Tennant 5400 Product manual

5400
Automatic Scrubber
Operator and Parts Manual
606863
Rev. 02 (02-03)
The safe scrubbing alternative™
Patents Pending
Model No.s
606912 – 610 mm Disc
610
606913 – 610 mm Cylindrical Brush
610
610876 – 660 mm Disc
660
613986 – 610 mm FaST™
FaST™ 610
613987 – 660 mm FaST™
FaST™ 660

2Tennant 5400 (02-03)
OPERATION
This manual is furnished with each new 5400 model.
It provides necessary operating and maintenance
instructions and an illustrated parts list.
Read this manual completely and understand the
machine before operating or servicing.
When ordering replacement parts, use the parts lists
section in this manual. Before ordering parts or
supplies, be sure to have your machine model number
and serial number available. Parts and supplies may
be ordered by phone or mail from any authorized
Service Center or Distributor.
This machine will provide excellent service. However,
the best results will be obtained at minimum costs if:
• The machine is operated with reasonable care.
• The machine is maintained regularly — per the
machine maintenance instructions provided.
• The machine is maintained with manufacturer
supplied or equivalent parts.
5400
•
•
•
Please fill out at time of installation for future reference.
Model No. –
Install. Date –
Serial No. –
© 2001, 2003 Tennant Company
Printed in U.S.A.
MACHINE DATA
–
–
–
Specifications and parts are subject to change without notice.

3
Tennant 5400 (02-03)
OPERATION
TABLE OF CONTENTS
SAFETY PRECAUTIONS ..................5
SAFETY LABELS ......................................8
MACHINE COMPONENTS ........................9
CONTROL CONSOLE SYMBOLS
...............................................................11
MACHINE INSTALLATION ......................12
UNCRATING MACHINE ......................12
INSTALLING BATTERIES ....................12
MACHINE SETUP ....................................13
ATTACHING SQUEEGEE ASSEMBLY
.....................................................13
INSTALLING BRUSHES/PADS
..................................................14
INSTALLING FaST™ PAK AGENT (OPTION)
FaST™ PAK ......................15
FILLING SOLUTION TANK
..................................................16
MACHINE OPERATION ...........................17
PRE–OPERATION CHECKS
..........................................................17
OPERATING MACHINE
..............................................................18
EMERGENCY STOPPING (OPTION)
.................................................20
OPERATING FaST™ SCRUB SYSTEM
(OPTION)
FaST™ ..........................22
OPERATING ES™ (OPTION)
ES™ ...............................................22
WHILE OPERATING MACHINE
..........................................................22
OPERATING OFF-AISLE WAND (OPTION)
................................23
CIRCUIT BREAKERS/FUSE .......25
HOUR METER .........................................25
DRAINING TANKS ...............................26
ADJUSTING SCRUB HEAD ................26
DISC BRUSH SCRUB HEAD ......26
CYLINDRICAL BRUSH SCRUB HEAD
......................................................27
REMOVING BRUSHES/PADS
.......................................................30
DISC SCRUB HEAD
..........................................................30
CYLINDRICAL SCRUB HEAD
..........................................................30
CHANGING SCRUB HEADS ...............31
CHARGING BATTERIES .........................33
MACHINE MAINTENANCE ......................35
DAILY MAINTENANCE
..............................................................35
WEEKLY MAINTENANCE
..............................................................37
MONTHLY MAINTENANCE
..............................................................38
QUARTERLY MAINTENANCE
..........................................................38
BATTERY MAINTENANCE
..............................................................39
MACHINE JACKING ................................40
TRANSPORTING MACHINE ...................41
STORING MACHINE ................................41
FREEZE PROTECTION
...............................................................41
FaST™ SYSTEM FREEZE PROTECTION
FaST™ .........................................42
RECOMMENDED STOCK ITEMS
...........................................................43
TROUBLESHOOTING ..............................44
SPECIFICATIONS ............................................48

4Tennant 5400 (02-03)
OPERATION
MACHINE DIMENSIONS ..........................50
TABLE OF CONTENTS – Continued

