5400

Service Manual

330735
Rev. 00 (3–01)

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This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT
Model 5400.

The set is organized into four major groups: General Information, Chassis, Scrubbing, and Electrical.

General Information: Machine safety, transport, jacking, lifting, and storage. Machine specifications,
Maintenance charts and Hardware information.

Chassis: Tire/wheel replacement, Caster replacement, Transaxle and Transaxle drive motor replacement.

Scrubbing: Squeegee assembly replace and adjust, Scrubber head replace and adjust, Scrubber brush
motor replacement, Vacuum fan replacement, Solution/recovery tank replacement, , Power wand pump
replacement, and Scrubbing troubleshooting chart.

Electrical: Battery maintenance and replacement, Charging instructions, Circuit breaker/relay

replacement, Instrument panel replacement, Vacuum fan motor brush replacement, Scrub brush brush
replacement, Electrical schematic, and Electrical troubleshooting.

Manual Number – 330735

Revision: 00
Published: 3–01

Copyright
2001 TENNANT, Printed in U.S.A.

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 GENERAL INFORMATION

CONTENTS

Page
SAFETY PRECAUTIONS . . . . . . . . . . . . . . 1–3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 1–5
MACHINE DIMENSIONS – 610mm (24 in)
and 660mm (26 in) DISK MODELS 1–6
MACHINE DIMENSIONS – 610mm (24 in)
CYLINDRICAL BRUSH MODEL . . . 1–7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . 1–8
MACHINE JACKING . . . . . . . . . . . . . . . . . . 1–10
MACHINE TRANSPORTING . . . . . . . . . . 1–10
STORING MACHINE . . . . . . . . . . . . . . . . . 1–11
TO STORE MACHINE . . . . . . . . . . . . . 1–11
STORAGE INFORMATION . . . . . . . . . . . . 1–11
HARDWARE INFORMATION . . . . . . . . . . 1–12
STANDARD BOLT TORQUE CHART 1–12
METRIC BOLT TORQUE CHART . . . 1–12
BOLT IDENTIFICATION . . . . . . . . . . . . 1–12
THREAD SEALANT AND LOCKING
COMPOUNDS . . . . . . . . . . . . . . . . . 1–12

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GENERAL INFORMATION

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 GENERAL INFORMATION
5.. When servicing machine:
SAFETY PRECAUTIONS – Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
– Block machine tires before jacking
This machine is intended for industrial and machine up.
commercial use. It is suited to scrub hard floors in – Jack machine up at designated
an indoor environment and is not constructed for locations only. Block machine up with
any other use. Use only recommended pads, jack stands.
brushes and cleaning detergents. – Use hoist or jack of adequate capacity
The following safety alert symbols are used to lift machine.
throughout this manual as indicated in their – Wear eye and ear protection when
description. using pressurized air or water.
– Disconnect battery connections before
WARNING: To warn of hazards or unsafe working on machine.
practices which could result in severe – Wear protective gloves when handling
personal injury or death. batteries or battery cables.
FOR SAFETY: To identify actions which must – Avoid contact with battery acid.
be followed for safe operation of equipment. – Use manufacturer supplied or
approved replacement parts.
The following information signals potentially
dangerous conditions to the operator or WARNING: Batteries emit hydrogen gas.
equipment: Explosion or fire can result. Keep sparks and
FOR SAFETY: open flame away. Keep covers open when
charging.
1.. Do not operate machine:
– Unless trained and authorized. WARNING: Flammable materials can
– Unless operation manual is read and cause an explosion or fire. Do not use
understood. flammable materials in tank(s).
– In flammable or explosive areas unless
designed for use in those areas. WARNING: Flammable materials or
reactive metals can cause explosion or fire.
2.. Before starting machine: Do not pick up.
– Make sure all safety devices are in
place and operate properly. WARNING: Moving parts. Turn off power
before working on machine.
3.. When using machine:
– Go slow on inclines and slippery WARNING: Actuator pinch point. Stay
surfaces. clear of head lift area.
– Use care when reversing machine.
– Do not carry riders on machine.
– Always follow safety and traffic rules.
– Report machine damage or faulty
operation immediately.
4.. Before leaving or servicing machine:
– Stop on level surface.
– Turn off machine.
– Set parking brake, if equipped.

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 GENERAL INFORMATION
The safety labels appear on the machine in the
locations indicated. Replace labels if they become
damaged or illegible.

BATTERY CHARGE LABEL – FLAMMABLE MATERIALS LABEL –

LOCATED ON THE RECOVERY TANK LOCATED ON THE RECOVERY TANK
COVER AND BOTTOM SIDE OF COVER.
RECOVERY TANK.
WARNING: Flammable materials
WARNING: Batteries emit can cause an explosion or fire. Do
hydrogen gas. Explosion or fire not use flammable materials in
can result. Keep sparks and open tank(s). Flammable materials or
flame away. Keep covers open reactive metals can cause explosion
when charging. or fire. Do not pick up.

GENERAL HAZZARD
LABEL – LOCATED ON
THE ACTUATOR
MOUNTING BRACKET

WARNING: Actuator
pinch point. Stay clear
of head lift area.

FOR SAFETY LABEL – LOCATED

ON THE SOLUTION FLOW PANEL.

FOR SAFETY: Do not operate

machine unless operation manual
is read and understood. MOVING PARTS LABEL – LOCATED
ON THE SCRUB HEAD SHROUD.

WARNING: Moving parts. Turn off

power before working on machine.

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 GENERAL INFORMATION
SPECIFICATIONS

MODEL 610mm (24 in) 660mm (26 in) 610mm (24 in)
Disk Head Disk Head Cylindrical Head
LENGTH 1270mm (50 in) 1289mm (50.75 in) 1359mm (53.50 in)
WIDTH / WIDTH WITH SCRUB HEAD 559mm (22 in) / 559mm (22 in) / 559mm (22 in) /
641mm (25.25 in) 699mm (27.5 in) 667mm (26.25 in)
HEIGHT 1041mm (41 in) 1041mm (41 in) 1041mm (41 in)
WEIGHT 142 kg (314 lb) / 260 142 kg (314 lb) / 260 142 kg (314 lb) / 260
Kg (570 lb) with bat- Kg (570 lb) with bat- Kg (570 lb) with bat-
teries teries teries
RECOVERY TANK CAPACITY 80 L (21 Gal) 80 L (21 Gal) 80 L (21 Gal)
SOLUTION TANK CAPACITY 80 L (21 Gal) 80 L (21 Gal) 80 L (21 Gal)
ES OPTION SOLUTION FILL CAPACITY 117 L (31 Gal) 117 L (31 Gal) 117 L (31 Gal)
DRIVE SYSTEM Transaxle, 24 V, 19 Transaxle, 24 V, 19 Transaxle, 24 V, 19
kw (.25 hp) kw (.25 hp) kw (.25 hp)
CLEANING RATE 2415 m2 per hour 2601 m2 per hour 2415 m2 per hour
(26,000 sq ft) (28,000 sq ft) (26,000 sq ft)
CLEANING PATH WIDTH 610mm (24 in) 660mm (26 in) 610mm (24 in)
PAD PRESSURE Variable 0–54 kg Variable 0–54 kg Variable 0–41 kg
(0–120 lb) (0–120 lb) (0–90 lb)
SQUEEGEE WIDTH 839mm (33 in) 839mm (33 in) 839mm (33 in)
TOTAL POWER CONSUMPTION 60 Amp nominal 60 Amp nominal 60 Amp nominal
BRUSH MOTOR Two – .75 h.p., 270 Two – .75 h.p., 270 Two – .63 h.p., 1700
rpm, 24 V, 33 A rpm, 24 V, 33 A rpm, 670 brush rpm,
24 V, 23 A
VACUUM MOTOR .75 h.p., 3–stage 5.7 .75 h.p., 3–stage 5.7 .75 h.p., 3–stage 5.7
in, 24 V, 21 A in, 24 V, 21 A in, 24 V, 21 A
WATER LIFT 1829mm (72 in) 1829mm (72 in) 1829mm (72 in)
BATTERIES Four – 6 V, 235 AH Four – 6 V, 235 AH Four – 6 V, 235 AH
RUN TIME PER CHARGE Up to 2.5 hours Up to 2.5 hours Up to 2.5 hours
DECIBEL RATING AT OPERATOR’S EAR, 74 dB(A) 74 dB(A) 74 dB(A)
INDOORS ON TILE.

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 GENERAL INFORMATION

MACHINE DIMENSIONS – 610mm (24 in) and 660mm (26 in) DISK MODELS

839mm (33 in)

559mm (22 in)

1041mm (41 in)

1270mm (50 in)

*1289mm (50.75 in) 641mm (25.25 in)
*699mm (27.5 in)

* Dimensions apply to 660 mm (26 in) disk models only

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 GENERAL INFORMATION

MACHINE DIMENSIONS – 610mm (24 in) CYLINDRICAL BRUSH MODEL

839 mm (33 in)

559 mm
(22 in)

1041 mm (41 in)

1359 mm 667 mm
(53.5 in) (26.25 in)

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GENERAL INFORMATION
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Machine will not Faulty key switch Contact Service Center
turn on
Batteries need charging See CHARGING BATTERIES
Faulty battery(s) Replace battery(s)
Loose battery cable Tighten loose cable
MAIN circuit breaker has tripped Determine cause and reset breaker
Optional power kill button activated Turn button clockwise to reset
Brush motors will not Faulty brush switch Contact Service Center
turn on
Control grips not rotated Rotate grips
Brush circuit breaker has tripped Replace pad or adjust pad pressure
and reset brush circuit breaker button
Faulty brush motor or wiring Contact Service Center
Worn carbon brushes Contact Service Center
Faulty brush solenoid Contact Service Center
Vacuum motor will not Faulty vacuum switch Contact Service Center
turn on
Squeegee is raised off floor Lower squeegee
Main circuit breaker has tripped Remove obstruction and reset circuit
breaker button
Vacuum motor circuit breaker has Determine cause and reset circuit
tripped breaker button
Faulty vacuum motor or wiring Contact Service Center
Worn carbon brushes Contact Service Center
Little or no solution Solution switch is not activated Turn on solution switch
flow
Clogged solution line or solution tank Remove hose and blow compressed
filter air through it. Flush solution tank after
each use
Clogged solution valve or solenoid Remove valve or solenoid and clean.
Do not scratch inside of valve
Faulty solution switch or solenoid Contact Service Center
Solution flow knob not activated Turn solution flow knob
Loose set screw on solution knob Calibrate knob and tighten screw
Poor Scrubbing Brushes/pads out of adjustment See ADJUSTING SCRUB HEAD
Performance
Worn Brushes/pads Replace brushes/pads
Debris caught in brushes/pads Remove debris
Low tire pressure Increase tire pressure
Low battery charge Charge batteries
Incorrect brush/pad pressure Readjust brush/pad pressure
Broken Brush belt (cylindrical brush) Replace belts
Poor Drive Traction Pad pressure set too high Decrease brush pressure
Tires slipping Contact distributor for advice
Uneven brush pressure Level scrub head
Broken brush belt (cylindrical brush) Replace belt

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 GENERAL INFORMATION
TROUBLESHOOTING – Continued
PROBLEM CAUSE SOLUTION
Poor water pickup Recovery tank is full and ball float has Empty recovery tank
been activated
Ball float screen inside recovery tank Remove screen and clean
is clogged
Clogged squeegee Clean squeegee
Worn squeegee blades Replace squeegee blades
Loose squeegee thumbscrews Tighten thumbscrews
Vacuum hose connections are loose Push hose cuffs firmly on connections.
or hose has a hole Replace hose if damaged
Clogged vacuum hose Remove clogged debris
Recovery tank inlet hole is obstructed Empty recovery tank and tilt tank side-
ways to access inlet hole, remove ob-
struction
Worn tank lid gasket Replace gasket
Loose drain hose plug Tighten plug
Recovery tank lid not in place Properly position lid
Loose vacuum motor Contact Service Center
Battery charge level is low Charge batteries. Do not run machine
when battery meter is in the red zone
ES option not ES filter is clogged Remove and clean ES filter
operating
Faulty ES pump Contact Service Center
Faulty ES ON/OFF switch Contact Service Center
ES float switch is dirty Rinse off float switch located in
recovery tank
Faulty ES float switch Contact Service Center
Short run time Batteries not fully charged Charge batteries
Defective batteries Replace battery
Batteries need maintenance See BATTERY MAINTENANCE
Faulty charger Repair or replace battery charger

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 GENERAL INFORMATION

MACHINE JACKING

Use designated locations under the solution tank

for jacking up machine. Use a piece of wood to
distribute machine weight load.

Always stop machine on a flat level surface and

block machine tires before jacking up machine.

FOR SAFETY: When servicing machine, block

machine tires before jacking machine up.

FOR SAFETY: When servicing machine, jack

machine up at designated locations only.
Block machine up with jack stands.

MACHINE TRANSPORTING

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

FOR SAFETY: When using machine, go slow

on inclines and slippery surfaces.

When transporting machine by use of trailer or

truck, be certain to follow tie–down procedures
below:
1. Raise squeegee and scrub head.

2. Load machine using a recommended

loading ramp.

3. Position front of machine up against front of

trailer or truck. Once machine is positioned,
lower scrub head and squeegee.

4. Set parking brake, if equipped, and place a

block behind each drive wheel to prevent
machine from rolling.

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 GENERAL INFORMATION

STORING MACHINE

Before storing the machine for an extended period

of time, the machine needs to be prepped to
lessen the chance of rust, sludge, and other
undesirable deposits from forming. Contact
TENNANT service personnel.
TO STORE MACHINE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

1. Make sure the tanks are drained and rinsed

out.

2. Un–plug the batteries and charge them

properly.

STORAGE INFORMATION

The following steps should be taken when storing

the machine for extended periods of time.
1. Drain and clean the solution and recovery
tanks.

2. Park the machine in a cool, dry area.

3. Remove the batteries, or charge them after

every three months.

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 GENERAL INFORMATION
HARDWARE INFORMATION

The following charts state standard plated NOTE: Decrease torque by 20% when using a
hardware tightening ranges for normal assembly thread lubricant.
applications. Decrease the specified torque by
20% when using a thread lubricant. Do not Exceptions to the above chart:
substitute lower grade hardware for higher grade
hardware. If higher grade hardware than specified Check the machine for exceptions!
is substituted, tighten only to the specified
hardware torque value to avoid damaging the
BOLT IDENTIFICATION
threads of the part being threaded into, as when
threading into speed nuts or weldments.
Identification Specification and
Grade Marking Grade
STANDARD BOLT TORQUE CHART SAE–Grade 5

SAE Grade 5 SAE Grade 8 SAE–Grade 8

Thread Torque ft lb Torque ft lb
Size (Nm) (Nm) ISO–Grade 8.8
0.25 in 7–10 (9–14) 10–13 (14–38)
ISO–Grade 10.9
0.31 in 15–20 (20–27) 20–26 (27–35)
0.38 in 27–35 (37–47) 36–47 (49–64) 01395

0.44 in 43–56 (58–76) 53–76 (72–103)

0.50 in 65–85 (88–115) 89–116 THREAD SEALANT AND LOCKING
(121–157) COMPOUNDS
0.62 in 130–170 117–265 Thread sealants and locking compounds may be
(176–231) (159–359) used on this machine. They include the following:
0.75 in 215–280 313–407
(291–380) (424–552) Locktite 515 sealant – gasket forming
1.00 in 500–650 757–984 material. TENNANT Part No. 75567,15 oz
(678–881) (1026–1334) (440 ml) cartridge.

