Tennant 5400 Service Manual
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Tennant 5400 Service Manual

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5400
Service Manual
330735
Rev. 00 (3–01)

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Summary of Contents for Tennant 5400

  • Page 1 5400 Service Manual 330735 Rev. 00 (3–01)
  • Page 2 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.

  • Page 3: Table Of Contents

    BOLT IDENTIFICATION ... . 1–12 THREAD SEALANT AND LOCKING COMPOUNDS ....1–12 5400 330735 (3–01)
  • Page 4 GENERAL INFORMATION 5400 330735 (3–01)

  • Page 5: Safety Precautions

    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. 5400 330735 (3–01)
  • Page 6 ON THE SOLUTION FLOW PANEL. FOR SAFETY: Do not operate machine unless operation manual MOVING PARTS LABEL – LOCATED is read and understood. ON THE SCRUB HEAD SHROUD. WARNING: Moving parts. Turn off power before working on machine. 5400 330735 (3–01)

  • Page 7: Specifications

    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. 5400 330735 (3–01)

  • Page 8: Machine Dimensions - 610Mm (24 In) And 660Mm (26 In) Disk Models

    MACHINE DIMENSIONS – 610mm (24 in) and 660mm (26 in) DISK MODELS 839mm (33 in) 559mm (22 in) 1041mm (41 in) 1270mm (50 in) 641mm (25.25 in) *1289mm (50.75 in) *699mm (27.5 in) * Dimensions apply to 660 mm (26 in) disk models only 5400 330735 (3–01)

  • Page 9: Machine Dimensions - 610Mm (24 In) Cylindrical Brush Model

    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) 5400 330735 (3–01)

  • Page 10: Troubleshooting

    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 5400 330735 (3–01)
  • Page 11 Rinse off float switch located in recovery tank Faulty ESt 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 5400 330735 (3–01)

  • Page 12: Machine Jacking

    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. 1-10 5400 330735 (3–01)

  • Page 13: Storing Machine

    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. 1-11 5400 330735 (3–01)

  • Page 14: Hardware Information

    They include the following: 0.75 in 215–280 313–407 (291–380) (424–552) Locktite 515 sealant – gasket forming material. TENNANT Part No. 75567,15 oz 1.00 in 500–650 757–984 (440 ml) cartridge. (678–881) (1026–1334) NOTE: Decrease torque by 20% when using a Locktite 242 blue –...
  • Page 15 REAR CASTER ..... . . 2–9 TO REPLACE REAR CASTER ..2–9 5400 330735 (3–01)
  • Page 16 CHASSIS 5400 330735 (3–01)

  • Page 17: Introduction

    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. 5400 330735 (3–01)

  • Page 18: Drive Transaxle

    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.
  • Page 19 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. 5400 330735 (3–01)

  • Page 20: To Install The Transaxle

    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. 5400 330735 (3–01)

  • Page 21: To Replace Drive Wheel/Tire Assembly

    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. 5400 330735 (3–01)
  • Page 22 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. 5400 330735 (3–01)

  • Page 23: Rear Caster

    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. 5400 330735 (3–01)
  • Page 24 CHASSIS 2-10 5400 330735 (3–01)
  • Page 25 ......3–41 TO REPLACE SOLUTION FLOW CONTROL CABLE ... . . 3–43 MACHINE TROUBLESHOOTING ..3–45 5400 330735 (3–01)
  • Page 26 SCRUBBING 5400 330735 (3–01)

  • Page 27: Introduction

    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.

