of Contents
page
MACHINE INFORMATION
Component Locator…………...……………………………..……………… 1
Machine Specifications……………………….………………………………5
MAINTENANCE
CHARGING BATTERIES…………………………………………………… 7
Battery Charger Specifications………………...…………………7
On-Board Battery Charger Settings………………………………7
Using the On-Board Battery Charger……………………………7
Using an Off-Board Battery Charger…………………………… 8
On-Board Battery Charger Error Codes…………………………9
ADJUSTING SCRUB HEAD BRUSHES……………………………………10
Disk Brush Model………………...…………………………………10
Cylindrical Brush Model……………………………………………10
MACHINE MAINTENANCE……………………………………………..……12
12
Daily Maintenance…………………………………………..………
14
Monthly Maintenance………………………………….……………
15
Battery Maintenance……………..…………………………………
15
Squeegee Blades……………………………...……………………
16
Motor Maintenance……………………………………….…………
FaST System Maintenance……………………………………… 16
JACKING UP MACHINE……………...………………………………………17
17
TRANSPORTING MACHINE…………………….……………...……………
STORING MACHINE………………………………………...…..……………17
17
FaST System Freeze Protection……………..……………………
18
RECOMMENDED STOCK ITEMS……………..……………….……………
BASIC TROUBLESHOOTING……………………….………………………20
CONTROL PANEL FAULT INDICATOR CODES…………………….……21
ELECTRICAL
22
Electrical Schematic…………………………...…..…………………..………
Wiring Harness Detail………………………...………………..…………… 24
35 Pin Connector Detail………………..………………..……………………30
Control Panel LED Details…………………………………..…..……………31
Electrical Symbols & Terms…………………………...……………..………32
Key OFF Power Distribution (Off-Board Charger Disconnected) …………………
33
Key OFF Power Distribution (Off-Board Charger Connected) ……………………
34
Key OFF Power Distribution (On-Board Charger Disconnected) …………………
35
Key OFF Power Distribution (On-Board Charger Connected) ……………………
36
37
Key OFF Propel System………………...……………….……………………
Key ON Power Distribution……………….………………………………… 38
Propel Forward System………………………………………………………39
Propel Reverse System………………………………………………………40
41
Propel System Neutral…………………………………………………………
42
Scrub Brushes……………………...…………………………..………………
Vacuum Fan System…………………………..………………..……………43
Conventional Solution Solenoid Valve………………………………………44
FaST Water Pump…………….………………………………………………45
Hour Meter & Off-Aisle Wand Water Pump…………………………………46
Scrub Head Actuator LOWER (Extend)……………………………………47
Scrub Head Actuator RAISE (Retract)………………………………………48
49
Operational Modes & Interlocks………………………………………………
Diagnostic LED Codes……………………………………………………… 50
High Current Faults……………………………………………………………50
Diagnostic & Configuration Modes………………………………………… 51
Display Software Revision Mode……………………………………………52
Self Test Mode………………………………..………………………………54
Input Display Mode……………………………………………...……………55
57
Manual Mode…………………………………………………...………………
Propel Diagnostics Mode…………………………………………………… 59
Battery Select Mode………………………………………………...…………60
Supervisor Mode…………………………………………..………………… 61
Scrub Propel Speed Selection Mode……………………………………… 62
63
Scrub Head Selection Mode…………………………………..………………
Inputs & Outputs Table………………………………………………….……64
T5 9002333 REV.02 (07-06)
iii
T5 Service Information Manual
!
BEFORE CONDUCTING TESTS:
!
z Read and Follow ALL Safety Warnings and Precautions in Operator's
Manual
z Always use an ESD (Electrostatic Discharge) strap when working near
the Control Board
z Be cautious when working near Control Board – Battery voltage is
always present, even with Key OFF
z Always Disconnect Batteries when removing or replacing components
DURING TESTS:
z Call Technical Services if Diagnostic Time Exceeds One Hour with
Unknown Cause or Course of Action
IMPORTANT INFORMATION FOR MACHINES WITH SERIAL
NUMBER DATE CODES PRIOR TO DC1006 (October, 2006)
Potential rolling hazard may exist when transporting the machine on a ramp or incline with key
turned to the “off” position. The machine could roll at an undesirable speed creating the risk for
potential injury or property damage.
To ensure operator safety and to prevent potential property damage,Tennant Company mandates
that the existing control box assembly be replaced with the Control Box Kit (p/n 9003250). For more
information, refer to Technical Service Bulletin # 130. To determine if the machine in question has
been updated with the new Control Box Kit, refer to the picture below.
If the Brake Relay (CR2) is present in the
Control Box, the machine has already been
updated and no further action is required.
If the Brake Relay (CR2) is NOT present in
the Control Box, follow the instructions in
Technical Service Bulletin # 130.
CR2
CONTROL BOX ASSEMBLY
iv
T5 9002333 REV.02 (11-07)
T5 Component Locator
(Page 1 of 4)
TOUCH PANEL
SPEED LIMIT
POTENTIOMETER P2
I
ONE STEP
SCRUB BUTTON
INCREASE BRUSH
PRESSURE BUTTON
INCREASE
SOLUTION BUTTON
DECREASE BRUSH
PRESSURE BUTTON
DECREASE
SOLUTION BUTTON
INSIDE VIEW
THROTTLE POSITION SENSOR P2
(POTENTIOMETER)
EMERGENCY STOP
SWITCH SW2
FaST/CONVENTIONAL
SWITCH SW7
HOUR METER H1
WAND PUMP
SWITCH SW8
KEY SWITCH SW3
SWITCH PANEL
T5 9002333 REV.02 (07-06)
1
T5 Component Locator
(Page 2 of 4)
I
VACUUM FAN
MOTOR M3
RECOVERY TANK
INTERLOCK SWITCH SW6
CONTROL BOARD AND
CIRCUIT BREAKERS
T
ON
FR
FR
O
BOTTOM
VIEW
FR
N
T
O
N
T
FRONT
BOTTOM
VIEW
PROPEL MOTOR M4
FaST PUMP MOTOR M6
2
T5 9002333 REV.02 (07-06)
T5 Component Locator
(Page 3 of 4)
MOTOR
M1
CYLINDRICAL SCRUB
BRUSH MOTORS
MOTOR
M2
MOTOR
M1
DISK SCRUB
BRUSH MOTORS
I
MOTOR
M2
ACTUATOR MID-STROKE SWITCH SW5
ACTUATOR RETRACT SWITCH SW9
ACTUATOR EXTEND LIMIT SWITCH SW10
SCRUB HEAD ACTUATOR M5
T5 9002333 REV.02 (07-06)
SCRUB HEAD ACTUATOR M5
3
T5 Component Locator
(Page 4 of 4)
I
ON-BOARD CHARGER
VACUUM FAN
SWITCH SW4
CHARGER
INTERLOCK
SWITCH SW1
(OFF-BOARD
CHARGER)
CONVENTIONAL SOLENOID VALVE SL1
10A CIRCUIT
BREAKER CB2
STANDOFF2
5A CIRCUIT
BREAKER CB1
100A FUSE F1
MAIN
CONTACTOR
CR1
VACUUM
FAN MOTOR
CONNECTOR
BRAKE
RELAY CR2
BRUSH
MOTORS
CONNECTOR
RIBBON CABLE
CONNECTOR
STANDOFF1
35 PIN
CONNECTOR
PROPEL
MOTOR
CONNECTOR
CONTROL BOARD AND CIRCUIT BREAKERS
4
T5 9002333 REV.02 (11-07)
MACHINE SPECIFICATIONS
MODEL
Disk,
600mm
Disk,
700mm
Disk,
800mm
LENGTH
1350mm (53 in)
WIDTH
580mm (23 in)
HEIGHT
Cylindrical,
650mm
Cylindrical,
800mm
1120mm (44 in)
MINIMUM AISLE TURN
1346mm (53 in)
1499mm (59 in)
1626mm (64 in)
1575mm (62 in)
1638mm (64.5 in)
WEIGHT
143 Kg (316 lbs)
165 Kg (365 lbs)
171 Kg (377 lbs)
162 Kg (357 lbs)
166 Kg (365 lbs)
WEIGHT WITH BATTERIES
263 Kg (580 lbs)
276 Kg (609 lbs)
282 Kg (621 lbs)
281 Kg (621 lbs)
285 Kg (629 lbs)
RECOVERY TANK CAPACITY
102 L (27 Gal)
SOLUTION TANK CAPACITY
85 L (22.5 Gal)
DRIVE SYSTEM
Transaxle, 24 V, .19 Kw (.25 hp)
TRAVEL SPEED, MAXIMUM
Cleaning: 67 m/min (220 ft/min)
Transporting: 72 m/min (235 ft/min)
PRODUCTIVITY RATE
Theoretical
2450m2
(26,400ft2)/hr
2860m2
(30,800ft2)/hr
3270m2
(35,200ft2)/hr
2660m2
(28,600ft2)/hr
3270m2
(35,200ft2)/hr
PRODUCTIVITY RATE
Estimated Actual
1660m2
(17,875ft2)/hr
1930m2
(20,800ft2)/hr
2230m2
(24,000ft2)/hr
1785m2
(19,200ft2)/hr
2230m2
(24,000ft2)/hr
CLEANING PATH WIDTH
600mm (24 in)
700mm (28 in)
800mm (32 in)
650mm (26 in)
800mm (32 in)
BRUSH DIAMETER
302mm (11.9 in)
353mm (13.9 in)
404mm (15.9 in)
151mm (5.9 in)
151mm (5.9 in)
BRUSH PRESSURE
18/36/54 Kg (40/80/120 lbs)
SOLUTION FLOW RATE -- Low:
1.70 L
(.45Gal)/min
1.90 L (.50Gal)/min
1.70 L
(.45Gal)/min
1.90 L
(.50Gal)/min
SOLUTION FLOW RATE -- Med:
1.30 L
(.35Gal)/min
1.51 L (.40Gal)/min
1.30 L
(.35Gal)/min
1.51 L
(.40Gal)/min
SOLUTION FLOW RATE -- Max:
.95 L
(.25Gal)/min
1.14 L (.30Gal)/min
.95 L
(.25Gal)/min
1.14 L
(.30Gal)/min
SQUEEGEE WIDTH
908mm (35.7 in)
standard
1051mm (41.3 in)
standard
1185mm (46.6 in)
standard
1051mm (41.3 in)
1185mm (46.6 in)
800mm (31.5 in)
908mm (35.7 in)
1051mm (41.3 in)
BRUSH MOTOR
Qty 2, .55Kw (.75hp), 220rpm, 24V, 29A
Qty 2, .47Kw (.63hp), 1500rpm,
24V, 23A
VACUUM MOTOR
640W (.85 hp), 3--stage 5.7, 24V, 26A
WATER LIFT/AIR FLOW
55mm (62 in) H2O/ 32.4 L3 (69ft3)/m
BATTERIES
Qty 4, 6V
RUN TIME PER CHARGE
BATTERY CAPACITY
ONBOARD CHARGER
Minimum 3.5 hrs / Maximum 4.75 hrs
WET (lead Acid) = 235Ah/20hr rate
Sealed (Gel)= 200Ah/20 hr rate
120VAC, 10A, 50/60Hz, 24VDC, 20A output / 230VAC, 5A, 50/60Hz, 24VDC, 20A output
TOTAL POWER CONSUMPTION
50 Amp nominal
VOLTAGE DC
24 VDC
PROTECTION GRADE
IPX3
SOUND POWER LEVEL
79.5dB
81dB
DECIBEL RATING AT OPERATOR’S EAR, INDOORS.*
67dB(A)
68dB(A)
VIBRATION AT CONTROLS
ACCELERATION RATE ON
OPERATOR -- MAX.
GRADE LEVEL, MAX.
I
<.1188m/s2 (<.39ft/s2)
<.103m/s2 (<.34ft/s2)
.179m (.56ft) /s2
Scrubbing 5% (3q), Transporting 8% (5q)
* Sound pressure (ISO 11201) as recommended by the American Association of Cleaning Equipment Manufacturers (AACEM) and OSHA.
T5 9002333 REV.02 (07-06)
5
I
FaST SYSTEM
Disk,
600mm
Disk,
700mm
Disk,
800mm
Cylindrical,
650mm
Cylindrical,
800mm
PRODUCTIVITY RATE
Estimated Actual
1865m2
(20,075ft2)/hr
2115m2
(22,750ft2)/hr
2440m2
(26,250ft2)/hr
1950m2
(21,000ft2)/hr
2440m2
(26,250ft2)/hr
SOLUTION PUMP
24 Volt DC, 3.5 A, 5.6L (1.5 Gal)/min open flow, 4.13 Bar (60psi) bypass setting
SOLUTION FLOW RATE
0.57 L
(0.15 Gal) /min.
0.83 L (0.22 Gal) /min.
0.57 L
(0.15 Gal) /min.
0.83 L
(0.22 Gal) /min.
CONCENTRATE FLOW RATE
0.57CC
(0.0193oz)/min.
0.83CC (0.028oz)/min.