NOTE: Decrease torque by 20% when using a Locktite 242 blue – medium strength thread
thread lubricant. locking compound. TENNANT Part No.
32676, 0.5 ml tube.
METRIC BOLT TORQUE CHART
Locktite 271 red – high strength thread
locking compound. TENNANT Part No.
Class 8.8 Class 10.9
19857, 0.5 ml tube.
Thread Torque ft lb Torque ft lb
Size _Nm) (Nm)
M4 2 (3) 3 (4)
M5 4 (5) 6 (8)
M6 7 (9) 10 (14)
M8 18 (24) 25 (34)
M10 32 (43) 47 (64)
M12 58 (79) 83 (112)
M14 94 (127) 133 (180)
M16 144 (195) 196 (265)
M20 260 (352) 336 (455)
M24 470 (637) 664 (900)

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 CHASSIS

CONTENTS

Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . 2–3
DRIVE TRANSAXLE . . . . . . . . . . . . . . . . . . 2–4
TO REMOVE DRIVE TRANSAXLE . . . 2–4
TO INSTALL THE TRANSAXLE . . . . . . 2–6
TO REPLACE DRIVE WHEEL/TIRE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 2–7
REAR CASTER . . . . . . . . . . . . . . . . . . . . . . . 2–9
TO REPLACE REAR CASTER . . . . . . . 2–9

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CHASSIS

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 CHASSIS

INTRODUCTION

This section includes information on the main

chassis related components for example the
transaxle, casters, and tires.

The transaxle drive motor and transaxle must be

replaced as one unit.

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CHASSIS

DRIVE TRANSAXLE

The drive transaxle on the 5400 provides the

forward and reverse movement for the machine.
The drive transaxle is powered by a 24V electric
motor.

TO REMOVE DRIVE TRANSAXLE

1. Lower the scrub head all the way to the
floor.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Turn Off
Machine.

2. Turn the machine power off.

3. Lift the rear of the machine until the

transaxle drive wheels are off the ground.

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 CHASSIS
4. Place a jackstand under the machine frame.

5. Remove the four 0.250 in. hex nuts and

washers holding each drive wheel to the
transaxle. Remove the drive wheels from the
machine.

6. Un–plug the transaxle drive motor from the

main harness.

7. Remove the four M8 hex screws and

washers holding the two transaxle mount
brackets to the machine frame.

8. The transaxle can now be removed from the

machine.

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CHASSIS
TO INSTALL THE TRANSAXLE
1. Position the new transaxle under the
machine frame. Make sure the drive motor
electric lead is positioned on the left hand
side of the machine.

2. Lift the transaxle up into the machine frame

until the mount brackets and M8 hex screws
can be reinstalled. Tighten to 18 – 24 Nm
(15 – 20 ft lb).

3. Plug the drive motor into the main harness.

See schematic in the ELECTRICAL section
of this manual.

4. Reinstall the drive wheels onto the transaxle

using the four 0.250 in. hex nuts and
washers. Tighten to 11 – 14 Nm
(7 – 10 ft lb).

5. Remove the jack stands and lower the

machine to the ground.

6. Raise the scrubber head.

7. Operate the machine, checking for proper

operation of the transaxle.

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 CHASSIS
TO REPLACE DRIVE WHEEL/TIRE ASSEMBLY
1. Lower the scrub head all the way to the
floor.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Turn Off
Machine.

2. Turn the machine power off.

3. Lift the rear of the machine until the

transaxle drive wheels are off the ground.

4. Place a jackstand under the machine frame.

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CHASSIS
5. Remove the four 0.250 in. hex nuts and
washers holding each drive wheel to the
transaxle. Remove the drive wheels from the
machine.

6. Position the new drive wheel onto the

transaxle using the four 0.250 in. hex nuts
and washers. Tighten to 11 – 14 Nm
(7 – 10 ft lb).

7. Remove the jack stands and lower the

machine to the ground.

8. Raise the scrubber head.

9. Operate the machine, checking for proper

operation of the drive wheels.

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 CHASSIS

CASTER

The casters have one grease fitting on the caster

swivel. Lubricate the caster with a grease gun
containing Lubriplate EMB grease every 80 hours
of machine operation.

TO REPLACE CASTERS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Turn the machine power off.

2. Lift the rear of the machine with an over

head hoist or other lifting device until the
rear caster is off the ground. Place a
jackstand under the machine frame.

3. Remove the four M8 hex screws and

washers holding the caster to the machine
frame. Remove the caster from the
machine.

4. Position the new caster under the machine

and reinstall the four M8 hex screws and
washers. Tighten to 18 – 24 Nm
(15 – 20 ft lb).

5. Remove the jackstand from under machine

frame. Lower the machine to the ground and
operate, checking for proper operation.

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CHASSIS

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 SCRUBBING

CONTENTS

Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . 3–3
SOLUTION TANK . . . . . . . . . . . . . . . . . . . . . 3–4
RECOVERY TANK . . . . . . . . . . . . . . . . . . . . 3–5
SCRUB BRUSHES . . . . . . . . . . . . . . . . . . . . 3–6
TO REPLACE DISC SCRUB BRUSH . 3–7
TO REPLACE CYLINDRICAL SCRUB
BRUSH . . . . . . . . . . . . . . . . . . . . . . . . 3–8
SCRUB HEAD . . . . . . . . . . . . . . . . . . . . . . . 3–10
TO REMOVE DISC SCRUB HEAD . . 3–11
TO ADJUST DISK BRUSH SCRUB
HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 3–13
TO REPLACE DISK SCRUB HEAD
SKIRT . . . . . . . . . . . . . . . . . . . . . . . . 3–14
TO REMOVE CYLINDRICAL SCRUB
HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
TO CHECK CYLINDRICAL BRUSH
PATTERN . . . . . . . . . . . . . . . . . . . . . 3–17
TO ADJUST TAPERED BRUSH
PATTERN . . . . . . . . . . . . . . . . . . . . . 3–20
TO ADJUST UNEVEN BRUSH
PATTERN . . . . . . . . . . . . . . . . . . . . . 3–22
TO ADJUST CYLINDRICAL SCRUB
HEAD SKIRTS . . . . . . . . . . . . . . . . . 3–23
TO REPLACE CYLINDRICAL
SCRUB HEAD SKIRT . . . . . . . . . . . 3–25
TO REPLACE CYLINDRICAL SCRUB
BRUSH DRIVE BELT . . . . . . . . . . . 3–26
TO REPLACE CYLINDRICAL SCRUB
BRUSH IDLER PLUG AND
BEARING ASSEMBLY . . . . . . . 3–29
TO REPLACE CYLINDRICAL SCRUB
BRUSH DRIVE PLUG BEARINGS 3–31
SQUEEGEE . . . . . . . . . . . . . . . . . . . . . . . . . 3–37
TO REMOVE SQUEEGEE . . . . . . . . . 3–37
TO REPLACE OR ROTATE
REAR SQUEEGEE BLADE . . . . . . 3–39
TO REPLACE OR ROTATE
FRONT SQUEEGEE BLADE . . . . 3–40
TO REPLACE SQUEEGEE LIFT
CABLE . . . . . . . . . . . . . . . . . . . . . . . . 3–41
TO REPLACE SOLUTION FLOW
CONTROL CABLE . . . . . . . . . . . . . 3–43
MACHINE TROUBLESHOOTING . . . . . . 3–45

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SCRUBBING

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 SCRUBBING

INTRODUCTION

When scrubbing with the 5400, the water flows

from the solution tank, through the solution valve,
and down to the scrub head. The brush scrubs
the floor. As the machine moves forward the
squeegee wipes the dirty solution off the floor,
which is then picked up and drawn into the
recovery tank by the vacuum fan.

This section includes information on the scrub

head, scrub brush, squeegee, lift actuator,
vacuum fan, float switches, and solution tanks.

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SCRUBBING

SOLUTION TANK

The solution tank holds the clean water and

detergent mixture that will be applied to the floor
for the scrubbing operation. The solution tank is
also the main frame component.

The solution tank does not require regular

maintenance except daily rinsing of any sludge or
deposits. If any deposits do form on the bottom of
the tank, rinse with a strong blast of warm water.

NOTE: The water must not be hotter than 60 C

(140 F), or tank damage may occur. Do not use
steam to clean the tank.

ES Option: The recovery tank should be

partially filled with clean water after using the
ES Option and clean water should be run
through the pump until it is clear of any deposits.

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 SCRUBBING

RECOVERY TANK

The recovery tank holds the used water and

detergent solution pulled off the floor by the
squeegee and scrubbing vacuum fan. The
recovery tank is the top tank on the machine. It
can be opened for battery, vacuum fan, head lift
actuator and water valve access.

The recovery tank should be drained and cleaned

daily.

NOTE: The water must not be hotter than 60 C

(140 F), or tank damage may occur. Do not use
steam to clean the tank.

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SCRUBBING

SCRUB BRUSHES

The scrub brushes should be checked daily for

wire or string tangled around the brush or brush
drive hub. The brushes should also be checked
for any damage and wear.

The scrub brush should be replaced if large

amounts of bristles are missing, or if the
remaining bristles’ length is less than 10 mm
(0.38 in).

NOTE: Be sure to replace brushes in sets.

Otherwise one brush will be more aggressive than
the other.

Cleaning pads must be placed on pad drives

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

Cleaning pads need to be cleaned with soap and

water after every use.

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 SCRUBBING
TO REPLACE DISC SCRUB BRUSH
1. Make sure the scrub head is in the raised
position.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Turn Off
Machine.

2. Turn the machine off.

3. Push the brush release knobs downward.

4. Remove the brush from the drive plug. Pull

the brush out from under the scrub head.

5. Reverse this order for installing the disc

scrub brush

5400 330735 (3–01) 3-7

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SCRUBBING
TO REPLACE CYLINDRICAL SCRUB BRUSH
1. Make sure the scrub head is in the raised
position.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Turn Off
Machine.

2. Turn the machine off.

3. The cylindrical scrub brush must be

removed from the end of the scrub head
opposite the brush drive motor.

4. The brush idler plate is held in place with a

spring clip. To remove the idler plate the
spring clip must be pressed down flat to the
top of the scrub head.

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 SCRUBBING
5. With the spring clip pressed down flat to the
top of the scrub head, pull the bottom of the
idler plate out of the end of the brush and off
the spring clip.

6. The scrub brush can now be removed from

the machine.

7. Position the new scrub brush under the

scrub head.

NOTE: One end of the cylindrical scrub brush has

a double row of bristles. This end must be on the
idler side of the scrub head.

8. Place the brush on the motor–drive end first.

9. Partially engage the idler plug into the other

end of the scrub brush.

10. Position the idler plate on the scrub head,

making sure that the notches on the idler
plate engage the lip of the scrub head.

11. Push the spring clip down until the slot is

positioned under the clip on the idler plate.
Release the spring.

12. Start the brushes and check for proper

brush pattern. See TO CHECK
CYLINDRICAL BRUSH PATTERN
instructions.

Note: Every 50 hours the front brush should be

installed in the rear and the rear brush installed in
the front to keep an even wear pattern on the
bristles.

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SCRUBBING

SCRUB HEAD

The scrub head includes the scrub brushes,

electric motors, lift actuator and a solution
dispensing system. The scrub head skirt controls
over-spray from the scrub brush. Make sure the
scrub head skirt touches the floor all the way
around when the scrub head is lowered.

Check the disk brush scrub head skirt for damage

or wear daily.

Check the cylindrical brush scrub head side skirt

for damage daily.

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 SCRUBBING
TO REMOVE DISC SCRUB HEAD
1. Lower the scrub head to the floor.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

2. Remove the scrub head shroud.

3. Disconnect the solution hose running from

the solution tank to the scrub head.

4. Unplug the electrical connectors attaching

the scrub head motor to the main harness.

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SCRUBBING
5. Remove the cotter pin and clevis pin from
the bottom of the head lift roller bracket.

6. Remove the two hair pins and two clevis

pins connecting the scrub head to the scrub
head lift arms.

7. Pull the disc scrub head away from the front

of the machine.

8. Reverse these steps to install a disc scrub

head.

NOTE: When reinstalling a scrub head, loosen the

two mounting screws on the switch box. Align the – Cylindrical

corresponding arrow printed on the switchbox – Disk

label with the notch in the spring bracket.
Notch
Switch
Spring
Box
Bracket

DETAIL

Roller
Bracket

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 SCRUBBING
TO ADJUST DISK BRUSH SCRUB HEAD
1. Check the air pressure in the drive tires.
Proper air pressure for standard pneumatic
tire is 315 to 345 kPa (45 to 50 psi).

2. Fill the solution tank.

3. Lower the scrub head to the floor .

Apply maximum down pressure.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

4. The scrub head levelness is checked by

measuring from the top of the scrub head to
the floor at the center front and center back.

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SCRUBBING
5. If the scrub head is not level, loosen the
scrub head adjustment screw jam nut. Use a
1 inch open end wrench on the adjustment
hex screw, located at the front of the pivot
bracket, to adjust the angle of the scrub
head. Make sure to re–tighten the jam nut.
Re–check the scrub head levelness.

NOTE: Make sure the scrub head skirt touches

the floor all the way around when the scrub head
is lowered. Check the skirt for damage or wear
daily.

TO REPLACE DISK SCRUB HEAD SKIRT

1. If the disc scrub head skirt is torn or worn, it
needs to be replaced. Remove the skirt
retaining band and skid strip holding the skirt
to the head.

3-14 5400 330735 (3–01)

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 SCRUBBING
TO REMOVE CYLINDRICAL SCRUB HEAD
1. Lower the scrub head to the floor.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

2. Remove the scrub head shroud.

3. Disconnect the solution hose running from

the solution tank to the scrub head.

4. Unplug the electrical connectors attaching

the scrub head motors to the main harness.

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SCRUBBING
5. Remove the socket screw connecting the
back of the scrub head to the head lift roller
bracket.

6. Remove the two hair pins and two clevis

pins connecting the scrub head to the scrub
head lift arms.

7. Pull the disc scrub head away from the front

of the machine.

8. Reverse these steps to install a cylindrical

scrub head. After installing scrub head, see
TO CHECK CYLINDRICAL BRUSH
PATTERN instructions.

NOTE: When reinstalling a scrub head, loosen the

two mounting screws on the switch box. Align the – Cylindrical

corresponding arrow printed on the switchbox – Disk

label with the notch in the spring bracket.
Notch
Switch
Spring
Box
Bracket

DETAIL

Roller
Bracket

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 SCRUBBING
TO CHECK CYLINDRICAL BRUSH PATTERN
Apply chalk, or some other material that will not
blow away easily, on a smooth, level floor.

1. Check the air pressure in the drive tires.

Proper air pressure for standard pneumatic
tire is 315 to 345 kPa (45 to 50 psi).