5
Tennant 5400 (02-03)
OPERATION
SAFETY PRECAUTIONS
This machine is intended for industrial and
commercial use. It is designed exclusively to
scrub hard floors in an indoor environment and is
not constructed for any other use. Use only
recommended pads, brushes and commercially
available floor cleaners intended for machine
application.
All operators must read, understand and practice
the following safety precautions.
The following safety alert symbol and the “FOR
SAFETY” heading are used throughout this manual
as indicated in their description.
WARNING: To warn of hazards or unsafe
practices which could result in severe personal
injury or death.
FOR SAFETY: To identify actions which must be
followed for safe operation of equipment.
Failure to follow these warnings may result in:
personal injury, electrocution, electrical shock, fire
or explosion.
WARNING: Do Not Use Flammable Liquids Or
Operate Machine In Or Near Flammable Liquids,
Vapors Or Combustible Dusts.
This machine is not equipped with explosion proof
motors. The electric motors will spark upon start
up and during operation which could cause a flash
fire or explosion if machine is used in an area
where flammable vapors/liquids or combustible
dusts are present.
WARNING: Do Not Pick Up Flammable
Materials Or Reactive Metals.
WARNING: Keep Sparks And Open Flame
Away. Keep Battery Hood Open When Charging.
WARNING: Disconnect Battery Cables Before
Servicing Machine.
WARNING: Moving parts. Turn off power
before working on machine.
/

6Tennant 5400 (02-03)
OPERATION
WARNING: Actuator pinch point. Stay clear of
head lift area.
The following information signals potentially
dangerous conditions to the operator or
equipment:
FOR SAFETY:
1. Do not operate machine:
– With flammable liquids or near flammable
vapors as an explosion or flash fire may
occur.
– Unless trained and authorized.
– Unless operation manual is read and
understood.
– If not in proper operating condition.
2. Before starting machine:
– Make sure all safety devices are in place and
operate properly.
3. When using machine:
– Go slow on inclines and slippery surfaces.
– Wear non-slip shoes.
– Use care when reversing machine.
– Report machine damage or faulty operation
immediately.
– Never allow children to play on or around.
– Follow mixing and handling instructions on
chemical containers.
4. Before leaving or servicing machine:
– Stop on level surface.
– Turn off machine.
– Set parking brake, if equipped.
– Remove key.
5. When servicing machine:
– Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
– Block machine tires before jacking up.
– Use hoist or jack that will support the weight
of the machine.
– Wear eye and ear protection when using
pressurized air on machine.
– Disconnect battery connections before
working on machine.
– Wear protective gloves and safety glasses
when handling batteries or battery cables.
– Avoid contact with battery acid.
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5.
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7
Tennant 5400 (02-03)
OPERATION
– Use manufacturer supplied or approved
replacement parts.
– All repairs must be performed by a qualified
service person.
– Do not modify the machine from it's original
design.
6. When transporting machine:
– Turn machine off.
– Get assistance when lifting machine.
– Do not lift machine when batteries are
installed.
– Use a recommended ramp when
loading/unloading into/off truck or trailer.
– Set parking brake after machine is loaded.
– Block machine tires.
– Tie machine down to truck or trailer.

8Tennant 5400 (02-03)
OPERATION
The safety labels appear on the machine in the
locations indicated. Replace labels if they become
damaged or illegible.
SAFETY LABELS
MOVING PARTS LABEL – LOCATED ON THE
SCRUB HEAD SHROUD.
WARNING: Moving parts. Turn off power
before working on machine.
GENERAL HAZARD
LABEL – LOCATED ON
THE ACTUATOR
MOUNTING BRACKET
WARNING: Actuator
pinch point. Stay clear of
head lift area.
BATTERY CHARGE LABEL –
LOCATED ON THE RECOVERY
TANK COVER AND BOTTOM
SIDE OF RECOVERY TANK.
WARNING: Keep sparks and
open flame away. Keep battery
hood open when charging.
WARNING LABEL – LOCATED ON THE RECOVERY TANK COVER.

9
Tennant 5400 (02-03)
OPERATION
1. Key Switch
2. Power ON/OFF Indicator Light
3. Speed Control Knob
4. Brush Pressure Switch
5. Brush Pressure Meter
6. Battery Meter
7. Control Grips
8. Solution ON/OFF Switch
9. Squeegee Lift Lever
10.Control Console
11.Control Console Height Adjustment Lever
12.Power Kill Button (Option)
13.Wand ON/OFF Switch (Option)
14.ES™ ON/OFF Switch (Option)
ES™
15.ES™ Pump Indicator Light (Option)
ES™
16.Charger Plug
17.Recovery Tank Drain Hose
MACHINE COMPONENTS
Model
Patents Pending