0.57CC
(0.0193oz)/min.
0.83CC
(0.028oz)/min.
CONCENTRATE TO WATER
DILUTION RATIO
1:1000
MACHINE DIMENSIONS
580mm
(23 in)
1120mm
(44 in)
1350mm
(53 in)
600mm (23.5 in)
650mm (25.5 in)
700mm (27.5 in)
800mm (31.5 in)
800mm (31.5 in)
908mm (35.7 in)
1051mm (41.3 in)
1185mm (46.6 in)
6
T5 9002333 REV.02 (07-06)
T5 –Maintenance
(Page 1 of 15)
CHARGING BATTERIES
ATTENTION: To prolong the life of the batteries
only recharge the batteries if the machine was
used for a total of 30 minutes or more. Do not leave
batteries discharged for lengthy periods.
To change the setting, unplug the charger, peel up the
corner of the display label and set the switches
accordingly (Fig. 41). The charger cord must be
unplugged when resetting.
WARNING: Fire Or Explosion Hazard.
Batteries Emit Hydrogen Gas. Keep Sparks And
Open Flame Away. Keep Battery Compartment
Open When Charging.
FOR SAFETY: When servicing batteries, wear
protective gloves and eye protection when
handling batteries and battery cables. Avoid
contact with battery acid.
M
BATTERY CHARGER SPECIFICATIONS:
S
S
S
S
S
CHARGER TYPE:
-- FOR SEALED (Gel) BATTERIES
-- FOR WET (Lead acid) BATTERIES
OUTPUT VOLTAGE - 24 VOLTS
SEALED “GEL” BATTERY
WET “Acd” BATTERY
FIG. 41
OUTPUT CURRENT - 20 AMPS
AUTOMATIC SHUTOFF CIRCUIT
USING THE ON--BOARD BATTERY CHARGER
FOR DEEP CYCLE BATTERY CHARGING
IMPORTANT: Before charging, make sure that the
charger setting is properly set for your battery type
(See ON--BOARD CHARGER SETTINGS).
ON--BOARD BATTERY CHARGER SETTINGS:
If your machine is equipped with the on--board charger,
the charger settings must be set for your battery type
before charging. Failure to properly set will result in
battery damage.
To determine your battery type, see battery label.
Contact your battery supplier if not specified.
To verify what the charger is currently for, connect the
charger cord into an electrical receptacle. The charger
will display a sequence of codes. One of the codes will
either read “GEL” or “Acd” (Figure 40).
1. Transport the machine to a well--ventilated area.
2. Park the machine on a flat, dry surface. Turn the
key off and set the parking brake, if equipped.
3. If charging wet (lead acid) batteries check the fluid
level before charging (See BATTERY
MAINTENANCE).
4. Prop up the recovery tank for ventilation
(Figure 42).
GEL = Set for sealed/maintenance free batteries
Acd = Set for wet/lead acid batteries
FIG. 42
5. Connect the charger’s AC power supply cord into a
properly grounded receptacle (Figure 43).
NOTE: The machine will not operate when charging.
FIG. 40
T5 9002333 REV.02 (09-06)
7
T5 –Maintenance
(Page 2 of 15)
USING AN OFF--BOARD BATTERY CHARGER
(OPTION)
1. Transport the machine to a well--ventilated area.
2. Park the machine on a flat, dry surface. Turn the
key off and set the parking brake, if equipped.
3. If charging wet (lead acid) batteries, check the fluid
level before charging (See BATTERY
MAINTENANCE).
4. Prop up the recovery tank for ventilation
(Figure 45).
FIG. 43
M
6. The charger will display a sequence of codes once
the cord is connected (Figure 44).
Three--digits + the following code:
A = Charging current
U = Battery Voltage
h = Charging time
C = Charging ampere--hours [Ah]
E = Energy used [Kwh]
“GEL” or “Acd” = Battery type the charger is
currently set for. Before charging make sure
your battery type matches the display:
GEL=Sealed, Acd=WET (lead acid). To change
setting, see ON--BOARD CHARGER
SETTINGS.
Press the arrow button to review the codes.
FIG. 44
7. Once the charging cycle begins, the indicator lights
will progress from red, yellow to green. 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).
8
FIG. 45
5. Connect the charger’s DC cord into the machine’s
battery receptacle (Figure 46).
6. Connect the charger’s AC power supply cord into a
properly grounded receptacle (Figure 46).
FIG. 46
7. The supplied charger will automatically begin
charging and shut off when fully charged.
NOTE: The machine will not operate when charging.
ATTENTION: Do not disconnect the charger’s DC
cord from the machine’s receptacle when the
charger is operating. Arcing may result. If the
charger must be interrupted during charging,
disconnect the AC power supply cord first.
T5 9002333 REV.02 (07-06)
T5 –Maintenance
(Page 3 of 15)
ON--BOARD BATTERY CHARGER ERROR CODES
DISPLAY CODE
FAULT
SOLUTION
bat
Loose or damaged battery cable
Check battery cable connections.
Battery exceeded maximum voltage level.
No action necessary.
E01
Exceeded maximum battery voltage allowed.
No action necessary.
E02
Safety thermostat exceeded maximum internal Check if the charger vents are obstructed.
temperature.
E03
Exceeded maximum time for charging phase
leaving the batteries undercharged due to a
sulfated or faulty battery.
Repeat the charging cycle and if the error
code E03 reappears check battery or
replace it.
SCt
Safety timer exceeded maximum charging
time. Interrupts charging cycle.
Replace battery.
Srt
Possible internal short circuit.
Contact Service Center.
T5 9002333 REV.02 (07-06)
M
9
T5 –Maintenance
(Page 4 of 15)
ADJUSTING SCRUB HEAD BRUSHES
CYLINDRICAL BRUSH MODEL
To ensure optimum scrubbing performance periodically
check the scrub head for proper adjustment.
After installing a new set of cylindrical brushes check
the brush pattern to ensure proper brush adjustment.
Brushes that are not properly adjusted will result in
premature wear and poor scrubbing performance
(Figure 49).
FOR SAFETY: Before adjusting scrub head, stop
machine on level surface, remove key and set
parking brake if equipped.
CORRECT BRUSH PATTERN
Even
Pattern
DISK MODEL
M
Tools required: Measuring device, 27mm (1--1/16 in)
wrench and 24mm (15/16 in) wrench
Uneven
Pattern
INCORRECT BRUSH PATTERNS
Tapered
Pattern
1. With brushes installed, lower the scrub head and
apply medium brush pressure.
2. Turn machine off and remove key.
3. From the center front and back of scrub head,
measure the distance from the top edge of scrub
head to the floor (Figure 47).
FIG. 49
To Inspect the Brush Pattern:
1. Position the machine on a dry dusty floor or apply a
powdered substance, such as chalk.
2. Disconnect the drive motor wire connector to keep
machine from moving forward (Figure 50).
FIG. 47
4. If scrub head is not level, loosen the lock nut and
turn the scrub head leveling screw to level. Tighten
down the lock nut once head is level (Figure 48).
FIG. 50
3. Lower the scrub head to the floor and apply
maximum brush pressure.
4. Shut off the solution flow.
Lock
Nut
FIG. 48
5. Pull the control handle bail to create a brush
pattern on the floor.
6. Raise the scrub head and pull the machine away.
7. Observe the brush pattern on floor. If the brush
pattern is uneven or tapered, adjustment is
required.
8. Reconnect drive motor wire.
10
T5 9002333 REV.02 (07-06)
T5 –Maintenance
(Page 5 of 15)
To Adjust an Uneven Brush Pattern:
To Adjust a Tapered Brush Pattern:
Tools required: Measuring device, 27mm (1--1/16 in)
wrench and 24mm (15/16 in) wrench
Tools required: 10mm (3/8 in) wrench and 6mm hex
wrench
1. Measure the distance from the front edge of the
scrub head to the floor and from the back edge of
the scrub head to the floor (Figure 51). The
measurements should be the same.
1. Raise the scrub head off floor and remove key.
2. Remove the idler plate from the brush (Figure 53).
M
FIG. 53
FIG. 51
2. To level the scrub head, loosen the lock nut and
turn the leveling screw clockwise to lower the rear
of the scrub head or counter--clockwise to lower the
front (Figure 52).
3. Hold the brush plug shaft with a wrench and loosen
the 6mm hex screw (Figure 54).
FIG. 54
FIG. 52
4. To lower the brush end, turn the shaft clockwise for
the front brush and counter--clockwise for the rear
brush. Retighten hex screw (Figure 55).
3. Recheck brush pattern.
NOTE: Replace brushes when worn to 15mm (5/8”).
FIG. 55
5. Recheck brush pattern.
NOTE: Replace brushes when worn to 15mm (5/8”).
T5 9002333 REV.02 (07-06)
11
T5 –Maintenance
(Page 6 of 15)
4. Remove the debris tray and empty (Figure 59)
MACHINE MAINTENANCE
To keep the machine in good working condition, it’s
important that the following maintenance procedures
are performed on a routine basis.
WARNING: Electrical Hazard. Disconnect
Battery Cables Before Servicing Machine.
DAILY MAINTENANCE (After Every Use)
1. Drain the recovery tank (Figure 56).
FIG. 59
5. Drain the solution tank (Figure 60).
M
FIG. 56
2.
Rinse and clean out the recovery tank (Figure 57).
FIG. 60
6
Clean the solution tank filter (Figure 61).
FIG. 57
3. Remove the recovery tank float shut--off screen
and clean (Figure 58).
FIG. 61
7. Rotate pad or replace when worn (Figure 62).
Disk Model
FIG. 58
12
FIG. 62
T5 9002333 REV.02 (07-06)
T5 –Maintenance
(Page 7 of 15)
8. Empty and rinse out the debris trough (Figure 63).
Cylindrical Brush Model
FIG. 66
FIG. 63
9. Inspect the cylindrical brushes for wear. Rotate
brushes from front--to--rear every 50 hours (Figure
64). Replace when worn to a length of 15mm
(5/8”).
12. Check the condition of the squeegee blade wiping
edge (Figure 67). Rotate blade if worn (See
SQUEEGEE BLADES).
M
15mm
(5/8”)
Cylindrical
Brush Model
FIG. 64
10. Remove debris buildup from the underside of the
cylindrical brush scrub head, including the idler
plates and drive hubs (Figure 65).
FIG. 67
13. Clean the machine with an all purpose cleaner and
damp cloth (Figure 68).
FOR SAFETY: When cleaning machine, do not
power spray or hose off machine. Electrical
malfunction may occur.
Cylindrical Brush Model
FIG. 65
FIG. 68
11. Wipe the squeegee blades clean (Figure 66). Store
the squeegee assembly in the raised position to
prevent blade damage.
T5 9002333 REV.02 (07-06)
13
T5 –Maintenance
(Page 8 of 15)
14. Inspect the condition of the scrub head skirt,
replace if worn or damaged (Figure 69).
MONTHLY MAINTENANCE
1. Check the cylindrical brush belt tension every 100
hours (Figure 72). Belt tension should flex 3mm
(0.1 in) at midpoint, with 1.13--1.22 Kg (2.5--2.7 lbs)
force.
WARNING: Electrical Hazard. Disconnect
Battery Cables Before Servicing Machine.
Disk Model
M
Cylindrical Brush Model
FIG. 69
15. FaST Model: Connect the FaST--PAK supply hose
to the storage plug when not in use (Figure 70).
Remove any dried concentrate from the hose
connector by soaking it in warm water.
Cylindrical Brush Model
FIG. 72
2. Inspect and clean the recovery tank cover seal
(Figure 73). Replace if damaged.
FIG. 70
16. Clean wet/lead acid batteries to prevent corrosion
and check for loose battery cable connections (See
BATTERY MAINTENANCE).
17. Recharge the batteries (Figure 71). To prolong the
life of the batteries, only recharge the batteries if
the machine was used for a total of 30 minutes or
more.
FIG. 73
3. Lubricate all pivot points and rollers with a water
resistant grease.
4. Lubricate the casters with a water resistant grease
(Figure 74).
FIG. 71
FIG. 74
14
T5 9002333 REV.02 (07-06)
T5 –Maintenance
(Page 9 of 15)
5. Clean the parking brake clamp with a cleaning
solvent.
6. Check the machine for loose nuts and bolts.
7. Check the machine for leaks.
BATTERY MAINTENANCE (Wet/lead acid batteries)
1. Check battery fluid level frequently to prevent
battery damage. The fluid should be at the level
shown (Figure 75). Add distilled water if low. DO
NOT OVERFILL, the fluid may expand and
overflow when charging.
FIG. 76
SQUEEGEE BLADES
When the blades become worn, simply rotate the
blades end-for-end or top-to-bottom to a new wiping
edge. Replace blades when all edges are worn.
M
The front blades on the 700mm/800mm squeegee
assemblies have 12/14 slots on one edge and 6 slots
on the opposite edge (Figure 77). If making sharp turns
with the cylindrical brush models use the 12/14 slotted
edge for maximum water pickup.