2. Fill the solution tank.

3. Position the machine with the scrub head

located over the top of the chalk area.
Lower the scrub head to the floor .
Apply minimal down pressure.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

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SCRUBBING
4. Turn the solution switch to the off position.

5. Turn the speed control knob to the slowest

setting.

NOTE: Make sure the side skirts on the scrub

head are not holding the scrub head and brushes
up off the floor when checking the brush pattern.
You may have to adjust them up or pull them to
the side.

6. Slightly rotate the control grips forward for 2

seconds while holding the machine in one
spot. Lower the scrub head, allowing the
brushes to spin on the floor in one spot for
15 to 20 seconds.

NOTE: If no chalk or other material is available,

allow the brushes to spin for 30 seconds in one
spot.

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 SCRUBBING
7. Raise the scrub head and drive the machine
from the test area. Check both brush
patterns to make sure they are the same
width from side to side. If both brush
patterns look good, the adjustment
procedure is complete. If either brush shows
a tapered pattern, see TO ADJUST
TAPERED BRUSH PATTERN instructions. If
either brush shows an uneven pattern, see
TO ADJUST UNEVEN BRUSH PATTERN
instructions.

Good pattern
Good pattern

Tapered pattern
Tapered pattern

Uneven pattern
Uneven pattern

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SCRUBBING
TO ADJUST TAPERED BRUSH PATTERN
1. Make sure the scrub head is in the raised
position.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Turn Off
Machine.

2. Turn the machine off.

3. Remove the brush idler plate from the end of

the brush that has a taper. The brush idler
plate is held in place with a spring clip. To
remove the idler plate the spring clip must
be pressed down flat to the top of the scrub
head.

4. With the spring clip pressed down flat to the

top of the scrub head, pull the bottom of the
idler plate out of the end of the brush and off
the spring clip.

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 SCRUBBING
8. Put a 3/8 inch open end wrench on the flat
of the idler eccentric shaft, loosen the flat
head screw with a 6mm. allen wrench.

9. Turn eccentric shaft to raise or lower that

end of the brush. Re–tighten the flat head
screw while holding the flat of eccentric
shaft.

10. Reinstall the idler plate and re–check the

brush pattern. Re–adjust if necessary.

NOTE: Make sure to install the idler plate on the

side it was removed from to avoid having to
re–adjust the brush taper.

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SCRUBBING
TO ADJUST UNEVEN BRUSH PATTERN
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

1. Lower the scrub head to the floor .

Apply maximum down pressure.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

2. The scrub head levelness is checked by

measuring from the edge of the scrub head
to the floor at all four corners of the scrub
head.

3. If the scrub head is not level, loosen the

scrub head adjustment screw jam nut. Use a
1 inch open end wrench on the adjustment
hex screw, located at the front of the pivot
bracket, to adjust the angle of the scrub
head. Make sure to re–tighten the jam nut.
Re–check the scrub head levelness.

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 SCRUBBING
TO ADJUST CYLINDRICAL SCRUB HEAD
SKIRTS
The cylindrical scrub head skirts should just touch
the floor when the head is the lowered position.
Check the skirts for damage or wear daily.

1. Lower the scrub head on a level floor until

the brushes make contact.

2. Turn the machine power off.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Turn Off
Machine.

3. Check to see if the scrub head skirts touch

the floor on both sides of the scrub head.

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SCRUBBING
4. Loosen the four M8 flat head screws holding
the skirt and retainer to the scrub head.

5. Adjust the skirt down so it lightly contacts

the floor. Hand tighten the M8 flat head
screws.

6. Operate the machine and check the scrub

head skirts for proper operation.

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 SCRUBBING
TO REPLACE CYLINDRICAL
SCRUB HEAD SKIRT
1. Make the scrub head is in the raised
position.

2. Turn the machine power off.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Turn Off
Machine.

3. Remove the four M8 flat head screws

holding the skirt retainer and skirt to the side
of the scrub head. Remove the skirt.

4. Position a new skirt under the skirt retainer

and reinstall the four M8 flat head screws.

5. Adjust the skirt down so it lightly contacts

the floor. Hand tighten the M8 flat head
screws. Do not over tighten.

6. Operate the machine and check the scrub

head skirts for proper operation.

5400 330735 (3–01) 3-25

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SCRUBBING
TO REPLACE CYLINDRICAL SCRUB BRUSH
DRIVE BELT
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

1. Remove the scrub brush from the motor that

the belt needs to be changed. See TO
REPLACE A CYLINDRICAL SCRUB
BRUSH instructions in this section.

2. Loosen the front and rear pivot bolts on the

brush motor.

3. Remove the two M6 hex screws holding the

belt guard onto the motor that the belt needs
changing. Remove the belt cover from the
scrub head.

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 SCRUBBING
4. Loosen the M8 hex nut on the belt tension
bolt under the motor. Turn the tension bolt
down far enough to allow the belt to be
slipped off the motor pulley. Push the drive
belt down toward the drive plug in the brush
area.

NOTE: Make sure the scrub head is in the raised

position before attempting to remove the drive
plug rubber seal.

5. Using a needle nose pliers, pull the rubber

seal off the brush drive plug. Remove the
belt cover from the bottom of the scrub
head. Take care not to damage the cover
gasket.

6. Pull the drive belt off the bottom drive pulley.

7. Slip the new drive belt over the drive plug.

Push the rest of the belt up to the drive
motor and onto the motor drive pulley.

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SCRUBBING
8. Install a new seal (part # 222820). Apply a
bead of silicone sealant (part # 08317)
around the seal to bond it in place. Reinstall
the lower cover and gasket.

9. Using the M8 hex screw located under the

brush motor, tension the belt by applying
2.5–2.7 lbs of force per belt at the middle of
the span that is opposite the belt travel with
a deflection of 0.10 inch.

10. Tighten the two pivot bolts to 18 – 24 Nm

(15 – 20 ft lb). Re–check the belt tension.

11. Reinstall the belt cover. Install the two M6

hex screws, and washers. Tighten to 11 – 14
Nm (7 – 10 ft lb).

12. Reinstall the scrub brush. See TO

REPLACE A CYLINDRICAL SCRUB
BRUSH instructions in this section.

13. Operate the machine and check for proper

operation.

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 SCRUBBING
TO REPLACE CYLINDRICAL SCRUB BRUSH
IDLER PLUG AND BEARING ASSEMBLY
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

1. Remove the scrub brush idler door. See TO

REPLACE A CYLINDRICAL SCRUB
BRUSH instructions in this section.

2. Remove the M10 flat screw holding the idler

plug to the brush door.

3. Remove the snap ring holding the plastic

idler plug and bearing assembly to the idler
plug shaft.

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SCRUBBING
4. Use an arbor press to remove the brush
plug and bearing assembly from the brush
plug shaft. Use the arbor press to install a
new bearing drive plug assembly onto the
existing idler shaft.

5. Reinstall the snap ring onto the idler shaft.

6. Reinstall the M10 flat screw holding the idler

plug shaft and hub assembly to the brush
door. Make sure to align the small pin on the
shaft base with the hole in the brush door.
Leave the flat screw loose for now, the brush
hub will need to be adjusted later.

7. Reinstall the cylindrical scrub brush idler

door. See TO REPLACE A CYLINDRICAL
SCRUB BRUSH instructions in this section.

8. Operate the machine. Check the cylindrical

scrub brush pattern. See TO CHECK
CYLINDRICAL BRUSH PATTERN
instructions in this section.

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 SCRUBBING
TO REPLACE CYLINDRICAL SCRUB BRUSH
DRIVE PLUG BEARINGS
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

1. Remove the scrub brush. See TO

REPLACE A CYLINDRICAL SCRUB
BRUSH instructions in this section.

2. Loosen the front and rear pivot bolts on the

brush motor.

3. Remove the two M6 hex screws holding the

belt guard and belt shield on the motor that
the belt needs changing. Remove the belt
cover from the scrub head.

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SCRUBBING
4. Loosen the M8 hex nut on the belt tension
bolt under the motor. Turn the tension bolt
down far enough to allow the belt to be
slipped off the motor pulley. Push the drive
belt down toward the drive plug in the brush
area.

NOTE: Make sure the scrub head is in the raised

position before attempting to remove the drive
plug rubber seal.

5. Using a needle nose pliers, pull the rubber

seal off the brush drive plug. Remove the
belt cover from the bottom of the scrub
head. Take care not to damage the cover
gasket.

6. Pull the drive belt off the bottom drive pulley.

7. Unscrew the drive plug assembly from the

scrub head casting.

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 SCRUBBING
9. Remove the snap ring holding the hub and
bearing to the hub shaft.

10. Use an arbor press to remove the two

bearings from the brush drive plug.

11. Use the arbor press to first––press the inner

bearing onto the hub shaft.

12. Secondly––press the drive hub onto the

inner bearing.

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SCRUBBING
13. Thirdly––press the outer bearing into the
drive hub.

14. Reinstall the snap ring onto the hub shaft.

15. Place a small amount of Loctite blue 242 on

the threads of the drive hub shaft.

16. Reinstall the drive hub shaft onto the scrub

head casting. Tighten firmly.

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 SCRUBBING
8. Slip the new drive belt over the drive plug.
Push the rest of the belt up to the drive
motor and onto the motor drive pulley.

9. Install a new seal (part # 222820). Apply a

bead of silicone sealant (part # 08317)
around the seal to bond it in place. Reinstall
the lower cover and gasket.

10. Using the M8 hex screw located under the

brush motor, tension the belt by applying
2.5–2.7 lbs of force per belt at the middle of
the span that is opposite the belt travel with
a deflection of 0.10 inch.

11. Tighten the two pivot bolts to 18 – 24 Nm

(15 – 20 ft lb). Re–check the belt tension.

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SCRUBBING
12. Reinstall the belt cover, two M6 hex screws,
and washers. Tighten to 11 – 14 Nm
(7 – 10 ft lb).

13. Reinstall the scrub brush. See TO

REPLACE A CYLINDRICAL SCRUB
BRUSH instructions in this section.

14. Operate the machine and check for proper

operation.

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 SCRUBBING

SQUEEGEE

The squeegee channels water into the vacuum

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

Check the squeegee blades for damage and wear

daily. Rotate or replace either of the squeegee
blades if the leading edge is torn or worn half-way
through the thickness of the blade.

The squeegee can be removed from the

squeegee pivot so the squeegee will not be
damaged during transport of the machine.

TO REMOVE SQUEEGEE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.
1. Raise the squeegee.

2. Remove the squeegee suction hose from

the squeegee.

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SCRUBBING
3. Loosen the two mounting thumbscrews.

4. Pull the squeegee off the machine.

NOTE: Reverse this order to install the squeegee

assembly.

5. Operate the machine. Check the squeegee

for proper operation.

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 SCRUBBING
TO REPLACE OR ROTATE REAR SQUEEGEE
BLADE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.
1. Raise the squeegee.

2. Un–snap the squeegee rear retainer clamp.

3. Remove the retainer and squeegee blade

from the squeegee frame.

NOTE: Reverse this order to install the squeegee

blade and retainer.

4. Operate the machine. Check the squeegee

for proper operation.

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SCRUBBING
TO REPLACE OR ROTATE FRONT
SQUEEGEE BLADE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.
1. Raise the squeegee.

2. Remove the six thumbscrews holding the

retainer and squeegee blade to the
squeegee frame.

3. Pull the squeegee blade off the squeegee

frame.

NOTE: Reverse this order to install the squeegee

blade and retainer.

4. Operate the machine. Check the squeegee

for proper operation.

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 SCRUBBING
TO REPLACE SQUEEGEE LIFT CABLE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.
1. Lower the squeegee.

2. Disconnect the tension spring from the

squeegee lift cable.

3. Remove the cotter pin and clevis pin from

the end of the lift cable where it attaches to
the lower bracket.

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SCRUBBING
4. Remove the clevis from the bottom end of
the cable.

Note the amount of threads the clevis is turned

onto the existing lift cable. Install the clevis onto
the new cable in the same location.

5. Loosen the jam nut holding the squeegee lift

cable to the ball joint. Un–screw the cable
from the ball joint.

6. Pull the cable end through the cable

bushing. Remove the cable from the
machine.

Remove the balljoint end and jam nut from the

existing cable. Install the jam nut and balljoint in
the same location on the new lift cable.

NOTE: Reverse this order to install the squeegee

lift cable.

7. Operate the machine. Check the squeegee

lift cable for proper operation.

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 SCRUBBING
TO REPLACE SOLUTION FLOW CONTROL
CABLE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.
1. Use a 5/64 inch allen wrench to loosen the
set screw holding the solution flow control
cable to the end of the valve. Pull the cable
off the valve.

2. Remove the four pan screws holding the

solution flow bracket assembly to the back
of the solution tank.

3. Use a small, flat screw driver to remove the

solution control knob from the top of the
cable.

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SCRUBBING
4. Use a 1/2 inch nut driver to remove the
cable jam nut. Remove the solution cable
from the bracket.

NOTE: Reverse this order to install the new

solution control cable.

5. Operate the machine. Check the new

solution cable for proper operation.

