Tennant 7400 Service Manual

7400
Service Manual
MM428
Rev. 04 (3--02)

Tennant 7400 Specifications

General

Brand	Tennant
Model	7400
Category	Scrubber
Language	English

Summary

General Information

Safety Precautions

Details on hazards and safe practices for operating the machine.

Emissions Label

Location and description of the emissions warning label on the machine.

For Safety Label

Location and description of the general safety warning label.

Flammable Spills Label

Location and description of the flammable spills warning label.

Fan and Belt Label

Location and description of the fan and belt warning label.

Strong Vacuum Label

Location and description of the strong vacuum warning label.

Flammable Materials Label

Location and description of the flammable materials warning label.

Specifications

Technical specifications including dimensions, capacities, and performance.

General Machine Dimensions/Capacities

Detailed dimensions and fluid capacities of the machine.

General Machine Performance

Performance metrics like speed, turning radius, and incline ratings.

Power Type

Information on engine types, displacement, fuel, and electrical systems.

Steering

Details on the steering system type, power source, and emergency steering.

Hydraulic System

Information on hydraulic system capacity and fluid types.

Braking System

Details on service and parking brake types and operations.

Tires

Specifications for tire type, size, and pressure.

Machine Dimensions

Diagrams showing overall machine dimensions.

Maintenance

General maintenance information and charts.

Maintenance Chart / G/LP

Schedule for routine maintenance tasks for Gas/LPG engines.

Pushing, Towing, and Transporting the Machine

Procedures for safely moving the machine when disabled or for transport.

Machine Jacking

Instructions on safely jacking the machine for service.

Storing Machine

Procedures for storing the machine for extended periods.

Hardware Information

Data on standard torque values, bolt identification, and sealants.

Hydraulic Fitting Information

Torque charts for various hydraulic fittings (NPT, JIC, O-ring).

Chassis

Introduction

Overview of chassis-related components like seat, steering, brakes, and tires.

Seat

Information on the adjustable seat assembly and its removal/replacement.

Operator Seat

Details on the fixed-back operator seat with forward-backward adjustment.

Static Drag Chain

Description of the static drag chain's purpose and maintenance.

Brakes and Tires

Information on the machine's braking system and tires.

Service Brakes

Details on the mechanical service brakes and their operation.

To Replace Brake Shoes

Step-by-step procedure for replacing brake shoes.

Rear Tires and Wheels

Information on the semi-pneumatic rear tires and wheels.

To Repack Rear Wheel Bearings

Procedure for repacking and adjusting rear wheel bearings.

Front Tire and Wheel Support

Details on the front wheel support and its lubrication requirements.

To Replace Front Drive Motor

Procedure for replacing the front wheel drive motor.

To Replace Front Wheel Housing Pivot Bearings

Procedure for replacing pivot bearings in the front wheel housing.

Scrubbing

Introduction

Overview of the scrubbing system's operation and components.

Solution Tanks

Description of the clean water and detergent solution tanks.

To Remove LH Solution Tank

Step-by-step instructions for removing the left-hand solution tank.

To Install LH Solution Tank

Step-by-step instructions for installing the left-hand solution tank.

To Remove RH Solution Tank

Step-by-step instructions for removing the right-hand solution tank.

To Install RH Solution Tank

Step-by-step instructions for installing the right-hand solution tank.

Recovery Tank

Description of the recovery tank's function.

To Remove Recovery Tank

Step-by-step instructions for removing the recovery tank.

To Install Recovery Tank

Step-by-step instructions for installing the recovery tank.

Scrub Head

Description of the scrub head components.

To Replace Main Scrub Brushes

Procedure for replacing the main scrub brushes.

Checking and Adjusting Scrub Brush Pattern

Method for checking and adjusting the scrub brush pattern.

To Replace Main Brush Idler Shaft Bearings

Procedure for replacing bearings in the main brush idler shaft.

To Remove Main Brush Drive Motor Mount Plate

Procedure for removing the main brush drive motor mount plate.

To Install Main Brush Drive Motor Mount Plate

Procedure for installing the main brush drive motor mount plate.

To Replace Optional Side Brush

Procedure for replacing the optional side brush.

Squeegees

Description of the squeegee system and its blades.

To Replace Rear Squeegee Lift Cable

Procedure for replacing the rear squeegee lift cable.

To Replace Rear Squeegee Centering Springs

Procedure for replacing rear squeegee centering springs.

To Remove Rear Squeegee Frame

Procedure for removing the rear squeegee frame.

To Install Rear Squeegee Frame

Procedure for installing the rear squeegee frame.

Squeegee Blades

Information on rear squeegee blades and their replacement.

To Replace or Rotate Rear Squeegee Blades

Procedure for replacing or rotating rear squeegee blades.