CORRECT BATTERY FLUID LEVEL:
Before Charging
6 Slots on
one edge
After Charging
12/14 Slots on
opposite edge
FIG. 75
WARNING: Fire Or Explosion Hazard.
Batteries Emit Hydrogen Gas. Keep Sparks And
Open Flame Away. Keep Battery Compartment
Open When Charging.
FIG. 77
Replacing Squeegee Blades:
1. Loosen the band clamp and remove the band from
the squeegee assembly (Figure 78).
2. Clean the batteries to prevent battery corrosion.
Use a scrub brush with a mixture of baking soda
and water (Figure 76).
FOR SAFETY: When cleaning batteries, wear
protective gloves and eye protection. Avoid
contact with battery acid.
FIG. 78
T5 9002333 REV.02 (07-06)
15
T5 –Maintenance
(Page 10 of 15)
2. Replace or rotate the rear blade to a new wiping
edge and replace band (Figure 79).
FaST SYSTEM MAINTENANCE
Every 1000 hours replace the orifice plate and filter
screen located inside the detergent injector assembly.
Order service kit p/n 9001489.
1. To access the detergent injector assembly, lower
the scrub head and remove the front shroud
(Figure 81)
M
FIG. 79
3. To change the front blade, remove the band and
loosen the four knobs. Replace or rotate the front
blade to a new wiping edge (Figure 80)
FIG. 81
2. Remove the injector assembly from clamps
(Figure 82).
FIG. 80
MOTOR MAINTENANCE
Contact an Authorized Tennant Service Center for
carbon brush replacement.
FIG. 82
Carbon Brush Replacement
Hours
Drive Transaxle Motor
Vacuum Motor
3
Unthread the black plastic filter housing and replace
the orifice plate and filter (Figure 83).
750
Disk Brush Motors
Cylindrical Brush Motors
1000
WARNING: Electrical Hazard. Disconnect
Battery Cables Before Servicing Machine.
FIG. 83
16
T5 9002333 REV.02 (07-06)
T5 –Maintenance
(Page 11 of 15)
JACKING UP MACHINE
Use the designated locations to jack up the machine for
service (Figure 84). Empty the recovery and solution
tank and position the machine on a level before jacking.
FOR SAFETY: When servicing machine, jack
machine up at designated locations only. Use jack
or hoist that will support machine weight.
FIG. 85
STORING MACHINE
1. Charge the batteries before storing machine to
prolong the life of the batteries.
M
2. Drain and rinse the tanks thoroughly.
FIG. 84
TRANSPORTING MACHINE
When transporting the machine by trailer or truck, be
certain to follow the transporting procedure below:
1. Drain machine tanks.
2. Load the machine using a ramp that can support
the machine weight and person loading it. The
maximum ramp incline should not exceed 11q at a
ramp length of 3.7m (12 ft).
3. Position the front of machine up against the front of
the trailer or truck. Lower the scrub head and
squeegee.
4. Set the parking brake, if equipped, and place a
block behind each wheel to prevent the machine
from rolling.
3. Store the machine in a dry area with the squeegee
and scrub head in the up position.
4. Open the recovery tank cover to promote air
circulation.
ATTENTION: Do not expose machine to rain, store
indoors.
5. If storing machine in freezing temperatures, make
sure to drain machine of all water.
For models equipped with the FaST System, follow
the FaST SYSTEM FREEZE PROTECTION
procedure below.
FaST SYSTEM FREEZE PROTECTION
Valve Coupling #1002856 and 15 cm Hose #63182 are
required (Purchased separately).
1. Remove the FaST--PAK carton and connect the
valve coupling and 15cm hose (purchased parts) to
the supply hose (Figure 86).
5. Secure with tie--down straps as shown (Figure 85).
It may be necessary to install tie-down brackets to
trailer or truck.
FOR SAFETY: When loading/unloading machine
onto/off truck or trailer, use a ramp that can
support the machine weight and person loading it,
do not exceed a 11q ramp incline at a ramp length
of 3.7m (12 ft), use tie--down straps to secure
machine and block machine wheels.
FIG. 86
T5 9002333 REV.02 (07-06)
17
T5 –Maintenance
(Page 12 of 15)
2. Disconnect the opposite end of the supply hose
from the injector assembly and drain the supply
hose (Figure 87). To access the injector assembly
remove the front shroud.
7. To drain the anti--freeze, repeat the draining
process above and reconnect the supply hose to
the FaST--PAK carton.
RECOMMENDED STOCK ITEMS
Refer to the Parts List Manual for recommended stock
items. Stock Items are clearly identified with a bullet
preceding the parts description. See example below:
M
FIG. 87
3. Reconnect the supply hose to injector assembly
and pour a recreational vehicle (RV) anti--freeze
into the supply hose until full (Figure 88).
FIG. 88
4. Operate the FaST system as normal until the
foaming stops. This step could take anywhere from
5--10 minutes.
5. Remove the valve coupling and connect the
storage plug (Figure 89).
FIG. 89
6. Drain the recovery and solution tanks and store
machine.
18
T5 9002333 REV.02 (07-06)
T5 –Maintenance
(Page 13 of 15)
TROUBLESHOOTING
PROBLEM
CAUSE
SOLUTION
Machine will not operate
Discharged batteries
Charge batteries
Emergency--stop button activated
Turn button clockwise to reset
Faulty battery(s)
Replace battery(s)
Loose battery cable
Tighten loose cable
Faulty control board
Contact Tennant Service 1-800-553-8033
Faulty key switch
Contact Tennant Service 1-800-553-8033
Machine fault detected.
See Contol Panel Fault Indicator Codes
Plug not connected to power supply
Check plug connection
Faulty charger fuse
Replace charger fuse
Faulty power supply cord
Replace cord
Error detected.
See On--board Battery Charger Error Codes
1--STEP scrub button is off
Turn on the 1--STEP scrub button
Brush motor overload
See Control Panel Fault Indicator Codes
Discharged batteries
Charge batteries
Faulty control board
Contact Tennant Service 1-800-553-8033
Faulty scrub head (up/down) switch
Contact Tennant Service 1-800-553-8033
Faulty control handle bail switch
Contact Tennant Service 1-800-553-8033
Faulty brush motor or wiring
Contact Tennant Service 1-800-553-8033
Worn carbon brushes
Contact Tennant Service 1-800-553-8033
Broken or loose belt
(cylindrical brush model)
Replace or tighten belt
Parking brake is set
Release parking brake lever
Machine fault detected
See Control Panel Fault Indicator Codes
Faulty control board
Contact Tennant Service 1-800-553-8033
Wheels raised off floor
Contact Tennant Service 1-800-553-8033
Faulty transaxle motor or wiring
Contact Tennant Service 1-800-553-8033
Worn carbon brushes
Contact Tennant Service 1-800-553-8033
Exceeded maximum incline
Avoid steep inclines and reset key
Squeegee is raised off floor
Lower squeegee
Discharged batteries
Charge batteries
Faulty control board
Contact Tennant Service 1-800-553-8033
Faulty vacuum motor or wiring
Contact Tennant Service 1-800-553-8033
Worn carbon brushes
Contact Tennant Service 1-800-553-8033
Solution tank is empty
Fill solution tank
Clogged solution tank filter
Clean solution tank filter
Discharged batteries
Charge batteries
Clogged solution valve
Remove valve and clean
Faulty control board
Contact Tennant Service 1-800-553-8033
Onboard battery charger
will not operate
Brush motor(s) will not
operate
Machine will not propel
Vacuum motor will not
operate
Little or no solution flow
T5 9002333 REV.02 (07-06)
M
19
T5 –Maintenance
(Page 14 of 15)
TROUBLESHOOTING -- Continued
PROBLEM
CAUSE
SOLUTION
Poor water pickup
Recovery tank is full or excessive foam
buildup
Drain recovery tank
Loose drain hose cap
Tighten cap
Clogged float shut--off screen located in
recovery tank
Clean screen
Clogged squeegee assembly
Clean squeegee assembly
Worn squeegee blades
Replace or rotate squeegee blades
Incorrect Squeegee blade deflection
Adjust Squeegee blade height
Loose vacuum hose connections
Secure hose connections
Clogged vacuum hose
Remove clogged debris
Damaged vacuum hose
Replace vacuum hose
Recovery tank cover not in place
Properly position cover
Damaged recovery tank cover seal
Replace seal
Faulty vacuum motor
Contact Tennant Service 1-800-553-8033
Debris caught in brush
Remove debris
Worn brushes/pads
Replace brushes/pads
Incorrect brush pressure setting
Adjust pressure setting
Wrong brush/pad type.
Use correct brush/pad
Batteries not fully charged
Fully recharge batteries
Defective batteries
Replace battery
Batteries need maintenance
See BATTERY MAINTENANCE
Faulty battery charger
Repair or replace battery charger
Solution flow and brush
pressure buttons and
FaST system switch are
locked
Supervisor controls are activated (lockout feature)
Contact your Supervisor
FaST Model: FaST
System does not operate
or operate correctly
FaST system switch is not turned on
Turn on FaST system switch
FaST--PAK supply hose not connected
Connect supply hose
Clogged FaST--PAK supply hose or connectors
Soak in warm water to unclog
Empty FaST--PAK carton
Replace FaST--PAK carton
Kink in FaST--PAK supply hose
Undo hose kink
Clogged FaST solution system
Contact Tennant Service 1-800-553-8033
Faulty FaST system on/off switch
Contact Tennant Service 1-800-553-8033
Faulty pump
Contact Tennant Service 1-800-553-8033
Clogged solution tank filter
Drain solution tank. remove solution tank
filter, clean and reinstall
Clogged detergent orifice/filter screen
Replace orifice/filter screen
(See FaST SYSTEM MAINTENANCE)
Clogged FaST solution inlet filter
Contact Tennant Service 1-800-553-8033
Faulty control board
Contact Tennant Service 1-800-553-8033
M
Poor scrubbing
performance
Reduced run time
20
T5 9002333 REV.02 (07-06)
T5 –Maintenance
(Page 15 of 15)
CONTROL PANEL FAULT INDICATOR CODES
The control panel fault indicator lights will display the following codes when the machine detects a fault.
Light #4
Light #1
Light #2
Light #3
Battery Lights
CODE
FAULT
SOLUTION
Light #1 blinks
Recovery tank is raised.
Lower recovery tank. Restart key to reset.
Lights #1, #2 and #3
ripple
Battery charger connected.
Disconnect battery charger. Restart key to
reset.
Lights #1 and #4 blink
Left Brush motor overload.
Inspect brush for entangled debris,
improper pad or contact service center.
Restart key to reset.
Lights #3 and #4 blink
Right Brush motor overload.
Inspect brush for entangled debris,
improper pad or contact service center.
Restart key to reset.
Lights #2 and #3 blink
Propel motor overload.
Exceeded maximum incline.
Avoid steep inclines or contact service
center. Restart key to reset.
Lights #1 and #3 blink
Scrub head movement is obstructed or
actuator motor malfunction.
Check scrub head for obstruction or contact service center. Restart key to reset.
Light #2 blinks
Vacuum motor malfunction.
Contact Tennant Service 1-800-553-8033
Lights #1 and #2 blink
Propel throttle malfunction.
Contact Tennant Service 1-800-553-8033
Light #3 blinks
FaST pump overload or malfunction.
Reset the 10A circuit breaker or contact
service center. Restart key to reset.
Light #3 blinks when
pressing the solution flow,
brush pressure buttons
and FaST system switch
Supervisor controls activated
(lockout feature)
Contact your Supervisor.
Lights #1, #2 and #3 blink
Wand Pump overload or malfunction.
Reset the 10A circuit breaker button or
contact service center. Restart key to
reset.
All battery lights blink
Emergency--Stop button activated
Turn button clockwise to reset.
All battery lights ripple
Key turned on while bail was engaged.
Release the control handle start bail.