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 SCRUBBING

MACHINE TROUBLESHOOTING

Problem Cause Remedy

Trailing water – poor or no water Worn squeegee blades Rotate or replace squeegee
pickup blades
Vacuum hose clogged Flush vacuum hoses
Recovery tank full Drain recovery tank
Vacuum fan will not turn on Drain recovery tank
Reset vacuum fan circuit breaker
Debris caught on squeegee Remove debris
Foam filling recovery tank Empty recovery tank; use less or
change detergent
Vacuum hose to squeegee or Reconnect or replace vacuum
recovery tank disconnected or hose
damaged
Recovery tank float screen Clean screen
clogged
Recovery tank cover not closed Close cover
completely
Little or no solution flow to the Solution tank empty Fill solution tank
floor
Solution switch off Turn switch on
Solution control cable broken or Replace and/or adjust cable
out of adjustment
Solution flow knob turn off Turn solution flow knob on
Solution supply lines plugged Flush solution supply lines
Solution solenoid clogged or Clean or replace
stuck
ES mode: ES switch off Turn ES switch on
Poor scrubbing performance Debris caught on scrub brushes Remove debris
Improper detergent, brush, or Check with TENNANT
pad used representative for advice
Worn scrub brush or pad Replace scrub brush or pad
Scrub brush motor circuit Reset circuit breaker
breaker tripped
Adjust scrub brush down
pressure, check with TENNANT
representative for advice
Low battery charge Charge batteries
Low scrub brush down pressure Adjust scrub brush down
pressure, check with TENNANT
representative for advice

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3-46 5400 330735 (3–01)

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 ELECTRICAL

CONTENTS

Page Page
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . 4–3 ELECTRIC MOTORS . . . . . . . . . . . . . . . . . 4–55
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 TO REPLACE VACUUM FAN
TO CHARGE BATTERIES . . . . . . . . . . . 4–6 MOTOR BRUSHES . . . . . . . . . . . . 4–55
TO REPLACE CHARGER SAFETY TO REPLACE DISC SCRUB BRUSH
SWITCH . . . . . . . . . . . . . . . . . . . . . . . 4–8 MOTOR BRUSHES . . . . . . . . . . . . . 4–57
INSTRUMENT PANEL . . . . . . . . . . . . . . . . 4–11 ELECTRICAL SCHEMATIC . . . . . . . . . . . . 4–59
TO ACCESS INSTRUMENT PANEL . 4–11 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . 4–60
TO REMOVE HANDLE BAR GEAR WIRING DIAGRAM (OPTIONS) . . . . . . . . 4–61
HUB . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13 TROUBLESHOOTING . . . . . . . . . . . . . . . . 4–63
TO REPLACE POTENTIOMETER POWER UP CIRCUIT . . . . . . . . . . . . . . 4–64
SWITCH . . . . . . . . . . . . . . . . . . . . . . 4–15 NO POWER (KEY ON AND BATTERY
TO ADJUST POTENTIOMETER . . . . 4–17 CHARGER DISCONNECTED) . . . 4–65
TO REPLACE SPEED CONTROL PROPEL CIRCUIT . . . . . . . . . . . . . . . . 4–68
BOARD . . . . . . . . . . . . . . . . . . . . . . . 4–18 NO PROPEL (POWER UP O.K.) . 4–69
TO REPLACE 24 VOLT NO PROPEL – CONTROL BOARD
CONTACTOR . . . . . . . . . . . . . . . . . . 4–20 TROUPBLESHOOTING . . . . . . . . . 4–71
TO REPLACE RESETTABLE BRUSH CIRCUIT . . . . . . . . . . . . . . . . . . 4–72
CIRCUIT BREAKER . . . . . . . . . . . . 4–21 BOTH BRUSHES DO NOT OPERATE
TO REPLACE 24 VOLT SOLENOID . 4–22 WITH BRUSH DECK DOWN . . . . . 4–73
VACUUM FAN . . . . . . . . . . . . . . . . . . . . . . . 4–25 BRUSH MOTOR 1 DOES NOT
TO REPLACE VACUUM FAN . . . . . . . 4–25 OPERATE . . . . . . . . . . . . . . . . . . . . . 4–75
TO REPLACE VACUUM FAN BRUSH MOTOR 2 DOES NOT
SWITCH . . . . . . . . . . . . . . . . . . . . . . 4–28 OPERATE . . . . . . . . . . . . . . . . . . . . . 4–76
SCRUB BRUSH MOTORS . . . . . . . . . . . . 4–31 ACTUATOR CIRCUIT . . . . . . . . . . . . . . 4–78
TO REPLACE DISC SCRUB BRUSH DECK WILL NOT LOWER 4–79
BRUSH MOTOR . . . . . . . . . . . . . . . 4–31 BRUSH DECK WILL NOT RAISE . 4–80
TO REPLACE CYLINDRICAL HEAD VACUUM FAN CIRCUIT . . . . . . . . . . . . 4–82
SCRUB BRUSH MOTOR . . . . . . . . 4–36 VACUUM FAN DOES
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . 4–42 NOT OPERATE . . . . . . . . . . . . . . . . 4–83
TO REPLACE SCRUB HEAD SOLUTION SOLENOID CIRCUIT . . . 4–86
LIFT ACTUATOR . . . . . . . . . . . . . . . 4–42 SOLUTION SOLENOID DOES NOT
SOLUTION SOLENOID VALVE . . . . . . . . 4–47 OPERATE (BRUSHES WORK) . . . 4–87
TO REPLACE SOLUTION SOLENOID ES SOLENOID CIRCUIT . . . . . . . . . 4–88
VALVE . . . . . . . . . . . . . . . . . . . . . . . . 4–47 ES PUMP DOES NOT OPERATE4–89
OPTIONAL EXTENDED SCRUB . . . . . . . 4–51 WAND PUMP CIRCUIT . . . . . . . . . . . . 4–92
TO REPLACE THE ES PUMP . . . . . 4–51 WAND PUMP DOES
OPTIONAL POWER WAND . . . . . . . . . . . 4–53 NOT OPERATE . . . . . . . . . . . . . . . . 4–93
TO REPLACE POWER WAND
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 4–53

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4-2 5400 330735 (3–01)

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 ELECTRICAL

ELECTRICAL SYSTEM

The 5400 electrical system consists of the

batteries, electrical drive motor, scrub brush
motors, vacuum fan motor, power control panel
and related components. This section includes
information on these components and their
troubleshooting.

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ELECTRICAL

BATTERIES

The batteries are unique in that they hold their

power for long periods of time. The lifetime of the
batteries is limited by the number of charges the
batteries receive. To get the most life from the
batteries, charge them when the battery discharge
indicator needle remains in the red zone of the
indicator.

Periodically clean the top surface of the batteries

and the terminals, and check for loose
connections. Use a strong solution of baking soda
and water. Brush the solution sparingly over the
battery tops, terminals, and cable clamps. Do not
allow any baking soda solution to enter the
batteries. Use a wire brush to clean the terminal
posts and the cable connectors. After cleaning,
apply a coating of clear battery post protectant to
the terminals and the cable connectors. Keep the
tops of the batteries clean and dry.

Keep all metallic objects off the top of the

batteries, which may cause a short circuit.
Replace any worn or damaged wires.

Never add acid to the batteries, only distilled

water. Always keep the battery caps on, except
when adding water or taking hydrometer readings.

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 ELECTRICAL
Measuring the specific gravity using a hydrometer
is a way to determine the charge level, and
condition of the batteries. If one or more of the
battery cells test lower than the other battery cells
(0.050 or more), the cell is damaged, shorted, or
is about to fail.

NOTE: Do not take readings immediately after

adding distilled water. If the water and acid are not
thoroughly mixed, the readings may not be
accurate. Check the hydrometer readings against
the following chart to determine the remaining
battery charge level:

SPECIFIC GRAVITY BATTERY

at 27 C (80F) CHARGE
1.265 100% Charged
1.223 75% Charged
1.185 50% Charged
1.148 25% Charged
1.110 Discharged

NOTE: If the readings are taken when the battery

electrolyte is any temperature other than 27 C
(80 F), the reading must be temperature
corrected. Add or subtract to the specific gravity
reading 0.004, 4 points, for each 6 C (10 F)
above or below 27 C (80 F).

5400 330735 (3–01) 4-5

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ELECTRICAL
TO CHARGE BATTERIES
1. Drive the machine to a flat, dry surface in a
well-ventilated area.

2. Turn the machine power off and set the

parking brake if your machine has this
option.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Turn Off
Machine.

3. Raise the recovery tank for access to the

batteries.

NOTE: The recovery tank must be empty.

4. Check fluid level (A) in each battery cell

before charging. If battery plates (B) are B
exposed, add just enough distilled water to
cover plates by approximately 3 mm (0.13
in). DO NOT OVERFILL. Overfilled batteries
can overflow during charging due to fluid A
expansion. Replace cell caps before
charging.

NOTE: Make sure the battery caps are in place

while charging.

FOR SAFETY: When Maintaining or Servicing

Machine, Avoid Contact With Battery Acid.

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 ELECTRICAL
5. Plug the charger connector into the battery
connector.

WARNING: Batteries Emit Hydrogen

Gas. Explosion Or Fire Can Result.
Keep Sparks And Open Flame Away. Keep
Covers Open When Charging.

6. Plug the battery charger into the wall outlet.

Grounded
Grounded Outlet
3 Hole Outlet

Grounding
Ground Pin
Edge/hole

(120V) (230V)

7. The charger will start automatically. When

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

8. After the charger has turned off, unplug the

charger from the wall outlet.

9. Unplug the charger connector from the

battery connector on the machine.

FOR SAFETY: When Maintaining or Servicing

Machine, Avoid Contact With Battery Acid.
07224

10. Check the electrolyte level in each battery

cell. Add just enough distilled water to bring
the electrolyte level up to the fill rings.

11. Lower the recovery tank.

12. Rotate the stop arm out of the way to allow

the recovery tank to close completely.

5400 330735 (3–01) 4-7

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ELECTRICAL
TO REPLACE CHARGER SAFETY SWITCH
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

NOTE: Drain the recovery tank.

1. Open the recovery tank.

2. Disconnect the positive battery cable from

the front, left machine battery. Machine Front

FOR SAFETY: Disconnect the battery BLACK

3
connections before working on the machine. 5

2
1
4 RED

3. Lower the squeegee.

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 ELECTRICAL
4. Remove the three hex screws holding the
squeegee lever bracket assembly to the left
side of the solution tank.

5. Locate the charger safety switch at the

bottom of the lever bracket assembly. Mark
and disconnect the wires leading to the
switch.

6. Remove the two hex screws and nuts

holding the charger safety switch to the
bracket. Remove the switch.

7. Install the new switch onto the bracket.

Reinstall the hex screws and nuts. Position
the switch so it is activated when the
connector from the battery charger is
plugged into the machine connector.
Tighten the hardware.

8. Reconnect the wires to the new switch.

See electrical schematic in this section.

9. Position the squeegee lever bracket

assembly to the left side of the solution tank.
Reinstall the three hex screws and tighten to
18 – 20 Nm (15 – 18 ft lb).

5400 330735 (3–01) 4-9

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ELECTRICAL
10. Raise the squeegee.

11. Reconnect the positive battery cable to the

battery. Machine Front

BLACK
3
5

2
1
RED
4

12. Operate the machine. Check the charger

safety switch for proper operation. The
machine MUST NOT turn on with the key
when the charger is plugged into the
machine connector. If the machine starts
with the charger plugged in, readjust the
safety switch.

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 ELECTRICAL

INSTRUMENT PANEL

The instrument panel contains the electrical

controls needed to operate the machine. The
battery meter, brush pressure gauge, rocker
switches, relays, contactor, and fuses are located
on the panel. By removing the attachment
hardware, the panel can be pulled back to access
these components.

TO ACCESS INSTRUMENT PANEL

FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Open the recovery tank.

2. Disconnect the positive battery cable from

the front, left machine battery. Machine Front

FOR SAFETY: Disconnect the battery BLACK

3
connections before working on the machine. 5

2
1
4 RED

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ELECTRICAL
3. Remove the eight pan head screws holding
the instrument panel to the handle housing.

4. Pull the instrument panel back for access to

the electrical components.

5. When reinstalling the panel, reconnect all

wires that were disconnected. Install the
eight phillips head mounting screws. DO
NOT over tighten the screws or damage to
the female brass insert could occur.
Reconnect the positive battery cable.

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 ELECTRICAL
TO REMOVE HANDLE BAR GEAR HUB
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Open the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

FOR SAFETY: Disconnect the battery

connections before working on the machine.

2. Remove the right handle grip.

3. Use a screwdriver to loosen the set screw

on the handle bar lock collar. The collar
should now move freely on the handle bar.
Make sure the rounded side of the lock
collar is facing OUT, towards the handle
grip, when reassembling handle bar.

5400 330735 (3–01) 4-13

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ELECTRICAL
4. Remove the hex screw and nut holding the
plastic gear hub to the handle bar.

5. Pull the handlebar out of the left side of the

console while sliding the gear and hub
assembly and shims off the bar. Remove the
gear hub from the machine.

6. To reassemble with a new gear hub, reverse

the above steps. When reinstalling the
handle grips onto the handlebar, use a light
film of alcohol to ease assembly.

7. Reinstall the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

8. Operate the machine. Check the propelling

for proper operation. Make sure the machine
stops propelling when the handles are
released.

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 ELECTRICAL
TO REPLACE POTENTIOMETER SWITCH
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Open the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

FOR SAFETY: Disconnect the battery

connections before working on the machine.

2. Mark the location of the plastic gear on the

shaft of the existing potentiometer. Loosen
the small set screw and remove the gear
from the shaft.

3. Remove the jam nut holding the

potentiometer to the mount bracket. Note
the orientation of the potentiometer on the
mount bracket.

5400 330735 (3–01) 4-15

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ELECTRICAL
4. Disconnect the potentiometer from the
harness and circuit board. Remove the
potentiometer from the machine.

5. Install the new potentiometer onto the mount

bracket in the same orientation as the old
one. Leave the jam nut loose for now.

6. Reinstall the plastic gear onto the shaft of

the new potentiometer. Make sure the gear
is in the same orientation on the shaft as the
old one.

7. See TO ADJUST POTENTIOMETER

instructions in this section.

8. Adjust the new potentiometer so that the

teeth on the gear fully engage the teeth on
the hub and gear assembly. Make sure not
to push the gears too tightly together so they
bind. Tighten the potentiometer jam nut. DO
NOT over tighten the jam nut or damage to
the switch may occur.
9. Reinstall the instrument panel. See TO
ACCESS INSTRUMENT PANEL
instructions. Operate the machine. Check
the propelling for proper operation. Make
sure the machine stops propelling when the
handles are released.

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 ELECTRICAL
TO ADJUST POTENTIOMETER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Open the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

FOR SAFETY: Disconnect the battery

connections before working on the machine.

2. Locate the potentiometer just below the

handle assembly.

3. Connect the red wires of the potentiometer

harness together.

4. Use an Volt/OHM meter to measure across

the black and white leads of the
potentiometer harness (take measurements
at wire connection to potentiometer or at 6
pin connector). Divide this reading by two to
calculate the midpoint. This reading should
be approximately 2500 OHMS.

5. While measuring from the black wire to the

red wire, adjust the potentiometer to the
midpoint.

6. Without moving the potentiometer shaft,

measure from the white wire to the red wire.
This reading should be the same as the
midpoint in step 4. If not, repeat steps 4 and
5 until the readings are within 100 OHMS.

7. Tighten the set screw of the small plastic

gear onto the potentiometer shaft. Re–check
steps 4 and 5, re–adjust if necessary.

8. Connect the red wires from the

potentiometer harness to the black wires
from the potentiometer mounted to the
instrument panel.

9. Carefully align the 6 pin connector from the

potentiometer harness to the mating
connector on the circuit board.

10. Reinstall the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions. Operate the machine. Check
the propelling for proper operation. Make
sure the machine stops propelling when the
handles are released.

5400 330735 (3–01) 4-17

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ELECTRICAL
TO REPLACE SPEED CONTROL BOARD
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Open the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

FOR SAFETY: Disconnect the battery

connections before working on the machine.

2. Locate the speed control board at the back

of the instrument panel box.

3. Mark and disconnect the wires leading to the

speed control board. See electrical
schematic in this section.

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 ELECTRICAL
4. Locate the two hex nuts holding the speed
control board to the heat sink plate. Remove
the hex nuts.

5. Remove the board from the instrument

panel. Make sure to retain the two steel
spacers.

6. Install the new board onto the heat sink

plate. Reinstall the two nuts. Lightly tighten
the nuts.

7. Reconnect the wires and connectors to the

new board. See electrical schematic in this
section.

8. Reinstall the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

9. Operate the machine. Check the propelling

for proper operation.

5400 330735 (3–01) 4-19

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ELECTRICAL
TO REPLACE 24 VOLT CONTACTOR
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Open the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

FOR SAFETY: Disconnect the battery

connections before working on the machine.

2. Locate the contactor at the bottom edge of

the instrument panel box.

3. Mark and disconnect the wires leading to the

contactor. Note the direction of the
line side of diode. Make sure the line
side is connected to wire 22YEL. Failure
to do so will result in a short circuit.

4. Remove the two hex nuts holding the

contactor to the panel. Remove the
contactor from the instrument panel.