  • Page 28: Solution Tank

    ESt Option: The recovery tank should be partially filled with clean water after using the ESt Option and clean water should be run through the pump until it is clear of any deposits. 5400 330735 (3–01)

  • Page 29: Recovery Tank

    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. 5400 330735 (3–01)

  • Page 30: Scrub Brushes

    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. 5400 330735 (3–01)

  • Page 31: To Replace Disc Scrub Brush

    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)

  • Page 32: To Replace Cylindrical Scrub Brush

    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. 5400 330735 (3–01)
  • Page 33 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. 5400 330735 (3–01)

  • Page 34: Scrub Head

    Check the disk brush scrub head skirt for damage or wear daily. Check the cylindrical brush scrub head side skirt for damage daily. 3-10 5400 330735 (3–01)

  • Page 35: To Remove Disc Scrub Head

    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. 3-11 5400 330735 (3–01)
  • Page 36 NOTE: When reinstalling a scrub head, loosen the – Cylindrical two mounting screws on the switch box. Align the corresponding arrow printed on the switchbox – Disk label with the notch in the spring bracket. Notch Switch Spring Bracket DETAIL Roller Bracket 3-12 5400 330735 (3–01)

  • Page 37: To Adjust Disk Brush Scrub Head

    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. 3-13 5400 330735 (3–01)

  • Page 38: To Replace Disk Scrub Head Skirt

    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)

  • Page 39: To Remove Cylindrical Scrub Head

    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. 3-15 5400 330735 (3–01)
  • Page 40 NOTE: When reinstalling a scrub head, loosen the – Cylindrical two mounting screws on the switch box. Align the corresponding arrow printed on the switchbox – Disk label with the notch in the spring bracket. Notch Switch Spring Bracket DETAIL Roller Bracket 3-16 5400 330735 (3–01)

  • Page 41: To Check Cylindrical Brush Pattern

    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. 3-17 5400 330735 (3–01)
  • Page 42 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. 3-18 5400 330735 (3–01)
  • Page 43 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 3-19 5400 330735 (3–01)

  • Page 44: To Adjust Tapered Brush Pattern

    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. 3-20 5400 330735 (3–01)
  • Page 45 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. 3-21 5400 330735 (3–01)

  • Page 46: To Adjust Uneven Brush Pattern

    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. 3-22 5400 330735 (3–01)

  • Page 47: To Adjust Cylindrical Scrub Head Skirts

    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. 3-23 5400 330735 (3–01)
  • Page 48 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. 3-24 5400 330735 (3–01)

  • Page 49: To Replace Cylindrical Scrub Head Skirt

    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. 3-25 5400 330735 (3–01)

  • Page 50: To Replace Cylindrical Scrub Brush Drive Belt

    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. 3-26 5400 330735 (3–01)
  • Page 51 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. 3-27 5400 330735 (3–01)
  • Page 52 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. 3-28 5400 330735 (3–01)

  • Page 53: To Replace Cylindrical Scrub Brush Idler Plug And Bearing Assembly

    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. 3-29 5400 330735 (3–01)
  • Page 54 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. 3-30 5400 330735 (3–01)

  • Page 55: To Replace Cylindrical Scrub Brush Drive Plug Bearings

    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. 3-31 5400 330735 (3–01)
  • Page 56 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. 3-32 5400 330735 (3–01)
  • Page 57 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. 3-33 5400 330735 (3–01)
  • Page 58 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. 3-34 5400 330735 (3–01)
  • Page 59 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. 3-35 5400 330735 (3–01)
  • Page 60 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. 3-36 5400 330735 (3–01)

  • Page 61: Squeegee

    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. 3-37 5400 330735 (3–01)
  • Page 62 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. 3-38 5400 330735 (3–01)

  • Page 63: To Replace Or Rotate Rear Squeegee Blade

    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. 3-39 5400 330735 (3–01)

  • Page 64: To Replace Or Rotate Front Squeegee Blade

    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. 3-40 5400 330735 (3–01)

  • Page 65: To Replace Squeegee Lift Cable

    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. 3-41 5400 330735 (3–01)
  • Page 66 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. 3-42 5400 330735 (3–01)

  • Page 67: To Replace Solution Flow Control Cable

    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. 3-43 5400 330735 (3–01)
  • Page 68 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. 3-44 5400 330735 (3–01)

