Tennant 5540 Product manual

ENGLISH - ESPAÑOL
Automatic Floor Scrubber
Fregadora Automática
5540/5560
Operator and Parts Manual
Manual del Operador y Piezas
607508
Rev. 04 (12-06)
Model No.:
607506 -- 5540
607507 -- 5540 Quick Ship Pack
607541 -- 5560
607542 -- 5560 Quick Ship Pack

OPERATION
2Tennant 5540/5560 (12--06)
This manual is furnished with each new model. It
provides necessary operation and maintenance
instructions and an illustrated parts list.
Read this manual completely and understand the
machine before operating or servicing it.
Use the illustrated Parts Lists to order parts. Before
ordering parts or supplies, be sure to have your
machine model number and serial number handy.
Parts and supplies may be ordered by phone or mail
from any authorized parts and service center,
distributor or from any of the manufacturer’s
subsidiaries.
This machine will provide excellent service. However,
the best results will be obtained at minimum costs if:
SThe machine is operated with reasonable care.
SThe machine is maintained regularly - per the
maintenance instructions provided.
SThe machine is maintained with manufacturer
supplied or equivalent parts.
PROTECT THE ENVIRONMENT
Please dispose of packaging materials,
old machine components such as
batteries, hazardous fluids such as
antifreeze and oil, in a safe
environmentally way according to your
local waste disposal regulations.
Always remember to recycle.
Tennant Company
PO Box 1452
Minneapolis, MN 55440
Phone: [phone] or (763) 513--2850
www.tennantco.com
Specifications and parts are subject to change without notice.
Copyright E1999, 2000, 2001, 2005, 2006 Tennant Company.
All rights reserved. Printed in U.S.A.
MACHINE DATA
Please fill out at time of installation for future reference.
Model No.-
Install. Date -
Serial No.-

OPERATION
Tennant 5540/5560 (08--05) 3
TABLE OF CONTENTS (ESPAÑOL ÍNDICE....21)
SAFETY PRECAUTIONS 4.........................
SAFETY LABELS 5................................
MACHINE COMPONENTS 6........................
MACHINE INSTALLATION 7........................
UNCRATING MACHINE 7.......................
INSTALLING BATTERIES 7.....................
MACHINE SETUP 8................................
ATTACHING SQUEEGEE ASSEMBLY 8..........
INSTALLING BRUSH OR PAD DRIVERS 8........
FILLING SOLUTION TANK 9....................
MACHINE OPERATION 10...........................
PRE--OPERATION CHECKS 10...................
OPERATING THE MACHINE 10...................
WHILE OPERATING MACHINE 11................
CIRCUIT BREAKERS 12.........................
DRAINING TANKS 12...............................
DRAINING RECOVERY TANK 12.................
DRAINING SOLUTION TANK 12..................
CHARGING BATTERIES 13..........................
MACHINE MAINTENANCE 14........................
DAILY MAINTENANCE 14........................
MONTHLY MAINTENANCE 15....................
QUARTERLY MAINTENANCE 15.................
BATTERY MAINTENANCE 15....................
DRIVE CHAIN MAINTENANCE 16.................
TRANSPORTING MACHINE 16.......................
STORING MACHINE 16.............................
RECOMMENDED STOCK ITEMS 17..................
TROUBLE SHOOTING 17............................
SPECIFICATIONS 19................................
ELECTRICAL DIAGRAM 39..........................
PARTS LIST 40.....................................
REPLACEMENT BRUSHES AND PAD
DRIVER GROUP 40.............................
RECOVERY TANK GROUP 42....................
CHASSIS GROUP 44............................
CONTROL CONSOLE GROUP 46.................
LEVER GROUP 48..............................
ELECTRICAL PANEL GROUP 50.................
DRIVE WHEEL GROUP 52.......................
BRUSH DRIVE AND SOLUTION HOSE GROUP 54..
SKIRT GROUP -- 5540 MODEL 56.................
SKIRT GROUP -- 5560 MODEL 57.................
SQUEEGEE CONTROL GROUP 58...............
CURVED SQUEEGEE GROUP -- 5540 MODEL 60..
CURVED SQUEEGEE GROUP -- 5560 MODEL 62..
OPTIONS 64.......................................
ES (EXTENDED SCRUB) KIT 64..................
WET PICK--UP TOOL KIT 66.....................