5. Install the new contactor onto the instrument

panel. Install the two nuts and hand tighten
tight.

6. Reconnect the wires to the contactor. See

electrical schematic in this section. DO NOT
over tighten the wire connections on the
contactor posts or damage may occur.

7. Reinstall the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

8. Operate the machine. Check the vacuum

fan for proper operation.

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 ELECTRICAL
TO REPLACE RESETTABLE CIRCUIT
BREAKER
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Open the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

FOR SAFETY: Disconnect the battery

connections before working on the machine.

2. Locate the resettable circuit breakers at the

center of the instrument panel box.

3. Mark and disconnect the wires leading to the

circuit breaker that needs to be changed.

4. Loosen and remove the breakers mounting

nut located on the front side of the switch
panel.

5. Connect the wires to the new circuit breaker.

See electrical schematic in this section.

6. Install the new breaker into the panel. DO

NOT over tighten the mounting nut or
damage may occur to the breaker.

7. Reinstall the instrument panel. See TO

ACCESS INSTRUMENT PANEL
instructions.

8. Operate the machine. Check the scrub

brush for proper operation.

5400 330735 (3–01) 4-21

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ELECTRICAL
TO REPLACE 24 VOLT SOLENOID
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

NOTE: Drain the recovery tank.

1. Open the recovery tank.

2. Disconnect the positive battery cable from

the front, left machine battery. Machine Front

FOR SAFETY: Disconnect the battery BLACK

3
connections before working on the machine. 5

2
1
4 RED

3. Remove the two pan screws holding the

hour meter mount plate to the solution tank.
Pull the hour meter mount plate up and out
of the way.

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 ELECTRICAL
4. Remove the two hex screws holding the
solenoid mount plate to the solution tank.
Pull the solenoid up for access to the wire
connections.

5. Mark and disconnect the wires leading to the

solenoid. Note the direction of the diode
connected to the coil terminals. Make
sure the line side is connected to wire 16
and 30BLU. Failure to do so will result in
a short circuit.

6. Remove the two hex nuts holding the

solenoid to the mount plate. Remove the
solenoid from the plate.

7. Install the new solenoid onto the plate using

the two hex nuts. Tighten to 7 – 9 Nm
(5 – 6 ft lb).

8. Reconnect the wires leading to the new

solenoid. See electrical schematic in this
section.
9. Position the solenoid mount bracket down
onto the solution tank. Reinstall the two hex
screws and tighten to 18 – 20 Nm
(15 – 18 ft lb).
10. Reinstall the hour meter mount plate and
two pan screws. Tighten to 7 – 9 Nm
(5 – 6 ft lb).

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ELECTRICAL
11. Reconnect the positive battery cable to the
battery. Machine Front

BLACK
3
5

2
1
RED
4
12. Operate the machine checking for proper
operation.

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 ELECTRICAL

VACUUM FAN

The vacuum fan, when activated, creates a

vacuum in the recovery tank. Water is pulled from
the rear squeegee to the recovery tank through a
vacuum hose.

TO REPLACE VACUUM FAN

FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

NOTE: Drain the recovery tank.

1. Open the recovery tank.

2. Disconnect the positive battery cable from

the front, left machine battery. Machine Front

FOR SAFETY: Disconnect the battery BLACK

3
connections before working on the machine. 5

2
1
4 RED

3. Disconnect the vacuum fan from the main

harness.

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ELECTRICAL
4. Remove the three hex screws holding the
vacuum fan to the recovery tank. Note the
orientation of the exhaust port on the fan.
Remove the fan from the recovery tank.
Make sure to retain the three spacers.

5. Remove the exhaust muffler from the

existing fan and install on the new fan using
a plastic tie.

6. Install a gasket on the new vacuum fan

motor.

7. Install the new vacuum fan onto the

recovery tank. Reinstall the three hex
screws and spacers. Tighten to 5 – 6 Nm
(50 – 60 in lb).

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 ELECTRICAL
8. Reconnect the vacuum fan to the main
harness.

9. Reconnect the positive battery cable to the

battery. Machine Front

BLACK
3
5

2
1
RED
4
10. Operate the machine. Check the vacuum
fan for proper operation.

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ELECTRICAL
TO REPLACE VACUUM FAN SWITCH
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

NOTE: Drain the recovery tank.

1. Open the recovery tank.

2. Disconnect the positive battery cable from

the front, left machine battery. Machine Front

FOR SAFETY: Disconnect the battery BLACK

3
connections before working on the machine. 5

2
1
4 RED

3. Lower the squeegee.

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 ELECTRICAL
4. Remove the three hex screws holding the
squeegee lever bracket assembly to the left
side of the solution tank.

5. Locate the vacuum fan switch at the middle

of the lever bracket assembly. Mark and
disconnect the wires leading to the switch.

6. Remove the two pan screws and nuts

holding the vacuum fan switch to the
bracket. Remove the switch.

7. Install the new switch onto the bracket.

Reinstall the pan screws and nuts. Tighten
the hardware.

8. Reconnect the wires to the new switch.

See electrical schematic in this section.

9. Position the squeegee lever bracket

assembly to the left side of the solution tank.
Reinstall the three hex screws and tighten to
18 – 20 Nm (15 – 18 ft lb).

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ELECTRICAL
10. Raise the squeegee.

11. Reconnect the positive battery cable to the

battery. Machine Front

BLACK
3
5

12. Operate the machine. Check the vacuum 2

1
RED
fan switch for proper operation. Make sure 4
the vacuum fan turns on when the key is on
and the squeegee is lowered.

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 ELECTRICAL

SCRUB BRUSH MOTORS

The scrub brush motors turn the scrub brush. The

disc scrub brush motor is direct drive. The
cylindrical scrub brush motor uses a drive belt
from the motor to the brush.

TO REPLACE DISC SCRUB BRUSH MOTOR

1. Make sure the scrub head is in the raised
position. Shut off the key.

2. Remove the scrub head shroud.

3. Remove the disc scrub brush.

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ELECTRICAL
4. Unplug the electrical connectors attaching
the scrub head motor to the main harness.

5. Go under the scrub head and remove the

5/16 inch hex screw and washers holding
the brush drive hub to the motor shaft.

6. Pull the brush drive hub off the brush motor

shaft. Retain the square key and two
washers.

7. Remove the four 3/8 inch hex screws and

washers holding the disc brush motor to the
scrub head frame.

NOTE: Make sure to mark the location of the

existing scrub brush motor on the scrub head.
The new brush motor needs to be positioned in
the same location. The right hand motor has slots
for motor adjustment.
S (The distance between the motor shafts is 12
inch for 24 inch head and 13 inch for the 26 inch
head).

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 ELECTRICAL
8. Start the machine and lower the scrub head
to the floor.

9. Remove the disc scrub brush motor from the

machine.

10. Remove the clamp holding the water shroud

to the brush motor. Remove the water
shroud.

11. Install the water shroud onto the new disc

brush motor in the same orientation. The
shroud opening should face the center of the
scrub head. Tighten the clamp.

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ELECTRICAL
12. Position the new disc scrub brush motor
onto the scrub head.

NOTE: Make sure to mark the location of the

existing scrub brush motor on the scrub head.
The new brush motor needs to be positioned in
the same location.
S (The distance between the motor shafts is 12
inch for 24 inch head and 13 inch for the 26 inch
head).

13. Raise the scrub head and turn off the key.

14. Reinstall the four 3/8 inch hex screws and

washers holding the disc brush motor to the
scrub head frame. Make sure the motor is
installed in the same location. The motor
spacing is important for proper brush
performance. Tighten the hardware to
31 – 40Nm (27 – 35 ft lb).

15. Place a small amount of water proof grease

on the shaft of the brush motor. Make sure
the square key and thick washer are in place
on the shaft. Position the brush drive hub THIN WASHER
onto the shaft.

THICK WASHER

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 ELECTRICAL
16. Reinstall the 5/16 inch hex screw and
washers holding the brush drive hub to the
motor shaft. Tighten to 18 – 24Nm (15 – 20
ft lb).

17. Reconnect the scrub brush motor to the

main harness.

18. Reinstall the disc scrub brush.

19. Reinstall the scrub head shroud.

20. Operate the machine. Check the new scrub

brush motor for proper operation.

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ELECTRICAL
TO REPLACE CYLINDRICAL HEAD SCRUB
BRUSH MOTOR
1. Start the machine and lower the scrub head
to the floor. Shut off the key.

2. Remove the scrub head shroud.

3. Remove the cylindrical scrub brush.

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 ELECTRICAL
4. Remove the two M6 hex screws holding the
belt guard and shield onto the motor that the
belt needs changing. Remove the belt cover
from the scrub head.

5. Loosen the front and rear pivot bolts on the

brush motor.

6. Loosen the belt tension bolt.

7. Remove the brush drive belt from the motor

sprocket.

5400 330735 (3–01) 4-37

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ELECTRICAL
8. Disconnect the electrical wires from the end
of the scrub brush motor.

9. Remove the front and rear pivot bolts from

the brush motor.

10. Remove the scrub brush motor from the

scrub head mounting bracket.

11. Loosen the set screws holding the belt

sprocket onto the existing motor shaft.
Remove the sprocket.

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 ELECTRICAL
12. Position the new motor onto the scrub head.
Reinstall the two pivot bolts and nuts. Leave
loose for now.

13. Apply grease to the new motor shaft.

Position the belt cover shield on the motor
before installing the sprocket.

14. Install the belt drive sprocket onto the shaft

of the new motor. Leave the set screws
loose for now. Make sure the square key is
in place in the motor shaft.

15. Position the cogged brush drive belt over the

motor sprocket.

5400 330735 (3–01) 4-39

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ELECTRICAL
16. Tighten the belt adjustment bolt. Tension the
belt by applying 2.5–2.7 lbs of force per belt
at the middle of the span that is opposite the
belt travel with a deflection of 0.10 inch.

17. Spin the brush drive plug to align the motor

sprocket with the lower drive sprocket.
Tighten the motor sprocket set screws.
Make sure to apply blue loctite 242 to the
set screws before installing.

18. Tighten the two pivot bolts to 18 – 24 Nm

(15 – 20 ft lb). Re–check the belt tension.

19. Reconnect the brush motor wires to the new

brush motor. See schematic in this section.
Make sure to reinstall the washers on the
terminal studs on the motor and the rubber
boots on the wires.

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 ELECTRICAL
20. Reinstall the belt cover. Install the two M6
hex screws, and washers. Tighten to
11 – 14 Nm (7 – 10 ft lb).

21. Reinstall the scrub brush. See TO

REPLACE A CYLINDRICAL SCRUB
BRUSH instructions in this section.

22. Operate the machine and check the new

motor for proper operation.

5400 330735 (3–01) 4-41

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ELECTRICAL

ACTUATOR

The 5400 is equipped with a scrub head lift

actuator. The lift actuator is used to electrically
raise and lower the scrub head..

TO REPLACE SCRUB HEAD LIFT ACTUATOR

FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Lower the scrub head until it just touches the

floor.

FOR SAFETY: Before Leaving Or Servicing

Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

2. Open the recovery tank.

3. Disconnect the positive battery cable from

the front, left machine battery. Machine Front

BLAC
5 K 3

2
1
RE
4
D

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 ELECTRICAL
4. Remove the scrub head shroud.

5. Remove the cotter pin and clevis pin holding

the bottom of the scrub head lift actuator to
the scrub head roller assembly.

6. Disconnect the lift actuator wire from the

main harness.

7. Remove the two pan screws holding the

hour meter mount plate to the solution tank.
Pull the hour meter mount plate up and out
of the way.

5400 330735 (3–01) 4-43

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ELECTRICAL
8. Remove the four hex screws holding the
actuator upper mount bracket to the
machine frame. Move the hour meter
bracket and contactor mount bracket out of
the way.
Lift the actuator and mount bracket out of
the machine.

9. Remove the hair pin and clevis pin holding

the top of the actuator to the mount bracket.

10. Remove the mount bracket from the

actuator.

11. Set the length of the new lift actuator to

13 inches from hole to hole.

12. Reinstall the actuator mount bracket onto

the top of the new actuator using the clevis
pin and hair pin.

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 ELECTRICAL
13. Position the new actuator and mount bracket
into the machine. Reinstall the contactor
mount plate and hour meter mount plate.
Install the four hex screws and tighten to
18 – 20 Nm (15 – 18 ft lb).

14. Align the hole in the bottom of the new

actuator lift tube with the mount hole in the
roller assembly. Reinstall the clevis pin and
cotter pin.

15. Remove the two pan screws holding the

hour meter mount plate to the solution tank.
Pull the hour meter mount plate up and out
of the way.

16. Connect the new lift actuator to the main

electrical harness.

5400 330735 (3–01) 4-45

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ELECTRICAL
17. Reconnect the positive battery cable to the
battery. Machine Front

BLACK
3
5

2
1
RED
4

18. Reinstall the scrub head shroud.

19. Close the recovery tank and operate the

machine. Check the scrub head lift actuator
for proper operation.

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 ELECTRICAL

SOLUTION SOLENOID VALVE

The solution valve is an electrically activated

device that starts and stops the solution flow to
the scrub head with the use of a panel mounted
switch.

TO REPLACE SOLUTION SOLENOID VALVE

FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

NOTE: Drain the solution and recovery tanks.

1. Open the recovery tank.

2. Disconnect the positive battery cable from

the front, left machine battery. Machine Front

FOR SAFETY: Disconnect the battery BLACK

3
connections before working on the machine. 5

2
1
4 RED

3. Lower the squeegee.

5400 330735 (3–01) 4-47

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ELECTRICAL
4. Orientate the solution valve and cable so the
set screw holding the cable end to the shaft
on the valve can be loosened. Use a 5/64
inch allen wrench to loosen the set screw.

5. Disconnect both solution hoses leading to

the valve.

6. Remove the two pan screws holding the

solution valve solenoid to the mount bracket.

7. Mark and disconnect both wires leading to

the existing valve. Remove the valve from
the machine. Reconnect the two wires to the
new solution valve. See the schematic in
this section. Note the direction of the diode
connected to the coil terminals. Make sure
the line side of the diode is connected to
wire #24 grey. Failure to do so will result in a
short circuit.

8. Install the new solution valve onto the mount

bracket. Reinstall the two pan screws and
tighten to 7 – 10 Nm (5 – 6 ft lb).
Turn the shaft on the solution control valve
clockwise with fingers until resistance is felt.
(this closes the valve opening)

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 ELECTRICAL
9. Reconnect the two solution lines to the new
valve.

10. Turn the knob, on the water control, at the

top of the machine, fully clockwise. (water
off position).

11. Reconnect the water control cable to the

shaft on the valve. Make sure the set
screw seats in the hole on the valve shaft.

12. Raise the squeegee.

5400 330735 (3–01) 4-49

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ELECTRICAL
13. Reconnect the positive battery cable to the
battery. Machine Front

14. Operate the machine. Check the solution BLACK

3
flow system for proper operation. 5

2
1
RED
4

15. If more or less flow is required, adjust the

location of the knob on top of the machine.
Loosen the flexible shaft set screw, adjust
knob, tighten set screw.