  • Page 69: Machine Troubleshooting

    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...
  • Page 70 SCRUBBING 3-46 5400 330735 (3–01)
  • Page 71 ....4–93 TO REPLACE POWER WAND PUMP ......4–53 5400 330735 (3–01)
  • Page 72 ELECTRICAL 5400 330735 (3–01)

  • Page 73: Electrical System

    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. 5400 330735 (3–01)

  • Page 74: Batteries

    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. 5400 330735 (3–01)
  • Page 75 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)

  • Page 76: To Charge Batteries

    DO NOT OVERFILL. Overfilled batteries can overflow during charging due to fluid 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. 5400 330735 (3–01)
  • Page 77 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)

  • Page 78: To Replace Charger Safety Switch

    NOTE: Drain the recovery tank. 1. Open the recovery tank. 2. Disconnect the positive battery cable from Machine Front the front, left machine battery. BLACK FOR SAFETY: Disconnect the battery connections before working on the machine. 3. Lower the squeegee. 5400 330735 (3–01)
  • Page 79 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)
  • Page 80 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. 4-10 5400 330735 (3–01)

  • Page 81: Instrument Panel

    Machine; Stop On Level Surface, Turn Off Machine. 1. Open the recovery tank. 2. Disconnect the positive battery cable from Machine Front the front, left machine battery. BLACK FOR SAFETY: Disconnect the battery connections before working on the machine. 4-11 5400 330735 (3–01)
  • Page 82 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. 4-12 5400 330735 (3–01)

  • Page 83: To Remove Handle Bar Gear Hub

    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. 4-13 5400 330735 (3–01)
  • Page 84 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. 4-14 5400 330735 (3–01)

  • Page 85: To Replace Potentiometer Switch

    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. 4-15 5400 330735 (3–01)
  • Page 86 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. 4-16 5400 330735 (3–01)

  • Page 87: To Adjust Potentiometer

    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. 4-17 5400 330735 (3–01)

  • Page 88: To Replace Speed Control Board

    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. 4-18 5400 330735 (3–01)
  • Page 89 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. 4-19 5400 330735 (3–01)

  • Page 90: To Replace 24 Volt Contactor

    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. 4-20 5400 330735 (3–01)

  • Page 91: To Replace Resettable Circuit Breaker

    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. 4-21 5400 330735 (3–01)

  • Page 92: To Replace 24 Volt Solenoid

    FOR SAFETY: Disconnect the battery connections before working on the machine. 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. 4-22 5400 330735 (3–01)
  • Page 93 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). 4-23 5400 330735 (3–01)
  • Page 94 ELECTRICAL 11. Reconnect the positive battery cable to the battery. Machine Front BLACK 12. Operate the machine checking for proper operation. 4-24 5400 330735 (3–01)

  • Page 95: Vacuum Fan

    1. Open the recovery tank. 2. Disconnect the positive battery cable from Machine Front the front, left machine battery. BLACK FOR SAFETY: Disconnect the battery connections before working on the machine. 3. Disconnect the vacuum fan from the main harness. 4-25 5400 330735 (3–01)
  • Page 96 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). 4-26 5400 330735 (3–01)
  • Page 97 ELECTRICAL 8. Reconnect the vacuum fan to the main harness. 9. Reconnect the positive battery cable to the Machine Front battery. BLACK 10. Operate the machine. Check the vacuum fan for proper operation. 4-27 5400 330735 (3–01)

  • Page 98: To Replace Vacuum Fan Switch

    NOTE: Drain the recovery tank. 1. Open the recovery tank. 2. Disconnect the positive battery cable from Machine Front the front, left machine battery. BLACK FOR SAFETY: Disconnect the battery connections before working on the machine. 3. Lower the squeegee. 4-28 5400 330735 (3–01)
  • Page 99 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). 4-29 5400 330735 (3–01)
  • Page 100 11. Reconnect the positive battery cable to the battery. Machine Front BLACK 12. Operate the machine. Check the vacuum fan switch for proper operation. Make sure the vacuum fan turns on when the key is on and the squeegee is lowered. 4-30 5400 330735 (3–01)