To Adjust Rear Squeegee Blade Deflection

Procedure for adjusting the rear squeegee blade deflection.

To Level the Rear Squeegee

Procedure for leveling the rear squeegee for even contact.

Side Squeegees

Information on side squeegees and their replacement.

To Replace Side Squeegee Blades

Procedure for replacing side squeegee blades.

To Replace Side Brush Squeegee

Procedure for replacing the side brush squeegee.

Side Brush Skirt

Description of the side brush skirt and its maintenance checks.

Vacuum Fan

Description of the vacuum fan and its hydraulic motor.

To Remove Vacuum Fan

Procedure for removing the vacuum fan assembly.

To Install Vacuum Fan

Procedure for installing the vacuum fan assembly.

To Replace Vacuum Impeller

Procedure for replacing the vacuum fan impeller.

Electrical

Introduction

Overview of the machine's electrical system components.

Battery

Information on the low-maintenance battery and its care.

To Replace Battery

Step-by-step procedure for replacing the battery.

Instrument Panel

Description of the instrument panel's functions and components.

To Replace Instrument Panel

Procedure for replacing the instrument panel.

To Disassemble Instrument Panel

Procedure for disassembling the instrument panel.

To Reassemble Instrument Panel

Procedure for reassembling the instrument panel.

To Replace Machine Relay

Procedure for replacing machine relays.

To Replace Circuit Breaker

Procedure for replacing circuit breakers.

Gas/LPG Electrical Schematic

Electrical schematic diagram for Gas/LPG systems.

Diesel Electrical Schematic

Electrical schematic diagram for Diesel engine systems.

Gas/LPG Wire Harness Group

Wiring diagram for Gas/LPG wire harnesses.

Diesel Wire Harness Group

Wiring diagram for Diesel wire harnesses.

Diagnostics

Information on the on-board diagnostic system.

Operating Modes

Description of the machine's different operating modes.

Normal Mode

Details on the normal operating mode.

Scrub Button

Function and operation of the scrub button.

Squeegee Button

Function and operation of the squeegee button.

Detergent

Function and modes of the detergent system.

ES Button

Function and operation of the ES system button.

Overflow Float

Information on the recovery tank overflow float activation.

Manual Mode

Details on the manual mode for operating functions.

Input Display Mode

Mode to display the state of floats, switches, and sensors.

Error Display Mode

Mode to display the cause of self-test failures.

ES LED

Troubleshooting for ES output problems.

Side Brush LED

Troubleshooting for side brush actuator/motor outputs.

Squeegee LED

Troubleshooting for squeegee actuator/vacuum fan motor outputs.

Scrub LED

Troubleshooting for main brush actuator/motor outputs.

Detergent LED

Troubleshooting for headlight or detergent pump outputs.

Pressure Adjust Mode

Mode to adjust down pressure levels for brushes.

Reset Scrub Pressures

Resets brush down pressure settings to factory defaults.

Troubleshooting

General section for troubleshooting electrical issues.

Instrument Panel Does Not Power Up (Schematic)

Schematic for diagnosing instrument panel power issues.

Scrub Brush Will Not Turn On And/Or Down (Schematic)

Schematic for diagnosing scrub brush activation issues.

Squeegee and Vacuum Fan Not Turning On and Going Down (Schematic)

Schematic for diagnosing squeegee/vacuum fan operation.

Side Brush Will Not Turn On and Go Down (Schematic)

Schematic for diagnosing side brush activation issues.

Water Valves Not Operating (Schematic)

Schematic for diagnosing water valve operation.

Head Lights Will Not Turn On (Schematic)

Schematic for diagnosing headlight activation issues.

ES Pump Not Working (Schematic)

Schematic for diagnosing ES pump operation issues.

Reverse Light or Alarm Not Working (Schematic)

Schematic for diagnosing reverse light/alarm issues.

Detergent Metering Pump Is Not Operating (Schematic)

Schematic for diagnosing detergent pump operation issues.

Alternator / Battery Warning Light Stays On When Engine Is Running (Schematic)

Schematic for diagnosing alternator/battery light issues.

Alternator / Battery Warning Light Will Not Turn On (Schematic)

Schematic for diagnosing alternator/battery light not turning on.

Engine Temperature Light Will Not Turn On Or Off (Schematic)

Schematic for diagnosing engine temp light issues.

Hydraulic (High) Pressure Indicator Light Will Not Turn On Or Off (Schematic)

Schematic for diagnosing hydraulic pressure indicator light.

Engine Oil Pressure Warning Light Will Not Turn On Or Off (Schematic)

Schematic for diagnosing engine oil pressure warning light.

Recovery Tank Full Light Will Not Turn On Or Off (Schematic)

Schematic for diagnosing recovery tank full light.