T5 9002333 REV.02 (07-06)
M
21
22
DIRECT
CONNECTION
FUSE TO
CONTACTOR
RED
Cr1
1A/RED
F1
DIODE
25/GRN
Cr2
Cr2
6 VDC
SW3
MOTOR PM
P1-- 1
PROPEL B
M4
50\TAN
5B GRN
KEYSWITCH
A
Cr2
+
_
--
1E/RED
14C/YEL
10 AMP
CIRCUIT BREAKER
CB2
5/GRN
M1
RT BRUSH A
M3
VACUUM
B
MOTOR PM -- 22AMP
A
MOTOR PM -- 30 AMP
B
MOTOR PM -- 30 AMP
+
CONN1
CONN1
J8-- 4
J8-- 3
J8-- 2
J8-- 1
J 11
RT BRUSH A
LFT BRUSH B
LFT BRUSH A
+24VDC
POWER
MAIN CONT
LOGIC POWER
SUPPLY
1AMPLOWD
PROPEL A
_
J9-- 1
12/BRN
VAC A
RT BRUSH B
J6-- 13
FLY BACK
14B/YEL
PATH
J9-- 2
VAC B
11/PNK
10/TAN
9/WHT
8/GRY
7/PUR
RED
56/
BLU
J6-- 5
6/BLU
J6-- 17
J6-- 24
J10-- 2
J10-- 1
PROPEL B
24/YEL
6A/BLU
BRAKE RELAY COIL
CR2
STANDOFF2
LFT BRUSH
B
A
M2
15/
GRN
CR1
_
6 VDC
6 VDC
CHARGER PLUG
3/ORG
Cr2
+
D1 DIODE
+
-6/BLU
5/GRN 5A/GRN
17/PUR
MAIN CONTACTOR COIL
OPTIONAL
SW--EMERG
SW2
FUSE 100A
1B/RED
+ D2
4A/YEL
5 AMP
CIRCUIT BREAKER
CB1
4/YEL
4B/YEL
1C/RED
1/RED
PWR GND
INTERLOCK
SIGNAL RETURN
6 VDC
_
THROTTLE HIGH
THROTTLE SIG
THROTTLE LOW
VACUUM
FaST
WAND PUMP
MID--STROKE SWITCH
+
E
2/BRN
BLK
CHARGER PLUG AND
CHARGER INTERLOCK
SWITCH REMOVED WITH
ONBOARD CHARGER
OPTION
27/PUR
29/WHT
34/YEL
38/GRY
J6-- 31
J6-- 34
J6-- 32
23/ORG
J6-- 10
30/TAN
J6-- 8
28/GRY
J6-- 20
J6-- 11
41/PINK
J6-- 7
26/BLU
F
C
SW5
N.C. 4B/YEL
1
2
SW4
VACUUM SWITCH
SW7
FaST SWITCH
P1
5K
SW8
WAND PUMP SWITCH
SW9
ACTUATOR RETRACT SWITCH
N.C.
ACTUATOR MID-STROKE SWITCH
COM
D
STANDOFF1
SW1 OPEN DURING
BATTERY CHARGE CHARGER INTERLOCK
J6-- 18
P1-- 1 SW1
J6-- 35
J7
13C/BLK
13/BLK
BLK
42/BRN
42F/BRN
3
42C/BRN
42E/BRN
SW9 OPEN WHEN
ACTUATOR IS FULLY
42G/BRN
RETRACTED
SW5, SW9 AND SW10
ARE INTERNAL TO
THE SCRUB HEAD
ACTUATOR
SW5 CLOSES
WHEN ACTUATOR
IS EXTENDED
2” OR MORE
OPTIONAL
ON-BOARD
CHARGER
BLK
RED
T5 –Electrical Schematic
(Page 1 of 2)
T5 9002333 REV.02 (11-07)
T5 9002333 REV.02 (11-07)
CB1
CB2
CR1
CR2
Cr1
Cr2
D1
D2
F1
H1
M1
=
=
=
=
=
=
=
=
=
=
=
1
A
M7
H1 --
MOTOR PM
FAST PUMP
M6
HOUR METER
+
RED
A
M2
M3
M4
M5
M6
M7
P1
P2
SL1
SW1
SW2
J6-- 4
=
=
=
=
=
=
=
=
=
=
=
FAST/PWM 1
HOUR METER
WAND/PWM 2
HEAD A
HEAD B
WATER SOL
U1
SW2
OPEN
SW3
OPEN
SW4
SW1
SW5
LED5
LED14
OPEN
LED13
LED4
LED12
LED3
LED11
LED2
LED10
OPEN
LED9
LED8
LED7
LED1
LED6
GND
OPEN
OPEN
LED15
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
+5vdc
PROPEL
INTERLOCK
+5 V
SPEED LIMIT POT.
MOTOR BRUSH LFT
MOTOR VACUUM FAN
MOTOR DRIVE
MOTOR SCRUB HEAD ACTUATOR
MOTOR PUMP FAST
MOTOR PUMP WAND
POTENTIOMETER 5K #1021853
POTENTIOMETER 20K #1022706
SOLENOID VALVE #1013599
SWITCH SAFETY CHARGER #611005
SWITCH E--STOP #1011735
J6-- 25
J6-- 14
21/PNK
31/PNK
J6-- 26
J6-- 23
19/WHT
20/TAN
J6-- 21
B 22/BRN 2
BLACK
MOTOR PM
WAND PUMP
M5
B
16/BLU
EXTEND
LIMIT
SW10
SL1
SOLENOID VALVE
CIRCUIT BREAKER 5A #383720
CIRCUIT BREAKER 10A #383721
MAIN CONTACTOR COIL #1011086
BRAKE RELAY COIL #1001219
CONTACT RELAY #1011086
CONTACT RELAY #1001219
DIODE #222290
DIODE #222290
FUSE 100A #86379
HOUR METER #1011282
MOTOR BRUSH RT
LEGEND
14C/YEL
14F/YEL
14A/YEL
14/YEL
18/GRY
36/BLU
P6-- 1
P6-- 2
P6-- 3
P6-- 4
P6-- 5
P6-- 6
P6-- 7
P6-- 8
P6-- 9
P6-- 10
P6-- 11
P6-- 12
P6-- 13
P6-- 14
P6-- 15
P6-- 16
P6-- 17
P6-- 18
P6-- 19
P6--20
P6-- 21
P6--22
P6--23
P6--24
P6--25
P6-- 26
P6--27
P6--28
P6--29
P6--30
P6-- 31
P6--32
P6--33
P6--34
J6-- 22
35/GRN
J6-- 3
J6-- 33
P2
20K
SW3
SW4
SW5
SW6
SW7
SW8
SW9
SW10
TP
U1
=
=
=
=
=
=
=
=
=
=
3
TP
42H/BRN
42A/BRN
SWITCH KEY #1011402
SWITCH VACUUM #1012568
SWITCH ACTUATOR MID STROKE
SWITCH PROPEL INTERLOCK #606292AM
SWITCH FAST #130787
SWITCH WAND PUMP #130787
SWITCH ACTUATOR RETRACT
SWITCH ACTUATOR EXTEND
TOUCH PANEL #1020677
CIRCUIT BOARD #1022812
SW6
PROPEL INTERLOCK SWITCH
1
2
T5 –Electrical Schematic
(Page 2 of 2)
E
23
T5 –Wiring Harness Detail
B
E
24
CONTINUED
Symbol Key
A
CONTINUED
(Page 1 of 6)
T5 9002333 REV.02 (11-07)
T5 –Wiring Harness Detail
Symbol Key
(Page 2 of 6)
B
E
T5 9002333 REV.02 (11-07)
25
T5 –Wiring Harness Detail
C
CONTINUED
(Page 3 of 6)
A
Symbol Key
E
26
T5 9002333 REV.02 (11-07)
T5 –Wiring Harness Detail
(Page 4 of 6)
E
C
Symbol Key
T5 9002333 REV.02 (11-07)
27
T5 –Wiring Harness Detail
(Page 5 of 6)
Symbol Key
E
28
T5 9002333 REV.02 (11-07)
T5 –Wiring Harness Detail
(Page 6 of 6)
Symbol Key
E
T5 9002333 REV.02 (11-07)
29
T5 – Main Harness to Control Board 35 Pin Connector Detail
E
pin #
wire #
input or
output
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
empty
empty
18
16
6
empty
27
29
empty
30
41
empty
14B
21
empty
empty
5B
26
empty
28
20
35
19
3
22
31
empty
empty
empty
empty
38
23
36
x
x
output
output
output
x
input
input
x
input
input
x
input
output
x
x
input
input
x
input
output
input
output
input
output
output
x
x
x
x
output
output
input
34
34
input
35
empty
x
active voltage
inactive
voltage
x
x
x
x
5v
x
BB+
BB+
x
x
Bopen
Bopen
x
x
Bopen
open
Bx
x
B+
open
BB+
x
x
B+
open
open
B+
x
x
Bopen
B+ or Bopen
Bopen
B+ or Bopen
B+
open
BB+
BB+
x
x
x
x
x
x
x
x
5v
x
0v
x
0v to 5v
x
0v to 2.4v &
2.4v to 2.6v
2.6v to 5v
x
x
function/component controlled
P1
P1
P2
x
x
Speed limit sensor sensor logic high
Conventional solenoid valve
Main contactor
x
Actuator mid-stroke switch
FaST pump switch
x
Vacuum fan switch
Actuator retract switch
x
Fly back path
Hour meter
x
x
Battery positive power supply
Battery charger interlock switch
x
Wand pump switch
Scrub head actuator
Recovery tank interlock switch
Scrub head actuator
Battery positive power supply
FaST pump motor
Wand pump motor
x
x
x
x
Throttle position sensor logic high
Throttle position sensor logic low
Speed limit sensor logic input
P1
Throttle position sensor logic input
P2
SL1
CR1
SW5
SW7
SW4
SW9
H1
SW1
SW8
M5
SW6
M5
M6
M7
x
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
30
Color of Wire
Pin 1
Pin 12
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
Pin 23
Pin 35
Pin 13
Viewed from front (plug-in)
side of harness connector
Pin 24
T5 9002333 REV.02 (07-06)
T5 – Control Panel LED Details
ONE STEP
SCRUB LED
BRUSH
PRESSURE
LED’s
3
3
2
2
1
1
SOLUTION
FLOW
LED’s
E
1
2
3
FAULT/SUPERVISOR LED’s
1
2
4
5
BATTERY DISCHARGE LED’s
LED #
T5 9002333 REV.02 (07-06)
3
COLOR
1
RED
2
YELLOW
3
GREEN
4
GREEN
5
GREEN
31
Commonly Used Electrical Symbols & Terms
NOTE: The term “NORMALLY” refers to the components’ “at rest” or “de-energized” position
-
+
Wires Not
Connected Together
Wires Connected
Together
Normally Open
Switch
Normally Open
Limit Switch
Relay Coil
(Part 1 of Relay)
Indicates Movement
from Normal Position
Battery
Normally Open
Normally Closed
Push-Button Switch
Limit Switch
Normally Open
CR1
Plug-in
Connection
Circuit Breaker
Normally Closed
Push-Button Switch
Fuse
Zener
Diode
Diode
Normally Closed
CR1
CR1
Relay Contacts (Part 2 of Relay)
Indicates Component in
Position Other than Normal
E
Solenoid (Valve
or Actuator)
Indicates Component
is Energized
Potentiometer
Motor
Assembly
i
!
Information
Warning!
Terms & Abbreviations
BDI – Battery Discharge Indicator
LED – Light Emitting Diode
PM – Permanent Magnet
PWM (Pulse Width Modulation) – A method of using controlled on/off times to regulate voltage and current to an electrical device
Standoff – A common connecting point for multiple wires
Zener Diode – A device used in an electrical circuit to prevent high voltage spikes
Example of Wiring Numbers & Colors:
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
32
Color of Wire
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
1 RED
25
7
13 BLK
T5 9002333 REV.02 (07-06)
T5 - Key OFF Power Distribution (With Standard Off-Board Battery Charger)
CONDITIONS: Key OFF, off-board battery charger NOT CONNECTED to charger plug
6 VDC
+
1 RED
-
6 VDC
+
-
-
+
6 VDC
-
13 BLK
13 BLK
13 BLK
1 RED
1 RED
6 VDC
+
STANDOFF1
CHARGER
PLUG
CB1
5A
EMERGENCY STOP
SWITCH (OPTION)
1 RED
SW2
4
4
5
CONTROL BOARD
MAIN
CONTACTOR
5
6
v
6
CR1
5
6
17
1 RED
D1
15
JUMPER
(STANDARD)
STANDOFF 2
CR2
5
D2
PIN J6-5
56
BRAKE
RELAY
5
PIN J6-17
1 RED
KEYSWITCH
4
3
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
PIN J6-18
SW1
1 RED POST J11
1 RED
2
26
+
POS
POST J7
NEG
-
13 BLK
13 BLK
RIBBON CABLE CONNECTOR P6
2
TO CIRCUIT
BREAKER CB2
E
TOUCH
PANEL
14
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
= Battery Negative
or Logic Ground
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
i
If Charger Plug is connected to battery charger, ALL machine
functions will be disabled when Key Switch is turned ON
i
If machine is not equipped with optional Emergency
Stop Switch, jumper wire 17/Purple will replace SW2
= Battery Positive
or Logic High
T5 9002333 REV.02 (11-07)
33
T5 - Key OFF Power Distribution (With Standard Off-Board Battery Charger)
CONDITIONS: Key OFF, off-board battery charger CONNECTED to charger plug
6 VDC
+
1 RED
-
6 VDC
+
-
-
+
6 VDC
-
13 BLK
13 BLK
13 BLK
1 RED
1 RED
6 VDC
+
STANDOFF1
CHARGER
PLUG
CB1
5A
EMERGENCY STOP
SWITCH (OPTION)
1 RED
SW2
4
4
5
CONTROL BOARD
MAIN
CONTACTOR
5
6
v
6
CR1
5
6
17
1 RED
D1
15
JUMPER
(STANDARD)
STANDOFF 2
CR2
5
D2
PIN J6-5
56
BRAKE
RELAY
5
PIN J6-17
1 RED
KEYSWITCH
4
3
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
PIN J6-18
SW1
1 RED
2
26
1 RED POST J11
+
POS
POST J7
NEG
-
13 BLK
13 BLK
RIBBON CABLE CONNECTOR P6
2
E
TO CIRCUIT
BREAKER CB2
TOUCH
PANEL
14
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
= Battery Negative
or Logic Ground
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
i
If Charger Plug is connected to battery charger, ALL machine
functions will be disabled when Key Switch is turned ON
i
If machine is not equipped with optional Emergency
Stop Switch, jumper wire 17/Purple will replace SW2
= Battery Positive
or Logic High
34
T5 9002333 REV.02 (11-07)
T5 - Key OFF Power Distribution (With Optional On-Board Battery Charger)
CONDITIONS: Key OFF, On-Board battery charger NOT CONNECTED to AC power
+
1 RED
6 VDC
-
+
6 VDC
-
6 VDC
+
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
SW2
4
5
MAIN
CONTACTOR
5
6
5
-
13 BLK
6
1 RED
PIN J6-5
6
17
STANDOFF 2
D1
JUMPER
(STANDARD)
15
KEYSWITCH
4
CR2
5
56
BRAKE
RELAY
5
PIN J6-17
3
3
PIN J6-24
CR1
SW3
1 RED
26
4
F1
100A
PIN J6-18
1 RED POST J11
1 RED
2
2
+ POS
26
Tan
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
T5 9002333 REV.02 (11-07)
E
OPTIONAL
ON-BOARD
CHARGER
Color of Wire
Brown
13 BLK
14
(Unless otherwise marked)
2
13 BLK
TOUCH
PANEL
Wiring Color Codes
Pink
-
RIBBON CABLE CONNECTOR P6
SEE
NOTE
BELOW
0
1
POST J7
NEG
STANDOFF1
TO CIRCUIT
BREAKER CB2
1 RED
Right Most Digit
of Wire Number
6 VDC
CONTROL BOARD
CR1
v
D2
+
If machine is not equipped with optional Emergency
Stop Switch, jumper wire 17/Purple will replace SW2
i
1 RED
-
AC POWER
CORD
26
4
4
NOT CONNECTED TO AC
1 RED
1 RED
!