4-50 5400 330735 (3–01)

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 ELECTRICAL

OPTIONAL EXTENDED SCRUB

The ES system on the 5400 allows the dirty

water in the recovery tank to be filtered and
returned to the solution tank to be re–used. This
greatly extends the amount of scrubbing that can
be done on one fill up. The ES  system is
activated by a switch on the instrument panel.

TO REPLACE THE ES PUMP

FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

NOTE: Drain the recovery tank.

1. Open the recovery tank.

2. Un–plug the ES pump from the main

harness.

5400 330735 (3–01) 4-51

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ELECTRICAL
3. Loosen the worm drive clamp on the small
outlet hose on the ES pump. Remove the
hose.

4. Remove the ES pump from the tank by

un–screwing it counter–clockwise.

5. Put water proof thread sealant on the

threads of the new ES pump.

6. Screw the new pump clockwise into the

recovery tank. Tighten until the outlet tube
points towards the back of the machine.

7. Re–connect the small water line and worm

drive clamp to the ES pump.

8. Re–connect the main wire harness to the

new pump. See schematic in the
ELECTRICAL section of this manual.

9. Close the recovery tank, operate the

machine and check the ES pump for
proper operation.

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 ELECTRICAL

OPTIONAL POWER WAND

The power wand uses the machine’s vacuum and,

solution systems. The power wand allows
scrubbing of floors that are out of reach of the
machine.

TO REPLACE POWER WAND PUMP

FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.

1. Drain the solution tank.

2. Locate the power wand pump at the bottom

of the machine frame, just in front the
transaxle.

3. Disconnect the pump from the main

electrical harness.

4. Loosen the worm drive clamps holding the

two hoses leading to the solution pump.
Remove the hoses from the fittings on the
pump.

5400 330735 (3–01) 4-53

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ELECTRICAL
5. Loosen the M8 hex screw holding the pump
mount bracket to the frame. Remove the
pump and mount bracket assembly from the
machine.

6. Remove the three pan head screws holding

the pump to the mount bracket. Remove the
pump from the bracket. Note the orientation
of the pump to the bracket.

7. Remove the brass elbow from the existing

pump. Install the elbow into the new pump in
the same orientation. Use a small amount of
thread sealant on the threads of the elbow
fitting.

8. Reverse these steps to install a new wand

solution pump.

9. Fill the solution tank and check the power

wand pump for proper operation.

4-54 5400 330735 (3–01)

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 ELECTRICAL

ELECTRIC MOTORS

The carbon brushes on the vacuum fan motor,

scrub brush motor, and propelling motor should be
inspected after every 400 hours of machine
operation.

TO REPLACE VACUUM FAN MOTOR

BRUSHES
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Remove the vacuum fan from the machine.

See TO REMOVE VACUUM FAN
instructions in this section.

2. Pry back the locking tabs and remove the

fan motor cover.

NOTE : DO NOT operate vacuum fan with the top

cover removed.

3. Remove the two pan head screws holding

the clamp and motor brushes in place.
Remove the brushes and measure.
NOTE: If the motor brushes measure 10 mm
(0.375 in.) of an inch or less in length, install
new brushes.

5400 330735 (3–01) 4-55

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ELECTRICAL
4. If motor brushes replacement is necessary,
carefully pull the wire tab connection out of
the brush mechanism using a needle nose
pliers.

5. Install the wire tab connections into each

one of the two replacement motor brush
mechanisms.

6. Remount both motor brushes into position

using the pan head screws and brush
clamps.

7. Reinstall the fan motor cover by pushing

down and locking into place.

8. Reinstall the vacuum fan motor assembly.

See TO INSTALL VACUUM FAN
instructions in this section.

9. Plug the vacuum fan in and start the

machine, checking for proper fan operation.

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 ELECTRICAL
TO REPLACE DISC SCRUB BRUSH MOTOR
BRUSHES
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Remove the disc scrub brush motor. See TO

REPLACE DISC SCRUB BRUSH MOTOR
instructions in this section.

2. Mark the location of the motor cover on the

motor body.

3. Remove the two long bolts holding the top of

the motor and motor body together.

4. Using a hammer and straight screwdriver

gently tap and pry the motor top off.

5400 330735 (3–01) 4-57

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ELECTRICAL
5. Change the motor brushes if worn to 10 mm
(0.375) of an inch or less in length.

NOTE: When installing new motor brushes, do

not push the brushes completely into the
brush holder. Let the brush spring rest on
the side of the brush. This will prevent the
brushes from hitting the commutator during
motor re–assembly. After the top of the
motor is properly assembled, push the motor
brushes completely into the brush holder
using a small screwdriver. The brush
springs should snap into position behind the
brush. Line-up the marks on the motor and
cover to reassemble.

6. Reinstall the disc scrub brush motor. See

TO REPLACE DISC SCRUB BRUSH
MOTOR instructions in this section.

7. Operate the machine. Check the disc scrub

brush for proper operation.

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 ELECTRICAL
ELECTRICAL SCHEMATIC

+ -

24 VDC POWER
INDICATOR
-60-
CHARGER G -33- BLK
10A KEY VOLT
SAFETY BREAKER SWITCH
SWITCH METER
-2- -4- -6- -32- -20-
-10- GRN -7- BLK
RED RED RED GRN GRN
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK DOWN LIMIT UPPER LIMIT
-15- BLK
-14-
GRN -62- HOUR -37-
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B
DELAY -75- BLK
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

5400 330735 (3–01) 4-59

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ELECTRICAL
WIRING DIAGRAM
BLK
RED
- 60 - GRN

BATTERY BRUSH
METER PRESSURE
- 33 - METER
G 20K
BLK
POWER - 38 -
INDICATOR - 12 - POTENTIOMETER R
- 11 - - 10 -G - 40 - E
D
R - 14 - GRN SOLUTION
-9- B G N R
L E SWITCH
B R D
K N
L -93-
K - 14 -
G
R G - 13 -
N R
-7- N B
-9- L - 16 -
B - 46 - - 15 - K
L B B
K O BRUSH HEIGHT B L - 24 -
ADJUSTMENT L K L
R SWITCH G U
G K R E
- 13 - BLK A
Y
-9- BLK

- 46 - ORG
- 10 - GRN
- 93 - GRN
- 10 -
G
- 13 - -7- BLK R
N
B - 93 -
L - 40 -
K G -7-
B R R
E - 17 - BLK N B
L D L
K K

R M2 M1 B+
E
D - 91 - BLK
- 48 - - 91 -
R 654321 B B- - 5 - BLK
E L - 64 -
5K D K
BLK O
R
POTENTIOMETER RED - 93 - GRN G
SPEED - 38 - - 31 - BLK
WHT CONTROLLER R VACUUM
-6- RED - 46 - E CONTACTOR
MAIN - 17 - BLK D
CIRCUIT -4- RED O
BREAKER CIRCUIT BREAKER - 48 - RED R
G -3-
10 1 30 B
DRIVE MOTOR L
- 44 - RED - 50 - - 28 - K
CIRCUIT BREAKER
- 40 - RED
CIRCUIT T T
15 2 30 BREAKER A A
N N - 22 -
- 64 - ORG - 64 - ORG
-6- Y
- 58 - RED E
2A R L
E
D
25 - 42 - WHT - 36 - RED
VACUUM - 4 - - 15 - - 22 -
MOTOR - 91 - BLK - 17 -
CIRCUIT R B Y
BREAKER - 13 - BLK E B L E
D L K L
- 19 - BLK K MAIN
KEY SWITCH
- 28 - T AN
- 20 - GRN
- 34- RED
- 32 - GRN
- 22 - YEL
- 52 - - 26 -
VACUUM - 19 -
SWITCH - 24 - G G
- 44 - B - 36 - R
G R
R - 34 -LK R R
N N
E E A
D R D Y
E
D
- 52 - GRN

-2- RED - 16 -
- 4 - RED B
L
U
- 58 - - 50 - E
-8- RED
CHARGER R T - 38 -
PLUG E A
D N R
CHARGER E
SAFETY SWITCH - 35 - D
B BRUSH
L CONTACTOR
K
RED
- 62 - BLUE
- 21 - BLK
HOUR
METER
- 35 - BLK - 46 - - 21 -
NEGATIVE - 37 - BLK
STANDOFF O - 24 - B
- 16 - BLUE R - 15 - L
- 25 - BLK G G K
- 44 - R
- 30 - B
L A
R -3- - 48 - Y
E B - 50 - - 17--68 - K
D - 27 - L - 54 - DOWN LIMIT
- 23 - B U R B O - 66- R SWITCH
- 42 - L E T E SOLUTION
B K A VACUUM D DRIVE L R RED E ACTUATOR SOLENOID
W L B N MOTOR MOTOR K G D MOTOR
H K L - 29 -
T K
LEFT RIGHT B DOWN LIMIT
B BRUSH BRUSH SWITCH
L
L K - 30 - BLUE - 26 - GRN
K B
L - 25 - BLK BRUSH MOTOR
K CONTROL SWITCH
- 42 - WHT - 3 - BLK
- 29 - BLK

4-60 5400 330735 (3–01)

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 ELECTRICAL
WIRING DIAGRAM (OPTIONS)

-31- BLK -31- BLK

- 20 - GRN

- 80 - GRN

- 76 - BLUE

- 20 -

WAND PUMP G
SWITCH ES / SWITCH R
N
- 80 - EMERGENCY
STOP
G SWITCH
R
N
- 56 - - 86 - GRN
- 20 -
- 84 - - 79 -
B - 77 - BLK
G
R R G B
N N R L TANK
N K FULL
LIGHT

NEGATIVE
STANDOFF - 72 - ORG
POSITIVE
STANDOFF - 75 - BLK
- 20 - GRN
- 73 - BLK
-31- BLK - 32 - GRN

ES -31-
-31-
TIMER
B RELAY B
L L
K - 74 - ORG - 76 - K
B
- 70 - PUR L
U
E
- 71 - - 74 -
- 82 - B O
L R
G K G
R
- 56 - - 70 - N - 78 - BLUE

P -31- BLK
B
R U
N R

ES
PUMP FLOAT
SWITCH

- 20 - GRN

- 32 - GRN

WAND OPTIONAL
PUMP

- 29 -

B
L
K

5400 330735 (3–01) 4-61

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ELECTRICAL

4-62 5400 330735 (3–01)

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 ELECTRICAL

TROUBLESHOOTING

The troubleshooting flow charts and high lighted

electrical schematics are used to diagnose and
repair electrical problems.

5400 330735 (3–01) 4-63

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ELECTRICAL

+ -

POWER UP 24 VDC POWER

INDICATOR

CIRCUIT CHARGER
SAFETY
10A KEY
-60-
VOLT
G -33- BLK
BREAKER SWITCH METER
SWITCH
-2- -4- -6- -32- -20-
-10- GRN -7- BLK
RED RED RED GRN GRN
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK DOWN LIMIT UPPER LIMIT
-15- BLK
-14-
GRN -62- HOUR -37-
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B -75- BLK
DELAY
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

4-64 5400 330735 (3–01)

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 ELECTRICAL

NO POWER (KEY ON AND BATTERY CHARGER DISCONNECTED)

START

CHECK VOLTAGE AT
NO VOLTAGE CHARGER SAFETY BATTERY VOLTAGE
2 RED OR 4 RED SWITCH (BOTH SIDES TO 2 RED ONLY
BATTERY NEG.)

BATTERY
CHECK WIRE
VOLTAGE
CONNECTIONS TO
REPAIR OR REPLACE 2 RED AND
4 RED CHARGER SAFETY
CONNECTIONS TO
SWITCH OR REPLACE
BATTERY
CHARGER SAFETY
SWITCH

CHECK VOLTAGE AT 10
YES AMP CIRCUIT BREAKER NO
4 RED TO BATTERY
NEGATIVE

CHECK VOLTAGE AT 10
NO YES REPAIR OR REPLACE
AMP CIRCUIT BREAKER
4 RED
6 RED TO BATT. NEG.

CHECK VOLTAGE AT
RESET OR REPLACE 10 YES NO
KEYSWITCH
AMP CIRCUIT BREAKER
6 RED TO BATT. NEG.

CHECK VOLTAGE AT
NO YES REPAIR OR REPLACE
KEYSWITCH
6 RED
32 GRN TO BATT. NEG.

REPAIR OR REPLACE CONTINUED ON

KEYSWITCH NEXT PAGE

5400 330735 (3–01) 4-65

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 ELECTRICAL
NO POWER (CONTINUED)
CONTINUE

MACHINE HAS OPTIONAL

YES NO
EMERGENCY STOP
BUTTON?

CHECK VOLTAGE AT
YES EMERGENCY STOP NO
SWITCH
80 GRN TO BATT. NEG.

CHECK VOLTAGE AT 32/80

YES NO
GRN CONNECTION
32 GRN TO BATT. NEG.

REPAIR OR REPLACE REPAIR OR REPLACE

80 GRN 32 GRN

CHECK VOLTAGE AT
NO EMERGENCY STOP YES
SWITCH
20 GRN TO BATT. NEG.

RESET OR REPLACE CHECK VOLTAGE AT 32/20

YES NO
EMERGENCY STOP GRN CONNECTION
SWITCH 32 GRN TO BATT. NEG.

CHECK VOLTAGE AT
HARNESS WIRE SPLICE
NO YES REPAIR OR REPLACE
(10, 18, 20, 26, 52 GRN)
32 GRN
20 GRN TO
BATTERY NEGATIVE

CHECK VOLTAGE AT
HARNESS WIRE SPLICE
REPAIR OR REPLACE YES NO
(10, 18, 20, 26, 52 GRN)
20 GRN
20 GRN TO
NEGATIVE STANDOFF

CHECK VOLTAGE AT
HARNESS WIRE SPLICE REPAIR OR REPLACE
YES NO
(10, 18, 20, 26, 52 GRN) NEGATIVE BATTERY
20 GRN TO 3 BLK AT CABLE
VACUUM CONTACTOR

REPAIR OR REPLACE REPAIR OR REPLACE

7 BLACK 3 BLACK

4-66 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL

5400 330735 (3–01) 4-67

Home Find... Go To..
ELECTRICAL

+ -

PROPEL 24 VDC POWER

INDICATOR

CIRCUIT CHARGER 10A KEY

-60-
VOLT
G -33- BLK
SAFETY BREAKER SWITCH METER
SWITCH
-2- -4- -6- -32- -20-
-10- GRN -7- BLK
RED RED RED GRN GRN
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK DOWN LIMIT UPPER LIMIT
-15- BLK
-14-
GRN -62- HOUR -37-
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B -75- BLK
DELAY
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

4-68 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL
NO PROPEL (POWER UP O.K.)
WHEN TESTING SPEED
START HERE
CONTROL BOARD OUTPUT
(TURN MACHINE ON)
TWIST ROLL GRIPS
FORWARD OR BACKWARD
DURING TESTS
TRANSPORT NOT RESET 15 AMP DRIVE TRANSPORT
WORKING CIRCUIT BREAKER WORKING

DISCONNECT TRANSAXLE
MOTOR FROM INSPECT MACHINE AND
> 1 VOLT < 1 VOLT
WIRING HARNESS WORK AREA FOR CAUSE
CHECK VOLTAGE AT OF OVERLOAD
48 RED AND 17 BLK

REMOVE 48 RED AND 17

> 1 VOLT BLK AND CHECK
REPAIR OR REPLACE < 1 VOLT
VOLTAGE AT SPEED
TRANSAXLE
CONTROL BOARD M1 TO
M2

CHECK VOLTAGE AT
YES NO
SPEED CONTROL BOARD
M1 TO BATT. NEG.