  • Page 101: Scrub Brush Motors

    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. 4-31 5400 330735 (3–01)
  • Page 102 The new brush motor needs to be positioned in the same location. The right hand motor has slots for motor adjustment. (The distance between the motor shafts is 12 inch for 24 inch head and 13 inch for the 26 inch head). 4-32 5400 330735 (3–01)
  • Page 103 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. 4-33 5400 330735 (3–01)
  • Page 104 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 THIN WASHER on the shaft. Position the brush drive hub onto the shaft. THICK WASHER 4-34 5400 330735 (3–01)
  • Page 105 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. 4-35 5400 330735 (3–01)

  • Page 106: To Replace Cylindrical Head Scrub Brush Motor

    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. 4-36 5400 330735 (3–01)
  • Page 107 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. 4-37 5400 330735 (3–01)
  • Page 108 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. 4-38 5400 330735 (3–01)
  • Page 109 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. 4-39 5400 330735 (3–01)
  • Page 110 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. 4-40 5400 330735 (3–01)
  • Page 111 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. 4-41 5400 330735 (3–01)

  • Page 112: Actuator

    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.
  • Page 113 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. 4-43 5400 330735 (3–01)
  • Page 114 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. 4-44 5400 330735 (3–01)
  • Page 115 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. 4-45 5400 330735 (3–01)
  • Page 116 17. Reconnect the positive battery cable to the battery. Machine Front BLACK 18. Reinstall the scrub head shroud. 19. Close the recovery tank and operate the machine. Check the scrub head lift actuator for proper operation. 4-46 5400 330735 (3–01)

  • Page 117: Solution Solenoid Valve

    NOTE: Drain the solution and recovery tanks. 1. Open the recovery tank. 2. Disconnect the positive battery cable from Machine Front the front, left machine battery. BLACK FOR SAFETY: Disconnect the battery connections before working on the machine. 3. Lower the squeegee. 4-47 5400 330735 (3–01)
  • Page 118 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) 4-48 5400 330735 (3–01)
  • Page 119 (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. 4-49 5400 330735 (3–01)
  • Page 120 14. Operate the machine. Check the solution flow system for proper operation. 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)

  • Page 121: Optional Extended Scrub

    ELECTRICAL OPTIONAL EXTENDED SCRUB The ES tsystem 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 t system is activated by a switch on the instrument panel.
  • Page 122 ES tpump. 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 tpump for proper operation. 4-52 5400 330735 (3–01)

  • Page 123: Optional Power Wand

    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. 4-53 5400 330735 (3–01)
  • Page 124 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)

  • Page 125: Electric Motors

    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. 4-55 5400 330735 (3–01)
  • Page 126 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. 4-56 5400 330735 (3–01)

  • Page 127: To Replace Disc Scrub Brush Motor Brushes

    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. 4-57 5400 330735 (3–01)
  • Page 128 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. 4-58 5400 330735 (3–01)

  • Page 129: Electrical Schematic

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- PUMP -70- PUR -71- BLK -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-59 5400 330735 (3–01)

  • Page 130: Wiring Diagram

    - 29 - DOWN LIMIT RIGHT LEFT SWITCH BRUSH BRUSH - 30 - BLUE - 26 - GRN - 25 - BLK BRUSH MOTOR CONTROL SWITCH - 42 - WHT - 3 - BLK - 29 - BLK 4-60 5400 330735 (3–01)

  • Page 131: Wiring Diagram (Options)

    - 71 - - 74 - - 82 - - 78 - BLUE - 70 - - 56 - -31- BLK PUMP FLOAT SWITCH - 20 - GRN - 32 - GRN OPTIONAL WAND PUMP - 29 - 4-61 5400 330735 (3–01)
  • Page 132 ELECTRICAL 4-62 5400 330735 (3–01)