i
13 BLK
13 BLK
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
The battery charger uses a normally closed relay to
send a signal to the control board – the relay opens
when the charger is plugged in to AC power
i
If On-Board Charger is connected to AC
power, ALL machine functions will be
disabled when Key Switch is turned ON
35
T5 - Key OFF Power Distribution (With Optional On-Board Battery Charger)
CONDITIONS: Key OFF, On-Board battery charger CONNECTED to AC power
+
1 RED
6 VDC
-
+
6 VDC
-
6 VDC
+
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
SW2
4
5
MAIN
CONTACTOR
5
6
5
13 BLK
6
1 RED
PIN J6-5
D1
JUMPER
(STANDARD)
15
KEYSWITCH
4
CR2
5
56
BRAKE
RELAY
5
PIN J6-17
3
3
PIN J6-24
CR1
SW3
1 RED
26
4
F1
100A
PIN J6-18
1 RED POST J11
1 RED
2
2
+ POS
OPTIONAL
ON-BOARD
CHARGER
(Unless otherwise marked)
Color of Wire
26
Tan
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
13 BLK
14
Wiring Color Codes
2
13 BLK
TOUCH
PANEL
SEE
NOTE
BELOW
Pink
-
RIBBON CABLE CONNECTOR P6
E
0
1
POST J7
NEG
STANDOFF1
TO CIRCUIT
BREAKER CB2
1 RED
36
-
6
17
STANDOFF 2
Right Most Digit
of Wire Number
6 VDC
CONTROL BOARD
CR1
v
D2
+
If machine is not equipped with optional Emergency
Stop Switch, jumper wire 17/Purple will replace SW2
i
1 RED
-
AC POWER
CORD
26
4
4
NOT CONNECTED TO AC
1 RED
1 RED
!
i
13 BLK
13 BLK
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
The battery charger uses a normally closed relay to
send a signal to the control board – the relay opens
when the charger is plugged in to AC power
i
If On-Board Charger is connected to AC
power, ALL machine functions will be
disabled when Key Switch is turned ON
T5 9002333 REV.02 (11-07)
T5 – Key OFF Propel System
CONDITIONS: Key OFF
+
1 RED
6 VDC
-
6 VDC
+
-
+
6 VDC
-
+
6 VDC
-
13 BLK
13 BLK
42
STANDOFF1
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
4
SW2
5
MAIN
CONTACTOR
6
5
CONTROL BOARD
6
CR1
v
5
17
POST J7
NEG
D1
JUMPER
(STANDARD)
STANDOFF 2
PIN J6-5
6
15
CR2
56
5
KEYSWITCH
4
THROTTLE
POSITION
SENSOR
PIN J6-17
3
3
SW3
1 RED
PIN J6-34
CHARGER
INTERLOCK
4
2
0V REFERENCE
5
PIN J6-24
CR1
F1
100A
PIN J6-18
47
38
+ POS
47
50
46
46
P1
5Kȍ
1
PIN J6-33
24
3
5V
REFERENCE
BRAKE RELAY CR2
25
2
PIN J6-31
1 RED POST J11
1 RED
34
SIGNAL
INPUT
26
SW1
TO CB2
23
23
PIN J6-32
BRAKE RELAY
D2
1 RED
13 BLK
-
PIN J10-1
SPEED
LIMITER
2
P2
36
SIGNAL
INPUT
20Kȍ
18
1
3
42
PIN J6-3
47
E
5V
REFERENCE
46
M4
SW6
PROPEL MOTOR
25
25
PIN J10-2
35
42
PIN J6-22
PIN / WIRING LAYOUT
BRAKE RELAY
CR2
50 TAN 1
3 50 TAN
25 GRN 4
Wiring Color Codes
Right Most Digit
of Wire Number
9 46 BLU
56 BLU A
B 15 GRN
Color of Wire
Tan
0
1
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
6 24 YEL
47 PUR 7
(Unless otherwise marked)
RECOVERY
TANK
INTERLOCK
White
= Battery Negative
or Logic Ground
i
The Brake Relay (CR2) is used to provide braking
when the Key Switch (SW3) is turned OFF.
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
i
The Recovery Tank Interlock will prevent propelling of the
machine when the Recovery Tank is raised; If the Recovery Tank
Interlock switch is OPEN (tank raised), Fault LED # 1 will flash.
= Battery Positive
or Logic High
T5 9002333 REV.02 (11-07)
37
T5 - Key ON Power Distribution
CONDITIONS: Key ON, all machine functions OFF
The troubleshooting information from this page forward applies to machines
with On-Board or Off-Board Chargers unless otherwise noted
i
+
1 RED
6 VDC
-
6 VDC
+
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
SW2
4
5
-
+
MAIN
CONTACTOR
CR1
6
5
6 VDC
-
+
6 VDC
-
13 BLK
CONTROL BOARD
6
PIN J6-5
v
5
17
D1
JUMPER
(STANDARD)
STANDOFF 2
1 RED
D2
15
56
BRAKE RELAY
CR2
5
KEY
SWITCH
5
PIN J6-17
1 RED
4
3
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
26
PIN J6-18
SW1
1 RED POST J11
1 RED
2
+
CB2
10A
E
6
2
FLYBACK PATH
14
POS
POST J7
NEG
-
13 BLK
13 BLK
14
PIN J6-13
14
Right Most Digit
of Wire Number
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
38
TOUCH
PANEL
Color of Wire
0
1
9
TO CB2 PROTECTED
COMPONENTS
Wiring Color Codes
(Unless otherwise marked)
RIBBON CABLE CONNECTOR P6
14
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
i
If Charger Plug is connected to battery charger, ALL machine
functions will be disabled when Key Switch is turned ON
i
The Flyback Path prevents high voltage
spikes when a component is turned OFF
i
If machine is not equipped with optional Emergency
Stop Switch, jumper wire 17/Purple will replace SW2
T5 9002333 REV.02 (11-07)
T5 – Propel Forward System
CONDITIONS: Key ON, forward propel engaged, all other machine functions OFF
+
1 RED
6 VDC
-
6 VDC
+
-
+
6 VDC
-
+
6 VDC
-
13 BLK
13 BLK
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
4
SW2
5
MAIN
CONTACTOR
CR1
6
5
42
STANDOFF1
CONTROL BOARD
6
PIN J6-5
v
5
17
15
13 BLK
-
56
BRAKE RELAY
CR2
5
PIN J6-32
0V REFERENCE
5
THROTTLE
POSITION
SENSOR
PIN J6-17
4
3
SW3
1 RED
PIN J6-34
KEY
SWITCH
4
2
3
PIN J6-24
CR1
F1
100A
CHARGER
INTERLOCK
34
SIGNAL
INPUT
PIN J6-18
38
PIN J6-31
+ POS
BRAKE RELAY CR2
47
47
46
50
P1
5Kȍ
PIN J6-33
24
46
1
3
5V
REFERENCE
1 RED POST J11
1 RED
25
2
26
SW1
TO CB2
23
23
D2
1 RED
POST J7
NEG
D1
JUMPER
(STANDARD)
STANDOFF 2
6
PIN J10-1
36
SIGNAL
INPUT
18
SPEED
LIMITER
2
P2
20Kȍ
1
3
42
PIN J6-3
47
SW6
PROPEL MOTOR FORWARD TRAVEL
25
E
5V
REFERENCE
46
M4
25
PIN J10-2
35
42
PIN J6-22
RECOVERY
TANK
INTERLOCK
PIN / WIRING LAYOUT
BRAKE RELAY
CR2
50 TAN 1
3 50 TAN
25 GRN 4
Wiring Color Codes
9 46 BLU
56 BLU A
B 15 GRN
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
6 24 YEL
47 PUR 7
!
i
The Brake Relay (CR2) is used to provide braking
when the Key Switch (SW3) is turned OFF.
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
The Throttle Position Sensor input signal will
vary from 0v to 5v – voltages between 2.4v
and 2.6v indicate neutral (machine stationary)
i
i
The Propel Motor (M4) is controlled by PWM; A
higher duty cycle will result in higher travel speed
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
T5 9002333 REV.02 (11-07)
i
The Recovery Tank Interlock will prevent propelling of the
machine when the Recovery Tank is raised; If the Recovery Tank
Interlock switch is OPEN (tank raised), Fault LED # 1 will flash.
39
T5 – Propel Reverse System
CONDITIONS: Key ON, reverse propel engaged, all other machine functions OFF
+
1 RED
6 VDC
-
6 VDC
+
-
+
6 VDC
-
+
6 VDC
-
13 BLK
13 BLK
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
4
SW2
5
MAIN
CONTACTOR
CR1
6
5
42
STANDOFF1
CONTROL BOARD
6
PIN J6-5
v
5
17
15
13 BLK
-
56
23
23
BRAKE RELAY
CR2
5
D2
1 RED
POST J7
NEG
D1
JUMPER
(STANDARD)
STANDOFF 2
6
PIN J6-32
0V REFERENCE
5
THROTTLE
POSITION
SENSOR
PIN J6-17
4
3
PIN J6-24
CR1
SW3
1 RED
PIN J6-34
KEY
SWITCH
4
2
3
F1
100A
CHARGER
INTERLOCK
34
SIGNAL
INPUT
PIN J6-18
38
1
PIN J6-31
+ POS
BRAKE RELAY CR2
47
47
46
50
PIN J6-33
24
46
3
5V
REFERENCE
1 RED POST J11
1 RED
25
P1
5Kȍ
26
SW1
TO CB2
2
PIN J10-1
36
SIGNAL
INPUT
18
SPEED
LIMITER
2
P2
20Kȍ
1
3
42
PIN J6-3
E
47
5V
REFERENCE
46
M4
SW6
PROPEL MOTOR FORWARD TRAVEL
25
25
PIN J10-2
35
42
PIN J6-22
RECOVERY
TANK
INTERLOCK
PIN / WIRING LAYOUT
BRAKE RELAY
CR2
50 TAN 1
3 50 TAN
25 GRN 4
Wiring Color Codes
9 46 BLU
56 BLU A
B 15 GRN
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
!
i
The Brake Relay (CR2) is used to provide braking
when the Key Switch (SW3) is turned OFF.
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
The Throttle Position Sensor input signal will
vary from 0v to 5v – voltages between 2.4v
and 2.6v indicate neutral (machine stationary)
i
i
The Propel Motor (M4) is controlled by PWM; A
higher duty cycle will result in higher travel speed
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
40
6 24 YEL
47 PUR 7
i
The Recovery Tank Interlock will prevent propelling of the
machine when the Recovery Tank is raised; If the Recovery Tank
Interlock switch is OPEN (tank raised), Fault LED # 1 will flash.