REPAIR OR REPLACE REPAIR OR REPLACE

17 BLK 48 RED

NO CHECK VOLTAGE AT YES

SPEED CONTROL BOARD
64 ORG TO 5 BLK

CHECK VOLTAGE AT
SPEED CONTROL BOARD
YES NO GO TO CONTROL BOARD
64 ORG TO 3 BLK
TROUBLESHOOTING
(AT VACUUM MOTOR
CONTACTOR CRI)

CHECK VOLTAGE AT
REPAIR OR REPLACE NO SPEED CONTROL BOARD YES
5 BLK 64 ORG TO 3 BLK
(AT NEGATIVE STANDOFF)

CONTINUED ON REPAIR OR REPLACE

NEXT PAGE 3 BLK

5400 330735 (3–01) 4-69

Home Find... Go To..
 ELECTRICAL

SAFETY NOTE: NO PROPEL (CONTINUED)

LEAVE TRANSAXLE
DISCONNECTED DURING CONTINUE
TESTS

CHECK VOLTAGE AT
YES NO
SPEED CONTROL BOARD
64 ORG TO BATT. NEG.

REPAIR OR REPLACE CHECK VOLTAGE AT 15

NO YES
NEGATIVE BATTERY AMP CIRCUIT BREAKER
CABLE 64 ORG TO BATT. NEG.

CHECK VOLTAGE AT 15
YES NO REPAIR OR REPLACE
AMP CIRCUIT BREAKER
64 ORG
58 RED TO BATT. NEG.

CHECK VOLTAGE AT
RESET OR REPLACE BATTERY PACK
NO YES
15 AMP CIRCUIT BREAKER BATTERY POSITIVE TO
BATTERY NEGATIVE

REPAIR OR REPLACE
RECHARGE OR SERVICE
POSITIVE BATTERY
BATTERY PACK
CABLE

4-70 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL
NO PROPEL – CONTROL BOARD TROUBLESHOOTING
CONTINUED FROM PAGE 4–69

DISCONNECT 6 PIN
CONNECTOR FROM
SAFETY NOTE: CONTROL BOARD,
LEAVE TRANSAXLE REMOVE WHITE STRAIN
NO YES
DISCONNECTED DURING RELIEF AND RECONNECT
TO CONTROL BOARD
TESTS
CHECK VOLTAGE AT
6 PIN CONNECTOR
PIN 3 GRN TO BATT. NEG.

CHECK VOLTAGE AT
YES 93GRN/18 GRN HARNESS NO
CONNECTION
18 GRN TO BATT. NEG.

REPAIR 93 GRN OR CHECK VOLTAGE AT

REPLACE NO HARNESS WIRE SPLICE YES
POTENTIOMETER (52,26,20,18,10 GRN) TO
HARNESS ASSEMBLY BATT. NEG.

GO TO
REPAIR OR REPLACE
NO POWER
18 GRN
TROUBLESHOOTING

CHECK VOLTAGES AT
5 VOLTS 6 PIN CONNECTOR 0 VOLTS
PIN 6 (BLK WIRE) TO
BATTERY NEGATIVE
CHECK RESISTANCE OF
20K DASH
POTENTIOMETER
DISCONNECT BOTH 5 BLK
AND 75 BLK FROM THE REPLACE SPEED
RED WIRES CONTROL BOARD
ON THE CONTROL BOARD
DEFECTIVE 0 – 20K OHMS
HARNESS MEASURE
RESISTANCE FROM 5 BLK
TO 75 BLK WHILE
ROTATING
POTENTIOMETER
READING SHOULD VARY
BETWEEN
0 – 20K OHMS
DISCONNECT 6 PIN CONNECTOR
FROM SPEED CONTROL BOARD
(LEAVE 20K DASH POTENTIOMETER
REPLACE 20K OHM
DISCONNECTED). CONNECT THE RED
DASH POTENTIOMETER
WIRES FROM THE THROTTLE
DEFECTIVE POTENTIOMETER HARNESS 0 – 5K OHMS
TOGETHER AND CHECK RESISTANCE
OF 5K THROTTLE POTENTIOMETER.
MEASURE FROM THE BLK PIN 6 TO
WHT PIN 4. TWIST GRIPS BACK AND
FORTH, READING SHOULD BE
VARIABLE BETWEEN 0 AND 5K OHMS

REPLACE
REPLACE SPEED
POTENTIOMETER
CONTROL BOARD
HARNESS ASSEMBLY

5400 330735 (3–01) 4-71

Home Find... Go To..
ELECTRICAL

+ -
BRUSH 24 VDC POWER
INDICATOR

CIRCUIT CHARGER 10A KEY

-60-
G -33- BLK
SAFETY VOLT
BREAKER SWITCH METER
SWITCH
-2- -4- -6- -32- -20-
-10- GRN -7- BLK
RED RED RED GRN GRN
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK DOWN LIMIT UPPER LIMIT
-15- BLK
-14-
GRN -62- HOUR -37-
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B -75- BLK
DELAY
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

4-72 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL

BOTH BRUSHES DO NOT OPERATE WITH BRUSH DECK DOWN

START HERE

IF ONE MOTOR WORKS:

NO RESET CIRCUIT YES
GO TO – ONE BRUSH DOES BREAKERS 1 AND 2
NOT OPERATE BRUSHES WORK?

CHECK VOLTAGE AT
NO BRUSH CONTACTOR(CR2) YES CHECK BRUSH DECK AND
36/38 RED TO BATT. NEG. FLOOR SURFACE FOR
(TWIST ROLL GRIPS CAUSE OF OVERLOAD
DURING TEST)

CHECK VOLTAGE AT
YES BRUSH CONTACTOR(CR2) NO
POSITIVE BATTERY
CABLE TO BATT. NEG.

REPAIR OR REPLACE
GO TO
POSITIVE BATTERY
NEXT PAGE
CABLE

CHECK VOLTAGE AT
NO BRUSH CONTACTOR(CR2) YES
36/38 RED TO NEGATIVE
STAND–OFF (TWIST ROLL
GRIPS DURING TEST)

CHECK VOLTAGE AT
REPAIR OR REPLACE BRUSH CONTACTOR(CR2) NO
YES
NEGATIVE BATTERY 36/38 RED TO 23 BLK
CABLE (TWIST ROLL GRIPS
DURING TEST)

CHECK VOLTAGE AT
BRUSH CONTACTOR(CR2)
YES NO REPAIR OR REPLACE
36/38 RED TO 27 BLK
23 BLK
(TWIST ROLL GRIPS
DURING TEST)

GO TO
REPAIR OR REPLACE
BRUSH 1 OR 2
27 BLK
DOES NOT OPERATE

5400 330735 (3–01) 4-73

Home Find... Go To..
 ELECTRICAL
BOTH BRUSHES DO NOT OPERATE (CONTINUED)
CONTINUED FROM PREVIOUS PAGE

CHECK VOLTAGE AT
YES BRUSH CONTACTOR COIL NO
CONNECTIONS 30 BLU TO
19 BLK(TWIST ROLL
GRIPS DURING TEST)

NO CHECK VOLTAGE AT YES

REPLACE BRUSH
BRUSH CONTACTOR(CR1)
CONTACTOR (CR2)
30 BLU TO BATT. NEG.

CHECK VOLTAGE AT
BRUSH MOTOR
YES CONTROL SWITCH(BLUE NO
WIRE IN ACTUATOR
CONNECTOR)
30 BLU TO BATT. NEG.

CHECK VOLTAGE AT
NO BRUSH MOTOR CONTROL YES
REPAIR OR REPLACE
SWITCH (GRN WIRE IN
30 BLU
ACTUATOR CONNECTOR)
26 GRN TO BATT. NEG.

CHECK VOLTAGE AT WIRE

NO SPLICE(10,18,20,26,52 YES REPAIR OR REPLACE
GRN) TO BRUSH DECK ACTUATOR
BATT. NEG.

GO TO
REPAIR OR REPLACE
NO POWER
26 GRN
TROUBLESHOOTING

CHECK VOLTAGE AT
BRUSH CONTACTOR 30
NO
BLU TO 19 BLK AT FUSE
HOLDER (TWIST ROLL
GRIPS DURING TEST)
CHECK VOLTAGE AT
NO BRUSH CONTACTOR 30 YES
BLU TO 91 BLK AT FUSE YES
HOLDER (TWIST ROLL
GRIPS DURING TEST)

CHECK VOLTAGE AT
BRUSH CONTACTOR 30
YES BLU TO 91 BLK AT PIN 1 NO
SPEED CONTROL BOARD REPLACE FUSE
CONNECTOR (TWIST
ROLL GRIPS DURING
TEST)

REPAIR OR REPLACE REPLACE SPEED REPAIR OR REPLACE

91 BLK CONTROL BOARD 19 BLK

4-74 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL
BRUSH MOTOR 1 DOES NOT OPERATE

NOTE: THE TWIST GRIPS MUST

BE ROLLED FORWARD OR
NO CHECK VOLTAGE AT
BACKWARD DURING TESTS BRUSH MOTOR 1
YES
44 RED TO 27 BLK

CHECK VOLTAGE AT REPAIR OR REPLACE

YES BRUSH MOTOR 1 NO BRUSH MOTOR
44 RED TO NEGATIVE
STAND–OFF

NO CHECK VOLTAGE AT YES

REPAIR OR REPLACE
BRUSH MOTOR 1
27 BLK
44 RED TO BATT. NEG.

YES CHECK VOLTAGE AT NO REPAIR OR REPLACE

CIRCUIT BREAKER 1 NEGATIVE BATTERY
44 RED TO BATT. NEG. CABLE

CHECK VOLTAGE AT
REPAIR OR REPLACE NO YES
CIRCUIT BREAKER 1
44 RED
40 RED TO BATT. NEG.

CHECK VOLTAGE AT
YES BRUSH PRESSURE NO RESET OR REPLACE
METER CIRCUIT BREAKER 1
40 RED TO BATT. NEG.

CHECK VOLTAGE AT
REPAIR OR REPLACE NO BRUSH PRESSURE YES
40 RED METER
38 RED TO BATT. NEG.

YES CHECK VOLTAGE AT NO REPLACE

BRUSH CONTACTOR(CR2) BRUSH PRESSURE
38 RED TO BATT. NEG. METER

CHECK VOLTAGE AT
REPAIR OR REPLACE NO BRUSH CONTACTOR(CR2) YES
38 RED POSITIVE BATTERY
CABLE TO BATT. NEG.

REPAIR OR REPLACE GO TO
POSITIVE BATTERY BRUSH CONTACTOR
CABLE TROUBLESHOOTING

5400 330735 (3–01) 4-75

Home Find... Go To..
 ELECTRICAL

BRUSH MOTOR 2 DOES NOT OPERATE

NOTE: THE TWIST GRIPS MUST

BE ROLLED FORWARD OR
BACKWARD DURING TESTS CHECK VOLTAGE AT
NO YES
BRUSH MOTOR 2
42 WHT TO 23 BLK

CHECK VOLTAGE AT REPAIR OR REPLACE

YES BRUSH MOTOR 2 NO BRUSH MOTOR
42 WHT TO NEGATIVE
STAND–OFF

NO CHECK VOLTAGE AT YES

REPAIR OR REPLACE
BRUSH MOTOR 2
23 BLK
42 WHT TO BATT. NEG.

YES CHECK VOLTAGE AT REPAIR OR REPLACE

NO
CIRCUIT BREAKER 2 NEGATIVE BATTERY
42 WHT TO BATT. NEG. CABLE

CHECK VOLTAGE AT
REPAIR OR REPLACE NO YES
CIRCUIT BREAKER 2
42 WHT
36 RED TO BATT. NEG.

CHECK VOLTAGE AT RESET OR REPLACE

YES NO
BRUSH CONTACTOR(CR2) CIRCUIT BREAKER 2
36 RED TO BATT. NEG.

CHECK VOLTAGE AT
REPAIR OR REPLACE NO BRUSH CONTACTOR(CR2) YES
36 RED POSITIVE BATTERY
CABLE TO BATT. NEG.

REPAIR OR REPLACE GO TO
POSITIVE BATTERY BRUSH CONTACTOR
CABLE TROUBLESHOOTING

4-76 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL

5400 330735 (3–01) 4-77

Home Find... Go To..
ELECTRICAL

+ -

ACTUATOR 24 VDC POWER

INDICATOR

CIRCUIT CHARGER
SAFETY
10A KEY
-60-
VOLT
G -33- BLK
BREAKER SWITCH METER
SWITCH
-2- -4- -6- -32- -20-
-10- GRN -7- BLK
RED RED RED GRN GRN
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK DOWN LIMIT UPPER LIMIT
-15- BLK
-14-
GRN -62- HOUR -37-
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B -75- BLK
DELAY
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

4-78 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL
BRUSH DECK WILL NOT LOWER

NOTE: PRESS BRUSH START

HEIGHT ADJUSTMENT
SWITCH DOWN DURING CHECK VOLTAGE AT
TESTS No HARNESS ACTUATOR Yes
CONNECTOR 54 RED TO
15 BLK

CHECK VOLTAGE AT
HARNESS ACTUATOR
Yes No REPAIR OR REPLACE
CONNECTOR 54 RED TO
BRUSH DECK ACTUATOR
15 BLK AT BRUSH HEIGHT
ADJUSTMENT SWITCH

CHECK VOLTAGE AT
HARNESS ACTUATOR
REPAIR OR REPLACE No Yes
CONNECTOR 54 RED TO
15 BLK
7 BLK AT BRUSH HEIGHT
ADJUSTMENT SWITCH

CHECK VOLTAGE AT
REPLACE
Yes HARNESS ACTUATOR No
BRUSH HEIGHT
CONNECTOR 54 RED TO
ADJUSTMENT SWITCH
BATT. NEG.

CHECK VOLTAGE AT
REPAIR OR REPLACE No Yes
LOWER LIMIT SWITCH
7 BLK
54 RED TO BATT. NEG.

CHECK VOLTAGE AT
Yes No REPAIR OR REPLACE
LOWER LIMIT SWITCH
54 RED
46 ORG TO BATT. NEG.

CHECK VOLTAGE AT
ADJUST OR REPLACE No BRUSH HEIGHT Yes
LOWER LIMIT SWITCH ADJUSTMENT SWITCH
46 ORG TO BATT. NEG.

CHECK VOLTAGE AT
Yes BRUSH HEIGHT No REPAIR OR REPLACE
ADJUSTMENT SWITCH 46 ORG
12 GRN TO BATT. NEG.

CHECK VOLTAGE AT
REPLACE BRUSH HEIGHT No Yes
BATTERY METER
ADJUSTMENT SWITCH
10 GRN TO BATT. NEG.