10 Tennant 5400 (02-03)
OPERATION
MACHINE COMPONENTS – Continued
18.Solution Tank Drain Hose
19.Solution Fill Port
20.Solution Flow Adjustment Knob
21.Squeegee Vacuum Hose
22.Squeegee Assembly
23.Squeegee Thumb Knobs
24.Wall Rollers
25.Recovery Tank Lid
26.Recovery Tank
27.Solution Tank
28.Interchangeable Disc Scrub Head
29.Scrub Head Leveling Screw
30.Scrub Head Skirt
31.Drive Wheels
32.Circuit Breaker Panel
33.Solution Tank Level Hose
34.Parking Brake (Option)
35.Interchangeable Cylindrical Brush Scrub Head
36.FaST™ System ON/OFF Switch (Option)
FaST™ /
37.FaST™ PAK Dispensing System (Option)
FaST™ PAK

11
Tennant 5400 (02-03)
OPERATION
Main Power
Indicator Light
Slow Speed
Fast Speed
Brush Pressure
Switch
Solution Switch &
Solution Control
Brush Pressure
Meter
Battery Charge
Meter
FaST™ System
Switch (option)
FaST™
Main Power 10A
Circuit Breaker
10A
Brush Motor (RH)
30A Circuit Breaker
(RH)
30A
Brush Motor (LH)
30A Circuit Breaker
(LH)
30A
Circuit Board
2A Fuse
2A
Drive Motor 15A
Circuit Breaker
15A
Vacuum Motor 25A
Circuit Breaker
25A
FaST™ System 10A
Circuit Breaker (option)
FaST™ 10A
ES™ (Extended Scrub)
ES™
ES™ Pump
Indicator Light
ES™
Off-Aisle Wand
Read Manual
Before Operating
CONTROL CONSOLE SYMBOLS
1
2
2A
™

12 Tennant 5400 (02-03)
OPERATION
MACHINE INSTALLATION
UNCRATING MACHINE
1. Carefully check carton for signs of damage. Report
damages at once to carrier.
1.
2. Check Carton Contents list, contact distributor for
missing items.
2.
Carton Contents:
– Battery Tray
– 3 Battery Cables
3
– 8 Battery Post Covers
8
– 8 Battery Cable Rubber Boots
8
– Squeegee Assembly
Batteries, battery charger, scrub brushes, pad
drivers and pads must be purchased separately
(See PARTS LIST section).
3. To uncrate your machine: unbolt rear of chassis
from shipping pallet, remove shipping straps and
carefully lift machine with assistance or use a ramp
to remove from pallet.
3.
ATTENTION: Do not roll machine off pallet,
machine damage may occur.
ATTENTION: To prevent possible machine damage,
install batteries after removing machine from
shipping pallet.
INSTALLING BATTERIES
WARNING: Keep Sparks And Open Flame
Away. Keep Battery Hood Open When Charging.
FOR SAFETY: When servicing machine, wear
protective gloves when handling batteries and
battery cables. Avoid contact with battery acid.
Recommended Battery Specifications:
Four 6 volt, deep cycle, 235 amp. hour batteries.
Maximum battery dimensions are 181 mm (7.13 in) W
x 260 mm (10.25 in) L x 292 mm (11.50 in) H.
6235
181 7.13 260
10.25 292 11.50
1. Remove key from machine and set parking brake, if
equipped.
1.
2. Hinge open recovery tank to access battery
compartment. Remove loose battery cables from
compartment (Figure 1).
2.
1
FIG.1 1

13
Tennant 5400 (02-03)
OPERATION
3. Carefully install batteries into battery compartment
tray and arrange battery posts as shown (Figure 2).
3.
2
FIG. 2 2
ATTENTION: Do not drop batteries into
compartment, battery and machine housing
damage may result. This damage is not covered
by warranty.
4. Before connecting battery cables, make sure
terminals and posts are clean. Use a post cleaner
and wire brush to clean posts and terminals.
4.
5. Connect cables to battery posts in numerical order
as labeled, RED TO POSITIVE & BLACK TO
NEGATIVE, use battery post covers and rubber
boots supplied (Figure 2).
5.
2
NOTE: Apply a light coating of non-metallic grease or
protective spray on the cable connections to prevent
battery corrosion.
6. Check battery meter charge level. Machine must be
in full operation for correct reading (See MACHINE
OPERATION). Charge batteries if necessary.
6.
MACHINE SETUP
ATTACHING SQUEEGEE ASSEMBLY
1. Turn key to the off position.
1.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface, turn off machine,
and set parking brake, if equipped.
2. Raise squeegee mount bracket using squeegee lift
lever (Figure 3).
2. 3
FIG. 3 3
Machine Front
5
RED
BLACK
4
3
12