T5 9002333 REV.02 (11-07)
T5 – Propel System Neutral (no travel)
CONDITIONS: Key ON, propel NOT engaged, all other machine functions OFF
+
1 RED
6 VDC
-
6 VDC
+
-
+
6 VDC
-
+
6 VDC
-
13 BLK
13 BLK
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
4
SW2
5
MAIN
CONTACTOR
CR1
6
5
42
STANDOFF1
CONTROL BOARD
6
PIN J6-5
v
5
17
15
13 BLK
-
56
BRAKE RELAY
CR2
5
PIN J6-32
0V REFERENCE
5
THROTTLE
POSITION
SENSOR
PIN J6-17
4
3
SW3
1 RED
PIN J6-34
KEY
SWITCH
4
2
3
PIN J6-24
CR1
F1
100A
CHARGER
INTERLOCK
34
SIGNAL
INPUT
PIN J6-18
38
PIN J6-31
+ POS
BRAKE RELAY CR2
47
47
46
50
P1
5Kȍ
PIN J6-33
24
46
1
3
5V
REFERENCE
1 RED POST J11
1 RED
25
2
26
SW1
TO CB2
23
23
D2
1 RED
POST J7
NEG
D1
JUMPER
(STANDARD)
STANDOFF 2
6
PIN J10-1
36
SIGNAL
INPUT
18
SPEED
LIMITER
2
P2
20Kȍ
1
3
42
PIN J6-3
47
SW6
PROPEL MOTOR NEUTRAL
25
E
5V
REFERENCE
46
M4
25
PIN J10-2
35
42
PIN J6-22
RECOVERY
TANK
INTERLOCK
PIN / WIRING LAYOUT
BRAKE RELAY
CR2
50 TAN 1
3 50 TAN
25 GRN 4
Wiring Color Codes
9 46 BLU
56 BLU A
B 15 GRN
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
6 24 YEL
47 PUR 7
!
i
The Brake Relay (CR2) is used to provide braking
when the Key Switch (SW3) is turned OFF.
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
The Throttle Position Sensor input signal will
vary from 0v to 5v – voltages between 2.4v
and 2.6v indicate neutral (machine stationary)
i
i
The Propel Motor (M4) is controlled by PWM; A
higher duty cycle will result in higher travel speed
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
T5 9002333 REV.02 (11-07)
i
The Recovery Tank Interlock will prevent propelling of the
machine when the Recovery Tank is raised; If the Recovery Tank
Interlock switch is OPEN (tank raised), Fault LED # 1 will flash.
41
T5 – Scrub Brushes
CONDITIONS: Key ON, propel engaged, One Step switch activated
+
1 RED
6 VDC
6 VDC
+
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
-
SW2
4
5
-
+
MAIN
CONTACTOR
CR1
6
5
6 VDC
6
-
+
6 VDC
-
13 BLK
CONTROL BOARD
PIN J6-5
v
5
17
D1
JUMPER
(STANDARD)
STANDOFF 2
1 RED
D2
6
15
BRAKE RELAY
CR2
5
KEY
SWITCH
5
1 RED
3
4
PIN J6-17
3
PIN J6-24
CR1
SW3
CHARGER
INTERLOCK
1 RED
F1
100A
2
26
PIN J6-18
SW1
1 RED POST J11
1 RED
+ POS
POST J7
NEG
13 BLK
-
7
8
TO CIRCUIT
BREAKER CB2
E
56
PIN J8-1
M2
LEFT BRUSH MOTOR
8
8
PIN J8-2
9
10
PIN J8-3
M1
10
RIGHT BRUSH MOTOR
10
J8-4
PIN J8-2
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
i
The Brush Motors (M1 & M2) are speed controlled
by PWM; As the batteries are discharged, the
Control Board will reduce the motor speed
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
42
T5 9002333 REV.02 (11-07)
T5 – Vacuum Fan System
CONDITIONS: Key ON, squeegee lowered
+
1 RED
6 VDC
-
+
6 VDC
-
+
6 VDC
-
+
6 VDC
-
13 BLK
42
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
4
SW2
5
MAIN
CONTACTOR
CR1
6
5
CONTROL BOARD
6
PIN J6-5
v
5
17
D1
JUMPER
(STANDARD)
STANDOFF 2
D2
1 RED
6
15
56
BRAKE RELAY
CR2
5
KEY
SWITCH
4
PIN J6-17
3
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
2
PIN J6-18
1 RED POST J11
1 RED
+ POS
TO CIRCUIT
BREAKER CB2
Wiring Color Codes
(Unless otherwise marked)
Color of Wire
13 BLK
-
SW4
PIN J9-2
30
VACUUM FAN
MOTOR
12
POST J7
NEG
42
PIN J6-10
12
PIN J9-1
E
VACUUM
FAN
SWITCH
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
i
The Vacuum Fan Motor (M3) is controlled by PWM; The
“Economy” setting will reduce the duty cycle to conserve battery
energy and reduce noise when the scrub system is activated
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
11
M3
!
0
1
26
SW1
12
Right Most Digit
of Wire Number
5
1 RED
i
Vacuum Fan Voltages:
Economy Mode – 21 volts
Standard Mode – battery voltage
TOUCH
PANEL
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
T5 9002333 REV.02 (11-07)
ECONOMY SETTING WILL
REDUCE FAN SPEED (ONLY
WHEN SCRUB SYSTEM IS ON)
43
T5 – Conventional Solution Solenoid Valve
CONDITIONS: Key ON, propel engaged, One Step switch activated, FaST switch OFF
6 VDC
+
1 RED
-
+
6 VDC
-
+
6 VDC
-
+
6 VDC
-
13 BLK
42
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
SW2
4
5
MAIN
CONTACTOR
CR1
6
5
CONTROL BOARD
6
PIN J6-5
v
5
17
D1
JUMPER
(STANDARD)
STANDOFF 2
1 RED
D2
6
15
56
BRAKE RELAY
CR2
5
KEY
SWITCH
5
PIN J6-17
1 RED
4
3
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
2
26
PIN J6-18
SW1
2
14
POST J7
1 RED POST J11
1 RED
+ POS
CB2
10A
FLYBACK PATH
14
NEG
13 BLK
-
14
PIN J6-13
E
i
The Flyback
Path prevents
high voltage
spikes when a
component is
turned OFF
CONVENTIONAL SOLENOID VALVE
16
14
PIN J6-4
SW7
SL1
29
22
14
M6
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
!
42
PIN J6-8
FaST PUMP MOTOR
FaST
SWITCH
PIN J6-25
J8-2
PIN
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
Color of Wire
Tan
0
1
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
= Battery Negative
or Logic Ground
i
The Conventional Solenoid Valve (SL1) is controlled by
PWM; As more Solution LED’s are lit, the duty cycle is
increased, and more solution is applied to the floor.
CONVENTIONAL MODE
TOUCH
PANEL
SOLUTION
LED’s
3
2
1
PU
SH
= Battery Positive
or Logic High
44
T5 9002333 REV.02 (11-07)
T5 – FaST Water Pump
CONDITIONS: Key ON, propel engaged, One Step switch activated, FaST switch ON
6 VDC
+
1 RED
-
+
6 VDC
-
+
6 VDC
-
+
6 VDC
-
13 BLK
42
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
4
SW2
5
MAIN
CONTACTOR
CR1
6
5
CONTROL BOARD
6
PIN J6-5
v
5
17
D1
JUMPER
(STANDARD)
STANDOFF 2
1 RED
D2
6
15
56
BRAKE RELAY
CR2
5
KEY
SWITCH
5
PIN J6-17
1 RED
4
3
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
2
PIN J6-18
SW1
1 RED POST J11
1 RED
+ POS
CB2
10A
2
26
14
FLYBACK PATH
14
POST J7
NEG
13 BLK
-
14
PIN J6-13
CONVENTIONAL SOLENOID VALVE
E
SW7
16
14
PIN J6-4
SL1
29
42
PIN J6-8
22
14
M6
PIN J6-25
J8-2
PIN
FaST
SWITCH
FaST PUMP MOTOR
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
Tan
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
i
The Flyback Path prevents high voltage
spikes when a component is turned OFF
FaST MODE
SH
PU
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
T5 9002333 REV.02 (11-07)
45
T5 – Hour Meter & Off-Aisle Wand Water Pump
CONDITIONS FOR HOUR METER OPERATION: Key ON, propel engaged AND/OR vacuum fan ON
CONDITIONS FOR OFF-AISLE WAND WATER PUMP: Key ON, wand switch ON
6 VDC
+
1 RED
-
+
6 VDC
-
+
6 VDC
-
+
6 VDC
-
13 BLK
42
MAIN
CONTACTOR
CR1
6
5
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
4
SW2
5
CONTROL BOARD
6
PIN J6-5
v
5
17
D1
JUMPER
(STANDARD)
STANDOFF 2
1 RED
D2
6
15
56
BRAKE RELAY
CR2
5
KEY
SWITCH
5
PIN J6-17
1 RED
4
3
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
2
PIN J6-18
SW1
1 RED POST J11
1 RED
+ POS
CB2
10A
2
26
14
FLYBACK PATH
14
POST J7
NEG
13 BLK
-
14
PIN J6-13
HOUR
METER
E
14
+
SW8
21
H1
-
PIN J6-14
28
42
PIN J6-20
31
14
M7
WAND
PUMP
SWITCH
PIN J6-26
J8-2
PIN
OFF-AISLE WAND PUMP MOTOR
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
Color of Wire
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
Tan
0
1
Pink
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
8
Gray
9
White
i
The Flyback Path prevents high voltage
spikes when a component is turned OFF
OFF-AISLE WAND MODE
SH
PU
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
46
T5 9002333 REV.02 (11-07)
T5 – Scrub Head Actuator LOWER (Extend)
CONDITIONS: Key ON, One Step switch activated
+
1 RED
6 VDC
-
+
6 VDC
-
6 VDC
+
-
+
6 VDC
-
13 BLK
42
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
SW2
4
5
MAIN
CONTACTOR
CR1
6
5
CONTROL BOARD
6
PIN J6-5
v
5
17
D1
JUMPER
(STANDARD)
STANDOFF 2
D2
1 RED
6
56
15
BRAKE RELAY
CR2
5
KEY
SWITCH
5
PIN J6-17
1 RED
POST J7
NEG
4
3
13 BLK
-
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
2
26
27
MID
STROKE
SWITCH
SW5
41
SW9
PIN J6-18
SW1
1 RED POST J11
1 RED
+ POS
20
42
PIN J6-7
20
TO CIRCUIT
BREAKER CB2
PIN J6-21
20
EXTEND
LIMIT
SWITCH
SW10
19
PIN J6-23
M5
SCRUB HEAD
ACTUATOR
E
PIN J6-11
RETRACT
SWITCH
SHOWN IN OPERATION DURING
LOWERING OF SCRUB HEAD
SCRUB HEAD ACTUATOR ASSEMBLY
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
Tan
Pink
i
The Extend Limit Switch SW10 is an additional safety device to prevent
over-extension of the actuator; The actual length of extension is based
upon the current draw of the scrub brush motors
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
Fully Retracted (UP)
8
Gray
Fully Extended (DOWN)
9
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
T5 9002333 REV.02 (11-07)
Scrub Head Actuator Switches Logic Chart
switch
condition
SW5
SW9
SW10
OPEN
OPEN
CLOSED
CLOSED
CLOSED
OPEN
Retracting (RAISING)
CLOSED CLOSED
*
Extending (LOWERING)
CLOSED CLOSED
*
* SW5 closes when actuator is extended 2" (50mm) or more
47
T5 – Scrub Head Actuator RAISE (Retract)
CONDITIONS: Key ON, One Step switch deactivated
+
1 RED
6 VDC
-
+
6 VDC
-
6 VDC
+
-
+
6 VDC
-
13 BLK
42
EMERGENCY STOP
SWITCH (OPTION)
CB1
5A
4
1 RED
SW2
4
5
MAIN
CONTACTOR
CR1
6
5
CONTROL BOARD
6
PIN J6-5
v
5
17
D1
JUMPER
(STANDARD)
STANDOFF 2
D2
1 RED
6
56
15
BRAKE RELAY
CR2
5
KEY
SWITCH
5
PIN J6-17
1 RED
4
3
13 BLK
-
3
PIN J6-24
CR1
SW3
1 RED
CHARGER
INTERLOCK
4
F1
100A
2
26
27
MID
STROKE
SWITCH
SW5
41
SW9
PIN J6-18
SW1
1 RED POST J11
1 RED
+ POS
20
TO CIRCUIT
BREAKER CB2
E
POST J7
NEG
42
PIN J6-7
20
PIN J6-21
20
EXTEND
LIMIT
SWITCH
SW10
19
PIN J6-23
M5
SCRUB HEAD
ACTUATOR
PIN J6-11
RETRACT
SWITCH
SHOWN IN OPERATION DURING
RAISING OF SCRUB HEAD
SCRUB HEAD ACTUATOR ASSEMBLY
Wiring Color Codes
(Unless otherwise marked)
Right Most Digit
of Wire Number
0
1
Color of Wire
Tan
Pink
i
The Extend Limit Switch SW10 is an additional safety device to prevent
over-extension of the actuator; The actual length of extension is based
upon the current draw of the scrub brush motors
2
Brown
3
Orange
4
Yellow
5
Green
6
Blue
7
Purple
Fully Retracted (UP)
8
Gray
Fully Extended (DOWN)
9
White
= Battery Negative
or Logic Ground
= Battery Positive
or Logic High
48
!