Fuel Gauge (Gas and Diesel) (Schematic)

Schematic for the gas and diesel fuel gauge system.

Fuel Gauge (LPG) (Schematic)

Schematic for the LPG fuel gauge system.

Hydraulics

Introduction

Overview of the machine's hydraulic system components.

Hydraulic Fluid Reservoir

Location and maintenance of the hydraulic fluid reservoir.

Hydraulic Fluid

Information on hydraulic fluid quality and types.

Hydraulic Hoses

Inspection guidelines for hydraulic hoses.

To Replace Directional Pedal Centering Spring

Procedure for replacing the directional pedal centering spring.

To Replace Directional Control Cable

Procedure for replacing the directional control cable.

To Adjust Centering Spring

Procedure for adjusting the centering spring.

To Replace Propel Pump

Procedure for replacing the propel pump.

To Replace Accessory Pump

Procedure for replacing the accessory pump.

To Replace Steering Cylinder

Procedure for replacing the steering cylinder.

To Replace Hydraulic Steering Valve

Procedure for replacing the hydraulic steering control valve.

To Replace Main Hydraulic Valve

Procedure for replacing the main hydraulic valve.

To Replace Side Brush Hydraulic Valve

Procedure for replacing the side brush hydraulic valve.

To Replace Solenoid Valve Cartridge

Procedure for replacing solenoid valve cartridges.

To Replace Engine Cooling Fan Hydraulic Motor

Procedure for replacing the engine cooling fan hydraulic motor.

To Replace Main Scrub Brush Hydraulic Motors

Procedure for replacing main scrub brush hydraulic motors.

To Replace Scrub Head Assembly Lift Cylinder

Procedure for replacing the scrub head lift cylinder.

To Replace Optional Side Brush Hydraulic Motor

Procedure for replacing optional side brush hydraulic motor.

To Replace Optional Side Brush Lift Cylinder

Procedure for replacing optional side brush lift cylinder.

To Replace Optional Side Brush Swing Cylinder

Procedure for replacing optional side brush swing cylinder.

To Replace Squeegee Lift Cylinder

Procedure for replacing the squeegee lift cylinder.

To Replace Vacuum Fan Hydraulic Motor

Procedure for replacing the vacuum fan hydraulic motor.

Hydraulic Schematic

Schematic diagram of the overall hydraulic system.

Hydraulic Hose Group

Diagram of hydraulic hose routing.

Hydraulic Hose Group / Side Brush Option

Diagram of hydraulic hoses for side brush option.

Troubleshooting

General section for troubleshooting hydraulic issues.

Engine Fan Circuit (Schematic)

Schematic diagram of the engine fan hydraulic circuit.

Engine Fan Slow or Doesn’t Run (Flow Chart)

Flow chart for diagnosing engine fan speed issues.

Engine Fan Motor Shaft Seal Leaks (Flow Chart)

Flow chart for diagnosing engine fan motor shaft seal leaks.

Main Brush On Circuit (Schematic)

Schematic diagram of the main brush hydraulic circuit.

Main Brushes Do Not Turn On (Flow Chart)

Flow chart for diagnosing main brush activation issues.

Main Brushes Do Not Turn Off (Flow Chart)

Flow chart for diagnosing main brush deactivation issues.

Main Brush Lower Circuit (Schematic)

Schematic diagram of the main brush lower hydraulic circuit.

Main Brushes Do Not Lower (Flow Chart)

Flow chart for diagnosing main brush lowering issues.

Main Brush Lift Circuit (Schematic)

Schematic diagram of the main brush lift hydraulic circuit.

Main Brushes Do Not Raise (Flow Chart)

Flow chart for diagnosing main brush raising issues.

Main Brushes Do Not Stay Up (Flow Chart)

Flow chart for diagnosing main brush stay-up issues.

Scrub Fan Circuit (Schematic)

Schematic diagram of the scrub fan hydraulic circuit.

Scrub Fan Does Not Turn On (Flow Chart)

Flow chart for diagnosing scrub fan activation issues.

Scrub Fan Does Not Turn Off (Flow Chart)

Flow chart for diagnosing scrub fan deactivation issues.

Scrub Fan Motor Shaft Seal Leaks (Flow Chart)

Flow chart for diagnosing scrub fan motor shaft seal leaks.

Main Brush On Circuit (Schematic)

Schematic diagram of the main brush hydraulic circuit.

Side Brush Does Not Turn On (Flow Chart)

Flow chart for diagnosing side brush activation issues.

Side Brush Does Not Turn Off (Flow Chart)

Flow chart for diagnosing side brush deactivation issues.

Side Brush Extend Circuit (Schematic)

Schematic diagram of the side brush extend circuit.