14 Tennant 5400 (02-03)
OPERATION
3. Loosen two thumb knobs on squeegee and slide
squeegee into slots of squeegee mount bracket.
Tighten thumb knobs securely (Figure 4).
3.
4
FIG. 4 4
4. Connect vacuum hose to squeegee assembly,
make sure vacuum hose forms a trap using rubber
band provided (Figure 5).
4.
5
FIG. 5 5
INSTALLING BRUSHES/PADS
(DISC SCRUB HEAD MODEL)
NOTE: Consult an authorized distributor for pad/brush
recommendations.
1. Press bottom half of brush pressure switch until
scrub head is completely raised (Figure 6).
1.
6
FIG. 6 6
2. Turn key to the off position.
2.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface, turn off machine,
and set parking brake, if equipped.
3. Attach pads to pad drivers before installing drivers.
Secure pad with centerlock (Figure 7).
3.
7
FIG. 7 7

15
Tennant 5400 (02-03)
OPERATION
4. Align brush/pad driver under motor hub and push
driver upward to engage. Be certain that brushes/
pad drivers are secure before operating machine
(Figure 8).
4.
8
FIG. 8 8
5. To remove brush/pad drivers: raise scrub head,
turn machine off, remove key and push brush
release knobs downward (Figure 9).
5.
9
FIG. 9 9
(CYLINDRICAL BRUSH SCRUB HEAD MODEL)
See REMOVING BRUSHES/PADS.
INSTALLING FAST™PAK AGENT (OPTION)
FaST™PAK
Machine must be equipped with the FaST™Option.
FaST™
1. Remove the perforated knock-outs from the FaST™
PAK 365 Floor Cleaning Concentrate carton. Do
not remove the bag from the carton. Pull out the
bag's hose connector at the bottom of the bag and
remove the orange hose cap from the connector
(Figure 10).
1. FaST™PAK 365
10
ATTENTION: The FaST™PAK 365 Floor Cleaning
Concentrate is specifically designed for the
FaST™system scrubbing application. NEVER use
a substitute, machine damage will result.
FaST™PAK 365
FaST™
FOR SAFETY: When using machine, always follow
the handling instructions on chemical container.
FIG. 10 10

16 Tennant 5400 (02-03)
OPERATION
2. Place the FaST™PAK carton in the carton holder
at the rear of the machine and connect the supply
hose to the FaST™PAK bag (Figure 11).
2. FaST™PAK
FaST™PAK
11
FIG. 11 11
NOTE: If any dried concentrate is visible on the supply
hose connector or on the FaST™PAK connector, soak
and clean with warm water.
FaST™PAK
3. Make sure to connect the supply hose onto the
hose storing plug when not in use (Figure 12). This
will prevent the FaST™solution system from drying
out and clogging up the supply hose.
3.
12 FaST™
FIG. 12 12
4. The FaST™solution system MUST be primed for
first time use. To prime system, make sure the
solution tank is empty and operate the machine in
the FaST™Scrub Mode for 3 minutes (See
MACHINE OPERATION). This step is only
required for first time FaST™ system use.
4. FaST™
FaST™
3
FaST™
FILLING SOLUTION TANK
ATTENTION: When using the FaST™system
(option), USE CLEAR COOL WATER ONLY. DO NOT
add cleaning agents in solution tank. Conventional
cleaning agents/restorers may cause failure to the
FaST™solution system.
FaST™
FaST™
1. Transport machine to filling station. Raise
squeegee and scrub head when transporting.
1.
2. Turn key to the off position.
2.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface, turn off machine,
and set parking brake, if equipped.