  • Page 133: Troubleshooting

    ELECTRICAL TROUBLESHOOTING The troubleshooting flow charts and high lighted electrical schematics are used to diagnose and repair electrical problems. 4-63 5400 330735 (3–01)

  • Page 134: Power Up Circuit

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- PUMP -70- PUR -71- BLK -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-64 5400 330735 (3–01)

  • Page 135: No Power (Key On And Battery Charger Disconnected)

    CHECK VOLTAGE AT RESET OR REPLACE 10 KEYSWITCH AMP CIRCUIT BREAKER 6 RED TO BATT. NEG. CHECK VOLTAGE AT REPAIR OR REPLACE KEYSWITCH 6 RED 32 GRN TO BATT. NEG. REPAIR OR REPLACE CONTINUED ON KEYSWITCH NEXT PAGE 4-65 5400 330735 (3–01)
  • Page 136 CHECK VOLTAGE AT HARNESS WIRE SPLICE REPAIR OR REPLACE (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)
  • Page 137 ELECTRICAL 4-67 5400 330735 (3–01)

  • Page 138: Propel Circuit

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- PUMP -70- PUR -71- BLK -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-68 5400 330735 (3–01)

  • Page 139: No Propel (Power Up O.k.)

    64 ORG TO 3 BLK TROUBLESHOOTING (AT VACUUM MOTOR CONTACTOR CRI) CHECK VOLTAGE AT REPAIR OR REPLACE SPEED CONTROL BOARD 5 BLK 64 ORG TO 3 BLK (AT NEGATIVE STANDOFF) CONTINUED ON REPAIR OR REPLACE NEXT PAGE 3 BLK 4-69 5400 330735 (3–01)
  • Page 140 AMP CIRCUIT BREAKER 64 ORG 58 RED TO BATT. NEG. CHECK VOLTAGE AT RESET OR REPLACE BATTERY PACK 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)

  • Page 141: No Propel - Control Board Troupbleshooting

    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 4-71 5400 330735 (3–01)

  • Page 142: Brush Circuit

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- PUMP -70- PUR -71- BLK -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-72 5400 330735 (3–01)

  • Page 143: Both Brushes Do Not Operate With Brush Deck Down

    DURING TEST) CHECK VOLTAGE AT BRUSH CONTACTOR(CR2) 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 4-73 5400 330735 (3–01)
  • Page 144 CHECK VOLTAGE AT BRUSH CONTACTOR 30 BLU TO 91 BLK AT PIN 1 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)

  • Page 145: Brush Motor 1 Does Not Operate

    BRUSH CONTACTOR(CR2) BRUSH PRESSURE 38 RED TO BATT. NEG. METER CHECK VOLTAGE AT REPAIR OR REPLACE BRUSH CONTACTOR(CR2) 38 RED POSITIVE BATTERY CABLE TO BATT. NEG. REPAIR OR REPLACE GO TO POSITIVE BATTERY BRUSH CONTACTOR CABLE TROUBLESHOOTING 4-75 5400 330735 (3–01)

  • Page 146: Brush Motor 2 Does Not Operate

    BRUSH CONTACTOR(CR2) CIRCUIT BREAKER 2 36 RED TO BATT. NEG. CHECK VOLTAGE AT REPAIR OR REPLACE BRUSH CONTACTOR(CR2) 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)
  • Page 147 ELECTRICAL 4-77 5400 330735 (3–01)

  • Page 148: Actuator Circuit

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- PUMP -70- PUR -71- BLK -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-78 5400 330735 (3–01)