Side Brush Does Not Go Out (Flow Chart)

Flow chart for diagnosing side brush extension issues.

Side Brush Does Not Go In (Flow Chart)

Flow chart for diagnosing side brush retraction issues.

Side Brush Lower Circuit (Schematic)

Schematic diagram of the side brush lower hydraulic circuit.

Side Brush Does Not Stay Up (Flow Chart)

Flow chart for diagnosing side brush stay-up issues.

Side Brush Does Not Raise (Flow Chart)

Flow chart for diagnosing side brush raising issues.

Side Brush Does Not Lower (Flow Chart)

Flow chart for diagnosing side brush lowering issues.

Squeegee Lift Circuit (Schematic)

Schematic diagram of the squeegee lift hydraulic circuit.

Squeegee Does Not Lower (Flow Chart)

Flow chart for diagnosing squeegee lowering issues.

Squeegee Does Not Raise (Flow Chart)

Flow chart for diagnosing squeegee raising issues.

Squeegee Does Not Stay Up (Flow Chart)

Flow chart for diagnosing squeegee stay-up issues.

Steering Circuit (Schematic)

Schematic diagram of the steering hydraulic circuit.

Engine-Gas/LP

Introduction

Overview of repair information for engine and related systems.

Lubrication

Maintenance procedures for engine oil and lubrication.

Engine Oil

Checking and changing engine oil and filter.

Cooling System

Maintenance for radiator coolant, hoses, and cleaning.

Engine Fan Belt

Information on engine fan belt tension and adjustment.

Air Intake System

Components of the air intake system.

Air Filter Indicator

Function and resetting of the air filter restriction indicator.

Air Filter

Maintenance and replacement of the air filter element.

To Replace Air Filter Element

Procedure for replacing the air filter element.

Fuel System - Gasoline

Description of the gasoline fuel system components.

Fuel Filter

Function and replacement of the fuel filter.

Carburetor

Carburetor adjustments for idle fuel mixture and speed.

Fuel System - LPG

Description of the LPG fuel system components.

LP Fuel Tanks

Inspection and checks for LPG fuel tanks.

To Change an LPG Fuel Tank

Procedure for changing the LPG fuel tank.

Fuel Filter Lock

Function of the fuel filter lock in the LPG system.

Vaporizer-Regulator

Maintenance and reassembly of the vaporizer-regulator.

Carburetor

Maintenance and reassembly of the carburetor.

Oil Pressure Switch

Description and safety features of the oil pressure switch.

LPG Fuel Troubleshooting

Troubleshooting guide for LPG fuel system issues.

Cylinder Head

Torque procedure for cylinder head reassembly.

Valve Tappet Clearance

Procedure for checking and adjusting valve tappet clearance.

Crankcase Ventilation System

Maintenance of crankcase ventilation system components.

Governor Troubleshooting

Troubleshooting guide for governor issues.

Governor

Description of the electronic governor system.

To Adjust Governor

Procedure for adjusting the governor settings.

Digital Controller Set-Up

Instructions for setting up the digital controller DIP switches.

Ignition System

Information on the engine's ignition system.

Spark Plugs

Maintenance and replacement of spark plugs.

To Replace Spark Plugs

Procedure for replacing spark plugs.

Ford Distributorless Ignition System

Overview of the Ford DIS ignition system.

Engine Temperature

Information on the engine coolant temperature sensor.

Engine-Diesel

Introduction

Overview of repair information for engine and related systems.

Lubrication

Maintenance procedures for engine oil and lubrication.

Engine Oil

Checking and changing engine oil and filter.

Cooling System

Maintenance for radiator coolant, hoses, and cleaning.

Engine Fan Belt

Information on engine fan belt tension and adjustment.

Air Intake System

Components of the air intake system.

Air Filter Indicator

Function and resetting of the air filter restriction indicator.

Air Filter

Maintenance and replacement of the air filter element.

To Replace Air Filter Element

Procedure for replacing the air filter element.

Fuel System - Diesel

Description of the diesel fuel system components.

Fuel Filter

Function and replacement of the fuel filter cartridge.

To Replace the Fuel Filter Cartridge

Procedure for replacing the fuel filter cartridge.

Fuel Lines

Inspection and replacement of fuel lines and clamp bands.

Priming Fuel System

Information on the self-priming diesel fuel system.

To Prime Fuel System

Procedure for priming the diesel fuel system.

To Replace Alternator on Diesel Engine

Procedure for replacing the alternator on the diesel engine.

To Replace Starter on Diesel Engine

Procedure for replacing the starter on the diesel engine.

To Remove Engine

Procedure for removing the diesel engine.

To Install Engine

Procedure for installing the diesel engine.

To Purge Air From Radiator

Procedure for purging air from the cooling system radiator.