Be cautious when working near Control Board Battery voltage is always present, even with Key OFF
Scrub Head Actuator Switches Logic Chart
switch
condition
SW5
SW9
SW10
OPEN
OPEN
CLOSED
CLOSED
CLOSED
OPEN
Retracting (RAISING)
CLOSED CLOSED
*
Extending (LOWERING)
CLOSED CLOSED
*
* SW5 closes when actuator is extended 2" (50mm) or more
T5 9002333 REV.02 (11-07)
T5 – Operational Modes & Interlocks
Mode
Entry Sequence
Indicator
Function
Forward
íBail Engaged in Forward
Direction
íDecal and Position of Bail
Forward movement of machine
Reverse
íBail Engaged in Reverse
Direction
íDecal and Position of Bail
Reverse movement of machine
Scrub Mode
íPress One-Step Scrub Button
íOne Step Scrub LED ON
ON
íLower Squeegee to Floor
FaST Mode
íVacuum Fan Running
íPress One Step Scrub Button
íOne Step Scrub LED ON
ON
íPress FaST Switch ON
íPress One Step Scrub Button
Conventional ON
Solution Mode
íPress FaST Switch OFF
íFaST Switch ON & Solution Flow LED's OFF
íOne Step Scrub LED ON
íFaST Switch OFF & Solution Flow LED(s) ON
Double Scrub íPress One Step Scrub Button íOne Step Scrub LED ON
ON
(no water
íRaise Squeegee
íVacuum Fan OFF
pickup)
Water pickup
(no Scrub)
Economy Mode
íOne Step Scrub LED OFF
íLower Squeegee to Floor
íVacuum Fan ON
íPress Brush Pressure
Decrease (-) to one LED
íPress Solution Flow Decrease
(-) to one LED
íPress Brush Pressure
Economy Mode Decrease (-) to one LED
w/ FaST
íPress FaST Switch ON
Battery
Discharged
íLower Brush Pressure (#1) LED ON; Middle (#2) &
Upper (#3) LED's OFF
íLower Solution Flow (#1) LED ON; Middle (#2) &
Upper (#3) LED's OFF
íLower Brush Pressure (#1) LED ON; Middle (#2) &
Upper (#3) LED's OFF
íFaST Switch ON & Solution Flow LED's OFF
íBattery voltage at or below full
íRed (#1) LED (on Battery Gauge) flashing
discharge voltage
Propel Interlock íController sensed a propel
or Motor Over interlock fault or an Over
Current Fault Current condition in a motor
T5 9002333 REV.02 (07-06)
íVarious LED's "rippling" or flashing
Activate Scrub Brushes, Vacuum Fan
& Solution Flow operations; Maximum
propel speed is limited to 220 ft/min
Activate FaST foam solution flow when
scrub and propel are engaged
Activate Conventional solution flow
when scrub and propel are engaged
Activate Scrub Brushes, apply cleaning
solution with no water pickup
Collect solution on floor with squeegee,
without scrubbing floor
Reduce Scrub Brush and Fan speeds
(to prolong battery life, reduce noise,
lower water usage)
Reduce Scrub Brush and Fan speeds
(to prolong battery life, reduce noise,
lower water usage)
Disable Scrub and Vacuum functions
(Additional operating time available by
re-engaging scrub system or
squeegee)
Prevent movement of machine or
prevent damage to motors; Refer to
appropriate chart for more information
49
E
T5 – Diagnostic & Fault Alarms
Diagnostic LED Codes
Fault
Entry Sequence
High Throttle
Disable
Charger
Connected
Throttle
Key switch turned ON with
propel engaged
Indicator
Battery Gauge LED's
continuously "ripple"
UP and Down
Battery charger connected to Fault LED's
machine and/or AC power
continuously "ripple"
with Key Switch ON
UP and DOWN
Function
Possible Solutions
Prevents movement of machine if Release propel bail before turning Key
propel is engaged before key is
Switch ON; Adjust Throttle Position Sensor
switched ON
neutral voltage (2.4v to 2.6v)
Prevents operation of the machine Plug in Battery Charger only when
with charger plugged in
machine is not in use
Prevents movement of machine
Repair throttle wiring; Repair or replace
with invalid throttle voltage. Scrub
machine Control Board
function shuts off.
Controller sensed an out-of
range Throttle signal
Fault LED's #1 and
Controller sensed an open
Prevents movement of the
Fault LED #1 flashing machine when Recovery Tank is
raised
Lower Recovery Tank when operating
machine
All Battery Gauge
LED's flashing
Turns OFF all machine functions
Reset Emergency Stop Switch
Notify operator of actuator fault
Examine Scrub Head Actuator or linkage
for binding; Repair or replace Scrub Head
Actuator
Recovery Tank circuit - Recovery Tank is
raised
Controller sensed an open
Emergency Stop
circuit - Emergency Stop
Switch
Switch activated
Scrub Head Actuator motor
Scrub Head
stalled or actuator position
Actuator Motor unknown
#2 flashing
Fault LED's #1 and
#3 flashing
FaST Pump
FaST Pump circuit OPEN or
Notify operator of FaST Pump
Fault LED #3 flashing fault
SHORTED
Repair FaST Pump wiring; Repair or
replace FaST Pump
Wand Pump
Wand Pump circuit OPEN or Fault LED's #1, #2
SHORTED
and #3 flashing
Repair Wand Pump wiring; Repair or
replace Wand Pump
High Current
Prevent damage to motors; Refer
Repair motor wiring; Repair or replace
Controller sensed an Over
Various LED's flashing to appropriate chart for more
Current condition in a motor
motor
information
E
Notify operator of Wand Pump
fault
High Current Faults
Fault
Description
- more than 24A for 10 minutes
- more than 35A for 1 minute
Excessive Propel current
- more than 45A for 30 seconds
- more than 60A for 5 seconds
Disk Heads
- more than 30A for 1 minute
Excessive Left Brush
- more than 35A for 2 seconds
Cylindrical Heads
Motor current
- more than 30A for 1 minute
- more than 35A for 2 seconds
Disk Heads
- more than 30A for 1 minute
Excessive Right Brush
- more than 35A for 2 seconds
Cylindrical Heads
Motor current
- more than 30A for 1 minute
- more than 35A for 2 seconds
Excessive Vacuum Fan - more than 27A for 30 seconds
- more than 30A for 5 seconds
Motor current
50
Indicator
Fault LED's #2 and #3 flashing
Fault LED #1 and Lower Brush
Pressure (#1) LED flashing
Fault LED #3 and Lower Brush
Pressure (#1) LED flashing
Fault LED #2 flashing
Function
Prevents movement of the machine;
Turn Key Switch OFF/ON to propel
for another time period.
Turns OFF all Scrub functions
Turns OFF all Scrub functions
Turns OFF all Scrub functions
T5 9002333 REV.02 (07-06)
T5 – Diagnostic & Configuration Modes
Mode
Entry Sequence
Indicator
Function
Upper Brush Pressure LED blinks Tens of days
of month, Upper Solution Flow LED blinks Single
day of month
Display Software
Revision Mode
Press and hold One Step Button, Middle Brush Pressure LED blinks Tens of
turn key switch ON, wait 10
month, Middle Solution Flow LED blinks Single
seconds, release One Step Button month
Blinking Brush Pressure and Solution Flow
LED’s indicate revision date (Refer to
Display Software Revision Mode page for
more information)
Lower Brush Pressure LED blinks Tens of year,
Lower Solution Flow LED blinks out Single year
Press and hold Increase Solution
Flow (+) and Decrease Brush
Start of test - Both Scrub Brush motors run
Pressure (-) Buttons, turn key
End of test - LED's indicate system pass or fail
switch ON, wait 10 seconds,
release buttons
Solid lit One Step LED indicates OK, A
Flashing LED indicates an OPEN Fault, A
Solid lit LED (other than One Step) indicates
a SHORT Fault (Refer to Self Test Mode
page for more information)
Input Display
Mode
Press and hold Decrease Solution
Flow (-) Button, turn key switch
LED's will indicate the the state of the control
ON, release button after forth
board inputs
battery LED starts to blink
Shows state of control board inputs from
various switches and sensors (Refer to Input
Display Mode pages for more information)
Manual Mode
Press and hold Decrease Brush
Pressure (-) Button, turn key
switch ON, release after Lowest
Brush Pressure LED starts to
blink.
Allows operation of individual functions
without the safety interlocks affecting or
controlling them (Refer to Manual Mode
pages for more information)
Self Test
Mode
Lowest down pressure LED will blink
Propel
Diagnostics
Mode
Press and hold Decrease Solution
Flow (-) and Increase Brush
Pressure (+) Buttons, turn key
Battery Gauge LED's indicate position of throttle
switch ON, release after One Step
LED starts to blink
Provides information regarding throttle input
signal and propel motor current (Refer to
Propel Diagnostics Mode page for more
information)
Battery Select
Mode
Press and hold the Increase
Solution Flow (+) Button, turn key
Any one of lower 4 Battery Gauge LED’s blinks
switch ON, release after one
Battery LED starts to blink
Allows selection of battery type (Refer to
Battery Select Mode page for more
information)
Toggle Supervisor Mode. When enabled,
the scrub mode settings are disabled and
Fault LED #3 is lit. If Solution Flow or Brush
Pressure buttons are pressed, Fault LED #3
will blink. (Refer to Supervisor Mode page
for more information)
Supervisor Mode
Press and hold Increase Solution Battery LED #3 (Green) flashing - Supervisor
mode enabled
Flow (+) and Increase Brush
Pressure (+) Buttons, turn key
switch ON, release after battery
Battery LED #1 (Red) flashing - Supervisor
LED 1 or 3 starts to blink
mode disabled
Scrub Propel
Speed Selection
Mode
Press and hold Increase Brush
Pressure (+) Button, turn key
Brush Pressure Lower, Middle, and Upper LED’s
switch ON, release after selecting represents LOW, MEDIUM and HIGH maximum
desired Brush Pressure LED
Forward Scrubbing Propel Speed selection
setting
Allows selection of maximum forward speed
during scrubbing
LOWER (#1) LED = 150 ft/min
MIDDLE (#2) LED = 200 ft/min
UPPER (#3) LED = maximum speed
(Refer to Scrub Propel Speed Selection
Mode page for more information)
Press and hold Decrease Solution
Flow (-) and Decrease Brush
Pressure (-) Buttons, turn key
Lower Brush Pressure LED (#1) – Disk
-Lower Solution Flow LED (#1) – 24”
switch ON, release after one
-Middle Solution Flow LED (#2) – 28”
Brush Pressure LED and one
-Upper Solution Flow LED (#3) – 32”
Solution Flow LED is lit. To
change setting, press & hold One Middle Brush Pressure LED (#2) – Cylindrical
-Lower Solution Flow LED (#1) – 26”
Step Button until it blinks, then
-Upper Solution Flow LED (#3) – 32"
press the Brush Pressure (+)
Button or Solution Flow (+) Button
to change setting.
Allows machine to be configured for various
scrub heads (Refer to Scrub Head Selection
Mode page for more information)
Scrub Head
Selection Mode
T5 9002333 REV.02 (11-07)
51
E
52
Indicates the Year (One’s)
Indicates the Year (Ten’s)
Note: The software revision LED will continue to blink until the machine is turned off.
Rev 00
Holding the One Step button on Power-up puts you into the software revision display mode. The number of blinks by the Down Pressure and
Water level LED’s represents the software revision.
1. The Highest Pressure (ten’s) & water level (one’s) numbers blinking together represents the month.
2. The Middle Pressure (ten’s) & water level (one’s) numbers blinking together represents the day.
3. The Low Pressure (ten’s) & water level (one’s) numbers blinking together represents the year.
No blinking of an LED means zero. For example if the high pressure LED does not blink and the high water LED blinks six times, that means the
month is JUNE. Also if the Middle Pressure LED blinks twice and the Middle water blinks once, that means the day is the 21st.
Indicates the Day (One’s)
Indicates Month (One’s)
Indicates the Day (Ten’s)
Indicates the Month (Ten’s)
E
Pu
Turn sh & H
old
Key
Swit ,
ch O
N
One Step Button
T5 – Display Software Revision Mode
(Page 1 of 2)
T5 9002333 REV.02 (07-06)
T5 9002333 REV.02 (07-06)
MONTH
DAY
2
0
MONTH
0
Number of Flashes
Pu
Turn sh & H
old
Key
Swit ,
ch O
N
EXAMPLE
TOUCH
PANEL
TOUCH
PANL
Month = 06
Day = 21
YEAR
Year = 06
Revision Date = June 21, 2006
YEAR
6
1
6
Number of Flashes
Rev 00
T5 – Display Software Revision Mode
(Page 2 of 2)
E
53
54
Indicates Wand Pump Fault
Indicates FaST Pump Fault
Indicates Water Valve Fault
In the example above, a blinking Low Down Pressure LED would indicate an open in the Scrub Head Actuator circuit. A solid Medium Solution
LED would indicate a short in the FaST Pump circuit.