GO TO
REPAIR OR REPLACE
NO POWER
12 GRN
TROUBLESHOOTING

5400 330735 (3–01) 4-79

Home Find... Go To..
 ELECTRICAL

BRUSH DECK WILL NOT RAISE

NOTE: PRESS BRUSH START

HEIGHT ADJUSTMENT
SWITCH UP DURING TESTS CHECK VOLTAGE AT
No HARNESS ACTUATOR Yes
CONNECTOR
15 BLK TO 54 RED

CHECK VOLTAGE AT
No BRUSH HEIGHT Yes REPAIR OR REPLACE
ADJUSTMENT SWITCH BRUSH DECK ACTUATOR
14 GRN TO 9 BLK

CHECK VOLTAGE AT
GO TO NO POWER Yes BRUSH HEIGHT No
TROUBLESHOOTING ADJUSTMENT SWITCH
14 GRN TO 46 ORG

CHECK VOLTAGE AT
REPLACE BRUSH
Yes BRUSH HEIGHT No PRESSURE ADJUSTMENT
ADJUSTMENT SWITCH 15
SWITCH
BLK TO 46 ORG

CHECK VOLTAGE AT
REPLACE BRUSH BRUSH HEIGHT
PRESSURE ADJUSTMENT
Yes ADJUSTMENT SWITCH 15
No
SWITCH BLK TO 46 ORG AT
LOWER LIMIT SWITCH

CHECK VOLTAGE AT
BRUSH HEIGHT
No Yes REPAIR OR REPLACE
ADJUSTMENT SWITCH 15
46 ORG
BLK TO 54 RED AT LOWER
LIMIT SWITCH

CHECK VOLTAGE AT
TEST DIODE AND WIRES BRUSH HEIGHT
68 ORG AND 66 RED Yes ADJUSTMENT SWITCH No
REPAIR OR REPLACE 15 BLK TO 54 RED IN
AS REQUIRED HARNESS ACTUATOR
CONNECTOR

REPAIR OR REPLACE REPAIR OR REPLACE

15 BLK 54 RED

4-80 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL

5400 330735 (3–01) 4-81

Home Find... Go To..
ELECTRICAL

VACUUM 24 VDC POWER

INDICATOR
FAN CHARGER
-60-
G -33- BLK
10A KEY VOLT
SAFETY BREAKER SWITCH
CIRCUIT -2-
SWITCH
-4- -6- -32- -20-
-10- GRN
METER
-7- BLK
RED RED RED GRN GRN
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK DOWN LIMIT UPPER LIMIT
-15- BLK
-14-
GRN -62- HOUR -37-
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B -75- BLK
DELAY
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

4-82 5400 330735 (3–01)

Home Find... Go To..

 ELECTRICAL
VACUUM FAN DOES NOT OPERATE
START HERE
NOTE: PERFORM TESTS
WITH KEYSWITCH ON
AND SQUEEGEE IN DOWN YES CHECK VOLTAGE AT NO
POSITION VACUUM MOTOR
50 TAN TO BATT. NEG.

CHECK VOLTAGE AT
NO YES
VACUUM MOTOR
50 TAN TO 25 BLK

CHECK VOLTAGE AT YES REPAIR OR REPLACE

NO
VACUUM MOTOR 50 TAN VACUUM MOTOR
TO NEGATIVE STANDOFF

REPAIR OR REPLACE RESET 25 AMP CIRCUIT

REPAIR OR REPLACE NO YES
NEGATIVE BATTERY BREAKER TEST VACUUM
25 BLK
CABLE FAN OPERATION

CHECK VOLTAGE AT
INSPECT VACUUM
NO VACUUM YES
MOTOR FOR CAUSE OF
CONTACTOR(CR1)
OVERLOAD
50 TAN TO BATT. NEG.

CHECK VOLTAGE AT
YES VACUUM NO REPAIR OR REPLACE
CONTACTOR(CR1) 50 TAN
28 TAN TO BATT. NEG.

NO CHECK VOLTAGE AT 25 YES

GO TO
AMP CIRCUIT BREAKER
NEXT PAGE
28 TAN TO BATT. NEG.

YES CHECK VOLTAGE AT 25

NO REPAIR OR REPLACE
AMP CIRCUIT BREAKER
28 TAN
34 RED TO BATT. NEG.

CHECK VOLTAGE AT
RESET OR REPLACE 25 NO BRUSH YES
AMP CIRCUIT BREAKER CONTACTOR(CR2)
34 RED TO BATT. NEG.

GO TO
REPAIR OR REPLACE
NO POWER
34 RED
TROUBLESHOOTING

5400 330735 (3–01) 4-83

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 ELECTRICAL

VACUUM FAN DOES NOT OPERATE (CONTINUED)

CONTINUE
NOTE: PERFORM TESTS
WITH KEYSWITCH ON CHECK VOLTAGE AT
AND SQUEEGEE IN DOWN YES VACUUM CONTACTOR NO
POSITION (CR1) 22 YEL TO
BATTERY NEGATIVE

CHECK VOLTAGE AT
SQUEEGEE HANDLE
YES NO
VACUUM SWITCH
22 YEL TO BATTERY
NEGATIVE

CHECK VOLTAGE AT
REPAIR OR REPLACE NO SQUEEGEE HANDLE YES
22 YEL VACUUM SWITCH
52 GRN TO BATT. NEG

GO TO VERIFY SWITCH
NO POWER CONNECTIONS OR
TROUBLESHOOTING REPLACE SWITCH

CHECK VOLTAGE AT
VACUUM
YES NO
CONTACTOR(CR1) COIL
CONNECTIONS
22 YEL TO 3 BLK

CHECK VOLTAGE AT
VACUUM
REPLACE VACUUM NO YES
CONTACTOR(CR1)
CONTACTOR(CR1)
22 YEL TO NEG.
STANDOFF

REPAIR OR REPLACE
REPAIR OR REPLACE
NEGATIVE BATTERY
3 BLK
CABLE

4-84 5400 330735 (3–01)

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 ELECTRICAL

5400 330735 (3–01) 4-85

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ELECTRICAL

+ -

SOLUTION 24 VDC POWER

INDICATOR

SOLENOID CHARGER
SAFETY
10A KEY
-60-
VOLT
G -33- BLK
BREAKER SWITCH METER
SWITCH
CIRCUIT -2-
RED
-4-
RED
-6-
RED
-32-
GRN
-20-
GRN
-10- GRN -7- BLK
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK UPPER LIMIT DOWN LIMIT
-15- BLK
-14-
GRN -62- HOUR -37-
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B -75- BLK
DELAY
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

4-86 5400 330735 (3–01)

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 ELECTRICAL

SOLUTION SOLENOID DOES NOT OPERATE (BRUSHES WORK)

START

TURN ON MACHINE AND

LOWER BRUSHES TO THE
FLOOR. TURN SOLUTION
SWITCH ON.

CHECK VOLTAGE AT
SOLUTION SOLENOID
YES 24 GRY TO 21 BLK NO
(TWIST ROLL GRIPS
DURING TEST)

CHECK VOLTAGE AT
CHECK FOR WATER
SOLUTION SOLENOID
SUPPLY PROBLEM NO YES
24 GRY TO 19 BLK
REPAIR OR REPLACE
(TWIST ROLL GRIPS
SOLUTION SOLENOID
DURING TEST)

CHECK VOLTAGE AT
SOLUTION SWITCH
YES NO REPAIR OR REPLACE
24 GRY TO 19 BLK
21 BLK
(TWIST ROLL GRIPS
DURING TEST)

CHECK VOLTAGE AT
REPAIR OR REPLACE SOLUTION SWITCH
24 GRY NO 16 BLU TO 19 BLK YES
(TWIST ROLL GRIPS
DURING TEST)

CHECK VOLTAGE AT
YES BRUSH CONTACTOR(CR2) NO REPLACE
16 BLU TO 19 BLK SOLUTION SWITCH
(TWIST ROLL GRIPS
DURING TEST)

CHECK VOLTAGE AT
REPAIR OR REPLACE BRUSH CONTACTOR(CR2)
16 BLU NO 16 BLU TO 91 BLK AT YES
FUSE HOLDER
(TWIST ROLL GRIPS
DURING TEST)

GO TO
REPLACE FUSE
BOTH BRUSHES
DO NOT OPERATE

5400 330735 (3–01) 4-87

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ELECTRICAL

+ -

ES
24 VDC POWER

INDICATOR
-60-
CIRCUIT CHARGER
SAFETY
10A
BREAKER
KEY
SWITCH
VOLT
METER
G -33- BLK

SWITCH
-2- -4- -6- -32- -20-
-10- GRN -7- BLK
RED RED RED GRN GRN
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK DOWN LIMIT UPPER LIMIT
-15- BLK
-14-
GRN -62- HOUR -37-
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B -75- BLK
DELAY
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

4-88 5400 330735 (3–01)

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 ELECTRICAL

ES
PUMP DOES NOT OPERATE

START
NOTE: WATER LEVEL IN
RECOVERY TANK MUST
TURN ON ES SWITCH.
BE ABOVE FLOAT No
CHECK VOLTAGE AT ES
Yes
SWITCH FOR TESTING PUMP 70 PUR TO 71 BLK

CHECK VOLTAGE AT ES
Yes PUMP 70 PUR TO 71 BLK No REPAIR OR REPLACE
AT NEGATIVE STAND–OFF ES PUMP
IN ACCESSORY BOX

CHECK VOLTAGE AT ES
REPAIR OR REPLACE No Yes
PUMP 70 PUR TO
71 BLK
BATT. NEG.

CHECK VOLTAGE AT
Yes No REPAIR OR REPLACE
TIMER RELAY 70 PUR TO
31 BLK
BATT. NEG.

CHECK VOLTAGE AT
REPAIR OR REPLACE No Yes
TIMER RELAY 78 BLU TO
70 PUR
73 BLK

CHECK VOLTAGE AT
Yes No
TIMER RELAY 78 BLU TO GO TO NEXT PAGE
BATT. NEG.

CHECK VOLTAGE AT
REPAIR OR REPLACE No Yes
TIMER RELAY 76 BLU TO
73 BLK
BATT. NEG.

CHECK VOLTAGE AT ES
Yes No REPAIR OR REPLACE
SWITCH 76 BLU TO BATT.
78 BLU
NEG.

CHECK VOLTAGE AT ES
REPAIR OR REPLACE No Yes
SWITCH 86 GRN TO BATT.
76 BLU
NEG.

GO TO NO POWER REPLACE
TROUBLESHOOTING ES SWITCH

5400 330735 (3–01) 4-89

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 ELECTRICAL

ES
PUMP DOES NOT OPERATE (CONTINUED)

CONTINUED FROM
PREVIOUS PAGE
NOTE: WATER LEVEL IN
RECOVERY TANK MUST CHECK VOLTAGE AT
No Yes
BE ABOVE FLOAT ES TIMER RELAY
SWITCH FOR TESTING 72/74 ORG TO BATT. NEG.

CHECK VOLTAGE AT
Yes No REPLACE ES TIMER
FLOAT SWITCH
RELAY
74 ORG TO BATT. NEG.

CHECK VOLTAGE AT
REPAIR OR REPLACE No Yes
FLOAT SWITCH
74 ORG
82 GRN TO BATT. NEG.

CHECK VOLTAGE AT
Yes POSITIVE STAND–OFF IN No REPLACE
ACCESSORY BOX FLOAT SWITCH
82 GRN TO BATT. NEG.

REPAIR OR REPLACE GO TO NO POWER

82 GRN TROUBLESHOOTING

4-90 5400 330735 (3–01)

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 ELECTRICAL

5400 330735 (3–01) 4-91

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ELECTRICAL

+ -

WAND 24 VDC POWER

INDICATOR

PUMP CHARGER 10A KEY

-60-
VOLT
G -33- BLK
SAFETY BREAKER SWITCH METER
CIRCUIT -2-
SWITCH
-4- -6- -32- -20-
-10- GRN -7- BLK
RED RED RED GRN GRN
-52-
-32- -22- YEL CR1 -3- BLK
GRN
-20- VACUUM VACUUM
SWITCH CONTACTOR
-68- -66-
-12-
GRN -46- -54- -15-
ACTUATOR
ORG RED MOTOR BLK
LOWER
-9- LIMIT
BLK DOWN LIMIT UPPER LIMIT
-15- BLK
-14-
GRN -62- -37-
HOUR
BRUSH HEIGHT BLU METER BLK
ADJUSTMENT BRUSH MOTOR
CONTROL SWITCH -30-
-26- GRN CR2 -19- BLK
BLU
2A
BRUSH FUSE
CONTACTOR -13-
G
BLK
-16- SOLUTION
SWITCH -24- -21-
BLU
GRY BLK
SOLUTION
SOLENOID
-7- BLK

-58-
-64- ORG
RED 15A DRIVE -64-
CIRCUIT -17- BLK -91-
BREAKER O
R B
G L
DRIVE -48- K
M2 M1 B+
MOTOR RED
SPEED
CONTROLLER
-18- GRN -93- GRN
6 5 4 3 2 1 -5- BLK
B-
BLK

POTENTIOMETER -91- BLK

5K WHT

R
DASH SPEED E
R ADJUSTMENT D
E 20K
D BLK

#1 30A
BRUSH PRESSURE CIRCUIT
CR 2 METER BREAKER
-38- BRUSH
RED -40- RED -44- RED -27- BLK
RED MOTOR
#2 30A
CIRCUIT
BREAKER
BRUSH
-36- RED -42- WHT -23- BLK
25A MOTOR
-32-
-20- CIRCUIT
CR 1
BREAKER
-34- RED -28- T AN -50- T AN VACUUM -25- BLK
MOTOR

-20- GRN -31-

EMERGENCY
-80- STOP SWITCH WAND PUMP SWITCH
GRN
-84- GRN G -79- BLK
EXTENDED
SCRUB SWITCH WAND
-56- BRN PUMP -29- BLK

-86- GRN G -77- BLK

-73- BLK

ES TIMER RELAY
30 SECOND -72- ORG B -75- BLK
DELAY
TANK FULL INDICATOR

-78- ES
-70- PUR PUMP -71- BLK
-76- BLU
BLU -74-
-82- GRN
ORG
FLOAT OPTIONAL
SWITCH

4-92 5400 330735 (3–01)

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 ELECTRICAL

WAND PUMP DOES NOT OPERATE

NOTE: WAND PUMP START HERE

SWITCH MUST BE ON
DURING TESTS
CHECK VOLTAGE AT
No Yes
WAND PUMP
56 BRN TO 29 BLK

CHECK VOLTAGE AT
Yes No
WAND PUMP REPLACE WAND PUMP
56 BRN TO BATT.NEG.

CHECK VOLTAGE AT
REPAIR OR REPLACE No Yes
WAND PUMP SWITCH
29 BLK
56 BRN TO BATT.NEG

CHECK VOLTAGE AT
Yes No REPAIR OR REPLACE
WAND PUMP SWITCH
84 GRN TO BATT.NEG 56 BRN

CHECK VOLTAGE AT
REPAIR OR REPLACE No ACCESSORY BOX Yes
WAND PUMP SWITCH POSITIVE STAND–OFF
84 GRN TO BATT.NEG

GO TO NO POWER REPAIR OR REPLACE

TROUBLESHOOTING 84 GRN

5400 330735 (3–01) 4-93

Home Find... Go To..