  • Page 149: Brush Deck Will Not Lower

    REPAIR OR REPLACE ADJUSTMENT SWITCH 46 ORG 12 GRN TO BATT. NEG. CHECK VOLTAGE AT REPLACE BRUSH HEIGHT BATTERY METER ADJUSTMENT SWITCH 10 GRN TO BATT. NEG. GO TO REPAIR OR REPLACE NO POWER 12 GRN TROUBLESHOOTING 4-79 5400 330735 (3–01)

  • Page 150: Brush Deck Will Not Raise

    TEST DIODE AND WIRES BRUSH HEIGHT 68 ORG AND 66 RED ADJUSTMENT SWITCH 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)
  • Page 151 ELECTRICAL 4-81 5400 330735 (3–01)

  • Page 152: Vacuum Fan Circuit

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- -70- PUR -71- BLK PUMP -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-82 5400 330735 (3–01)

  • Page 153: Vacuum Fan Does Not Operate

    AMP CIRCUIT BREAKER 28 TAN 34 RED TO BATT. NEG. CHECK VOLTAGE AT RESET OR REPLACE 25 BRUSH AMP CIRCUIT BREAKER CONTACTOR(CR2) 34 RED TO BATT. NEG. GO TO REPAIR OR REPLACE NO POWER 34 RED TROUBLESHOOTING 4-83 5400 330735 (3–01)
  • Page 154 CHECK VOLTAGE AT VACUUM CONTACTOR(CR1) COIL CONNECTIONS 22 YEL TO 3 BLK CHECK VOLTAGE AT VACUUM REPLACE VACUUM 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)
  • Page 155 ELECTRICAL 4-85 5400 330735 (3–01)

  • Page 156: Solution Solenoid Circuit

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- PUMP -70- PUR -71- BLK -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-86 5400 330735 (3–01)

  • Page 157: Solution Solenoid Does Not Operate (Brushes Work)

    (TWIST ROLL GRIPS DURING TEST) CHECK VOLTAGE AT BRUSH CONTACTOR(CR2) REPAIR OR REPLACE 16 BLU TO 91 BLK AT 16 BLU FUSE HOLDER (TWIST ROLL GRIPS DURING TEST) GO TO REPLACE FUSE BOTH BRUSHES DO NOT OPERATE 4-87 5400 330735 (3–01)

  • Page 158: Est Solenoid Circuit

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- -70- PUR -71- BLK PUMP -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-88 5400 330735 (3–01)

  • Page 159: Est Pump Does Not Operate4-89

    CHECK VOLTAGE AT ES REPAIR OR REPLACE SWITCH 76 BLU TO BATT. 78 BLU NEG. CHECK VOLTAGE AT ES REPAIR OR REPLACE SWITCH 86 GRN TO BATT. 76 BLU NEG. GO TO NO POWER REPLACE TROUBLESHOOTING ES SWITCH 4-89 5400 330735 (3–01)
  • Page 160 REPAIR OR REPLACE FLOAT SWITCH 74 ORG 82 GRN TO BATT. NEG. CHECK VOLTAGE AT POSITIVE STAND–OFF IN 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)
  • Page 161 ELECTRICAL 4-91 5400 330735 (3–01)

  • Page 162: Wand Pump Circuit

    -29- BLK -56- BRN PUMP -86- GRN -77- BLK -73- BLK ES TIMER RELAY 30 SECOND -72- -75- BLK DELAY TANK FULL INDICATOR -78- -70- PUR -71- BLK PUMP -76- -74- -82- GRN FLOAT OPTIONAL SWITCH 4-92 5400 330735 (3–01)

  • Page 163: Wand Pump Does Not Operate

    WAND PUMP SWITCH 56 BRN 84 GRN TO BATT.NEG CHECK VOLTAGE AT REPAIR OR REPLACE ACCESSORY BOX WAND PUMP SWITCH POSITIVE STAND–OFF 84 GRN TO BATT.NEG REPAIR OR REPLACE GO TO NO POWER 84 GRN TROUBLESHOOTING 4-93 5400 330735 (3–01)

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