17
Tennant 5400 (02-03)
OPERATION
5. If equipped with ES™option, pour between 19 and
38 liters (5 and 10 gal) of hot water, 60°C (140°F)
maximum, into recovery tank (Figure 14) (See
OPERATING ES™OPTION).
5. ES™19 38 5
10 60°C
(140°F) 14 ES™
FIG. 14 14
MACHINE OPERATION
FOR SAFETY: Do not operate machine, unless
operation manual is read and understood.
PRE-OPERATION CHECKS
1. Sweep and dust-mop floor (disc brush model only).
1.
2. Check battery meter's charge level, machine must
be in full operation for correct reading.
2.
3. Check that pads/brushes are installed.
3.
4. Lower pads/brushes to floor and check that scrub
skirt touches floor all the way around scrub head.
4.
5. Check that squeegee is installed and condition of
squeegee blades.
5.
3. Remove fill-port cover at front of machine and fill
solution tank with hot clean water, 60°C (140°F)
maximum. The clear hose at rear of machine
indicates amount of water in solution tank
(Figure 13).
3.
60°C (140°F)
13
FIG. 13 13
4. For conventional scrubbing, pour a recommended
cleaning detergent into the solution tank according
to mixing instructions on bottle. For FaST™
scrubbing (Option), DO NOT add cleaning agents
in solution tank.
4.
FaST™
FOR SAFETY: When using machine, follow mixing
and handling instructions on chemical containers.
ATTENTION: Use only recommended cleaning
detergents for conventional scrubbing, DO NOT
use substitutes. Consult an authorized distributor
for cleaning detergent recommendations.
WARNING: Do Not Use Flammable Liquids Or
Operate Machine In Or Near Flammable Liquids,
Vapors Or Combustible Dusts.

18 Tennant 5400 (02-03)
OPERATION
6. Check that debris trough is installed and empty
(cylindrical brush model).
6.
7. FaST™scrubbing (option): Make sure that the
solution tank is filled with clear cool water only.
All conventional cleaning agents/restorers must be
drained and rinsed from solution tank. Check
FaST™PAK agent level, replace carton as needed.
7. FaST™
FaST™PA K
OPERATING MACHINE
NOTE: If your machine is equipped with the FaST™or
ES™Option, refer to pages 20 and 22 for additional
operation procedures.
FaST™ES™
20 22
1. Release parking brake, if equipped (Figure 15).
1.
15
FIG. 15 15
2. Adjust control console to a comfortable operating
height, 5 settings. To adjust height, pull control
console trigger and lift or lower console to desired
height, release trigger to lock position (Figure 16).
2. 5
16
FIG. 16 16
3. Turn key and solution switch to the on position.
3.
4. To conventional scrub with a FaST™model, make
sure the FaST™system switch is in the off (O)
position (Figure 17).
4. FaST™
FaST™(O)
17
FIG. 17 17

19
Tennant 5400 (02-03)
OPERATION
5. Lower squeegee assembly to floor using squeegee
lift lever, vacuum motor will automatically turn on
(Figure 18).
5.
18
FIG. 18 18
6. Press top half of brush pressure switch to lower
scrub head to floor (Figure 19).
6.
19
FIG. 19 19
NOTE: Brushes and solution will start when control
grips are rotated.
7. Turn speed control knob to slowest setting
(Figure 20).
7. 20
FIG. 20 20
8. Rotate control grips completely forward and
gradually turn speed control knob to a desired
maximum scrubbing speed (Figure21).
8.
21
FIG. 21 21
9. Turn solution flow knob to desired solution flow rate
(Figure 22).
9.
22
FIG. 22 22

20 Tennant 5400 (02-03)
OPERATION
NOTE: When scrubbing with the FaST™Option, the
solution flow is pre-set by the FaST™system.
FaST™
FaST™
10.Observe brush pressure meter while operating.
Meter should read within the green zone, press
brush pressure switch to adjust (Figure 23).
10.
23
FIG. 23 23
ATTENTION: Do not operate machine with the pad
pressure meter in the red zone, circuit breakers
will trip and floor damage may occur.
11.To operate machine in reverse, gradually rotate
control grips backwards.
11.
12.To stop scrubbing, release control grips, raise
scrub head and squeegee.
12.
13.After scrubbing, perform the Daily Maintenance
procedures (See MACHINE MAINTENANCE).
13.
EMERGENCY STOPPING (OPTION)
In the event of an emergency while operating, strike
the power kill button at rear of control console to halt
machine. Turn button clockwise to reset (Figure 24).
24
FIG. 24 24
OPERATING FAST™SCRUB SYSTEM (OPTION)
FaST™
How the FaST™System operates (Foam Scrubbing
Technology). The FaST™PAK concentrate agent is
injected into the system with a mixture of a small
amount water and compressed air. This mixture
creates a large volume of expanded wet foam. The
expanded foam mixture is then dispersed onto the
floor while two scrubbing discs go to work. By the time
the squeegee picks up the mixture, the patented
foaming agent has collapsed and recovered into the
recovery tank. By performing the FaST™system
application, you can increase your productivity rate by
30% by reducing your dump/fill cycle. You will also
reduce your chemical usage and storage space. One
FaST™PAK of concentrated agent allows you to
scrub up to 1 million sq. ft.
FaST™
FaST™PA K
FaST™
30%