Rev 03
1. Hold the (-) Down pressure and (+) Increase Water buttons simultaneously on start-up. Machine will perform Self-Test for about 30-40
seconds.
2. After the self-test, either the One-Step Button LED will be lit solid to indicate system OK, or another panel LED will be flashing (which means
OPEN fault) or solid lit LED (which means a SHORT fault) to indicate a system failure.
* FAULT LED # 3: Flashing indicates an actuator stall during retract. Solid LED on indicates a retract timeout error, or a mid-stroke switch fault.
Note: If Optional FaST and/or Wand Pump are installed, each switch must be in the ON position before entering Self-Test Mode. If FaST
or Wand Pump switches are in the OFF position when entering Self-Test Mode, that circuit will not be tested.
Indicates Scrub Head Actuator
Switch Fault*
Indicates Vacuum Motor Fault
Indicates Controller Fault
Indicates Scrub Head Actuator Fault
ld, ON
Ho itch
& w
sh y S
u
P Ke
rn
Tu
E
Indicates Left Brush Motor Fault
Indicates Right Brush Motor Fault
ld, ON
Ho itch
& w
sh S
Pu Key
rn
Tu
Indicates System Pass
T5 – Self Test Mode
T5 9002333 REV.02 (11-07)
T5 9002333 REV.02 (07-06)
Press and hold the Decrease Water (-) button and then turn on the key switch.
To enter the Input Display Mode:
Rev 01
The purpose of the Input Display Mode is to show the condition of the different control board inputs. A description of the machine’s operation in
Input Display Mode is described below.
Decrease Water Button
ld, ON
Ho itch
& w
sh S
Pu Key
rn
Tu
T5 – Input Display Mode
(Page 1 of 2)
E
55
E
56
= E-stop Switch is open.
= Vacuum Fan is active.
= Charger Interlock Switch is closed; charger is not plugged-in.
= Actuator Retract Switch is closed; actuator is not in the retract (parked) position.
= Actuator Mid-Stroke Switch is closed; actuator has been extended at least two inches.
= FaST Switch is closed.
= Propel Interlock Switch is closed; recovery tank is down.
= Wand Pump Switch is closed.
= Left Scrub Brush Pressure. Scrub Brush Down Pressure LED’s indicate low, medium, & high pressure.
= Right Scrub Brush Pressure. Water Flow LED’s indicate low, medium, & high pressure.
Fault LED 1 is on.
Fault LED 2 is on
Fault LED 3 is on.
Battery LED # 1 is on.
Battery LED #2 is on.
Battery LED 3 is on.
Battery LED 4 is on.
Battery LED 5 is on.
Brush Down Pressure LED’s
Water Flow LED’s
Rev 01
= One Step Button on; scrub is active.
One Step LED is on.
When in the Input Display Mode, the following input conditions will be associated with the following LED’s:
T5 – Input Display Mode
(Page 2 of 2)
T5 9002333 REV.02 (07-06)
T5 9002333 REV.02 (07-06)
N
ALL Propel functions are
disabled while in Manual Mode
x
Rev 00
Press and hold the Down Pressure (-) button and then turn on the key switch. Hold the button until the lowest brush pressure LED starts to
blink, indicating that you’re in Manual Mode.
To enter the Manual Mode:
In Manual Mode, all of the Normal mode interlocks except for E-stop, and charger interlock are disabled. All Propel functions are disabled in
Manual Mode. The purpose of the Manual Mode is to allow the technician to exercise individual scrub functions on the machine. Extreme care
must be exercised when operating the machine in this mode. (Note: there is no brush head pressure control in this mode)
Down Pressure (-) Button
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T5 – Manual Mode
(Page 1 of 2)
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57
58
x
x
x
x
x
x
x
x
x
!
i
ALL Propel functions are
disabled while in Manual Mode
Do NOT hold the Increase Brush Pressure (+) too long – the Scrub
Head may make excessive contact with the floor, possibly
damaging the floor surface, Scrub Head actuator, or brush motors.
Rev 00
Pressing and holding the (+) Down Pressure button will lower the scrub head. The scrub head will continue to lower as long as the button is
pressed, or until the actuator lower limit switch is opened. (Note: there is no brush head pressure control in this mode)
Pressing and holding the (-) Down Pressure button will raise the scrub head. The scrub head will continue to rise as long as the button is
pressed, or until the actuator upper limit switch is opened.
Pressing and releasing the One Step button will toggle the brush motors on and off. When the One Step button is on, the One Step LED will
light and both brush motors will turn on. When the One Step button is off, the One Step LED and both brush motors will turn off. Caution: if
you hold the (+) down pressure button on too long with the One Step button on, the Scrub Head assembly may make excessive
contact with the floor, possibly damaging the floor surface.
Lowering the squeegee lift lever will activate the vacuum fan switch and turn on the vacuum fan.
Raising the squeegee lift lever will deactivate the vacuum fan switch and turn off the vacuum fan after a 12 second delay.
Turning on the FAST switch, will turn the FAST pump on, and disable the solution valve.
Turning off the FAST switch, will turn the FAST pump off, and enable the solution valve.
Pressing and releasing the (+) Water Flow button will increase the flow rate from the Solution valve. The Solution Flow LED’s will indicate the
solution valve setting (Off, Low, Medium, or High).
(Note: in this mode the Water-Flow-Auto-Off/On interlock is disabled)
Pressing and releasing the (-) Water Flow button will decrease the flow rate from the Solution valve. The Solution Flow LED’s will indicate the
solution valve setting (Off, Low, Medium, or High).
Turn key switch off to exit Manual Mode.
E
x
While in Manual Mode:
T5 – Manual Mode
(Page 2 of 2)
T5 9002333 REV.02 (07-06)
Indicates Throttle is in Reverse Position
Indicates Throttle is in Neutral Position
N
Tu Pu
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Ke &
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N
Battery gauge LED’s display the throttle
output voltage.
INDICATOR
THROTTLE VOLTAGE
LED #1 (red) = < 2.2V.
LED#2 (amber) = > 2.2 and < 2.4V.
LED #3 (green) is lit when the throttle
voltage is > 2.4 and < 2. 6V.
LED #4 (green) = > 2.6 and < 2.8V.
LED #5 (green) = > 2.8V.
Indicates Minimum Throttle
Indicates Throttle position between
Minimum and Maximum
Indicates Maximum Throttle
The Fault LED’s indicate the sensed position of the Speed Limit Potentiometer (the speed control on the panel).
Rev 00
The Solution Level LED’s indicate the sensed position of the throttle potentiometer between Min and Max in forward or reverse.
The Down Pressure LED’s indicate the throttle position, reverse, neutral, or forward. When the bail is not activated, Down
Pressure LED #2 and Battery LED #3 (green) should be lit. This indicates that the throttle is in the center position and that the
controller is sensing Neutral.
To Enter Propel Diagnostics Mode, simultaneously hold the (-) Decrease Water and (+) Increase Down Pressure buttons on
power up. Note: The Propel Motor is disabled in Propel Diagnostics Mode.
Fault LED’s 1, 2, and 3 Indicate the sensed level
of the Speed Limit Potentiometer.
No Fault LED’s ON = 30% of Maximum Propel
Voltage
Fault LED 1 ON >= 40% of Maximum Propel
Voltage.
Fault LED’s 1 and 2 ON >= 66% of Maximum
Propel Voltage.
Fault LED’s 1,2, and 3 ON = 100% of Maximum
Propel Voltage
T5 9002333 REV.02 (07-06)
Indicates Throttle is in Forward Position
Tu Pu
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T5 –Propel Diagnostics Mode
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59
60
3. Shut off machine, setting is stored.
First battery gauge LED (red) flashing
Second battery gauge LED (yellow) flashing
Third battery gauge LED (green) flashing
Fourth battery gauge LED (green) flashing
==
==
==
==
USA levels (default)
EU levels
TNV levels
GEL levels
Rev 00
2. Push the SOLUTION (-) key to select battery type. Matching this selection to the batteries in your machine is crucial for longest battery life.
1. Power up holding the SOLUTION (+) key. Hold until one of the battery gauge LED’s flashes.
E
(+) Solution Button
ld, ON
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T5 – Battery Select Mode
T5 9002333 REV.02 (07-06)
T5 9002333 REV.02 (07-06)
N
ld, ON
Ho itch
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sh y S
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2. Cycle the key switch to return to Normal Mode and observe Fault LED #3 (below padlock symbol).
Fault LED 3 on indicates Supervisor Mode enabled. The LED will flash if a locked out button is pressed.
Fault LED 3 off indicates Supervisor Mode disabled.
Rev 00
1. Activate Supervisor Mode by holding both the Increase Down Pressure (+) button and the Increase Water (+) button down simultaneously
during power up until battery LED 1 or 3 blinks four times.
Battery LED 3 (Green) indicates that supervisor mode has been enabled. This will lock in the current Scrub Head Down Pressure, Solution
Flow, and FaST settings.
Battery LED 1 (Red) indicates that supervisor mode has been disabled. This will unlock the current Scrub Head Down Pressure, Solution Flow,
and FaST settings, and allow the settings to be changed in Normal Mode.
In Supervisor Mode the machine will function normally, but the Scrub Head Down Pressure, Solution Flow and FaST controls are locked out from the
operator. Scrub Head Down Pressure, Solution Flow and FaST settings may be preset and locked into the machine. Once the setting is locked into memory
it cannot be changed until the machine is toggled back out of Supervisor Mode.
Indicates Supervisor Lockout active
when LED is illuminated.
Tu Pu
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T5 –Supervisor Mode
61
E
62
N
E
High Pressure LED represents High Scrub Propel Speed Selection.
Medium Pressure LED represents Medium Scrub Propel Speed Selection.
Low Pressure LED represents Low Scrub Propel Speed Selection.
Rev 00
Enter Scrub Propel Speed Select Mode by holding down the Increase Down Pressure (+) button on Start up till you see the Down
Pressure LED’s illuminate. The Increase Down Pressure (+) and Decrease Down Pressure (-) buttons may be used to change the
speed setting. Turn the key switch off to exit Scrub Propel Speed Select Mode. After the setting is changed it is maintained in
non-volatile memory until changed.
Indicates Minimum Speed Setting
Indicates Medium Speed Setting
Indicates Maximum Speed Setting
Tu Pu
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T5 – Scrub Propel Speed Selection Mode
T5 9002333 REV.02 (07-06)
T5 9002333 REV.02 (07-06)
N
ld,
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ON
Indicates 24” (60cm) or 26” (65 cm) Width
Indicates 28” (70 cm) Width
Rev 01
1. To enter Scrub Head Select Mode simultaneously hold down the Decrease Down Pressure (-) button and the Decrease Water (-)
button when turning on the key switch. Hold the buttons until a Down Pressure LED and a Solution LED are illuminated. The current
machine configuration is displayed. In the example above, the shaded LED’s indicate that the machine is configured for a 28” (70cm)
Disc Scrub Head. To exit Scrub Head Select Mode without changing the scrub head setting, turn the key switch off.
2. To change the scrub head setting, press and hold the One-Step button for five seconds until the One-step button starts to blink. Now,
the Increase Down Pressure (+) button may be used to change the Scrub Head Type. The Increase Water (+) button may be used to
change the Scrub Head Size. Each button press will increment the setting up to the next setting. Note: Only valid values will be
allowed.
3. Turn the key switch off to lock the setting into memory.
Indicates Disc Type Head
Indicates Cylindrical Type Head
Indicates 32” (80 cm) Width
T5 – Scrub Head Selection Mode
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63
64
X
*
*
X
X
X
X
FaST Pump
Conventional
Solenoid Valve
Solution Flow
Control
X
X
X
X**
X**
X**
X
X
* Vacuum Fan and/or Propel will enable the Hour Meter
** Activated by pressing a combination of buttons on Touch Panel
*** Cycle Vacuum switch OFF/ON for an additional minute of vacuum motor operation
= Input that will DISABLE Output
= Input that will ENABLE Output
X
X
X
Wand Pump
Hour Meter
X
X
X
X
X
X
X
X
Battery Charge
Indicator
X
X
X
X***
X
Vacuum Motor
X
Scrub Head
Pressure Control
X
X
X
Propel Reverse
X
X
X
Propel Forward
Scrub Brush Motors
X
X
Main Contactor &
Brake Relay
Key Switch
(ON)
Inputs
X
Charger
Recovery
Throttle
One Step
Emergency
Switch
Tank
Low Voltage
Input
Vacuum
Wand
Supervisor FaST Switch FaST Switch
Scrub Button
(Charger Stop Switch
Interlock
Interrupt
(Forward or Switch (ON)
(OFF)
Switch (ON)
Lockout
(ON)
(ON)
plugged in to (Pressed) Switch (Tank
Reverse)
machine)
UP)
E
Outputs
Inputs and the
Outputs they
Control
T5 – Inputs & Outputs Table
T5 9002333 REV.02 (11-07)