OPERATION
4Tennant 5540/5560 (08--05)
SAFETY PRECAUTIONS
This machine is intended for 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 warning 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, electrical shock, fire or explosion.
WARNING: Fire Or Explosion Hazard:
-- Never 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.
-- Do Not Pick Up Flammable Materials Or
Reactive Metals.
-- Batteries Emit Hydrogen Gas. Keep Sparks
And Open Flame Away. Keep Battery
Compartment Open When Charging.
WARNING: Electrical Hazard. Disconnect
Battery Cables Before Servicing Machine.
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 no--slip shoes.
-- Reduce speed when turning.
-- 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.
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.
-- Disconnect battery connections before
working on machine.
-- Wear protective gloves and eye protection
when handling batteries or battery cables.
-- Avoid contact with battery acid.
-- Do not power spray or hose off machine.
Electrical malfunction may occur.
-- Use manufacturer supplied or approved
replacement parts.
-- All repairs must be performed by a
qualified service person.
-- Do not modify the machine from its
original design.

OPERATION
Tennant 5540/5560 (08--05) 5
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.
-- Use tie--down straps to secure machine to
truck or trailer.
SAFETY LABELS
The safety labels appear on the machine in the locations indicated. Replace labels if they are missing or become
damaged or illegible.
WARNING LABEL -- LOCATED ON THE RECOVERY TANK.
BATTERY CHARGE LABEL --
LOCATED IN BATTERY COMPARTMENT.
WARNING: Fire Or Explosion
Hazard. Batteries Emit Hydrogen
Gas. Keep Sparks And Open Flame
Away. Keep Battery Compartment
Open When Charging.

OPERATION
6Tennant 5540/5560 (08--05)
MACHINE COMPONENTS
1
2
8910
14
11
12
16
15
7
17
13
26
5
6
3
4
19
18
20
25
22
24
25
23
21
1. Control Console
2. Control Grips
3. Main ON/OFF switch
4. Vacuum ON/OFF Switch
5. Brush ON/OFF Switch
6. Battery Meter
7. Circuit Breakers
8. Squeegee Lift Lever
9. Squeegee Release Lever
10. Solution Flow Lever
11. Solution Flow Adjustment Knob
12. Adjustable Control Console Levers
13. Scrub Head Lift Foot Pedal
14. Recovery Tank Drain Hose
15. Solution Tank Drain Hose with Gallon Markers
16. Rear Fill Port
17. Squeegee Assembly
18. Recovery Tank
19. Recovery Tank Lid
20. Solution Fill Door
21. Safety Lights
22. Rear Casters
23. Skirt Housing
24. Scrub Head Skirt
25. Wall Rollers
26. Brush Pressure Lever

OPERATION
Tennant 5540/5560 (08--05) 7
MACHINE INSTALLATION
UNCRATING MACHINE
1. Carefully check the shipping crate for signs of
damage. Report damages at once to carrier.
2. Check the contents list. Contact distributor for
missing items.
Contents:
S4--6V Batteries -- Optional
S1--Battery Charger -- Optional
S1--Battery Plate (#100707)
S3--Battery Cables (#130367)
S1--Squeegee Assembly
Pad drivers, brushes and pads must be purchased
separately.
3. To uncrate your machine, remove the shipping
hardware and straps that secure the machine to
the pallet. With assistance, carefully lift the
machine off the pallet.
ATTENTION: Do not roll machine off pallet unless
a ramp is used, machine damage may occur.
ATTENTION: To prevent possible machine
damage, install batteries after removing machine
from shipping pallet.
INSTALLING BATTERIES
WARNING: Fire Or Explosion Hazard.
Batteries Emit Hydrogen Gas. Keep Sparks And
Open Flame Away. Keep Battery Hood Open When
Charging.
FOR SAFETY: When servicing machine, wear
protective gloves and eye protection when
handling batteries and battery cables. Avoid
contact with battery acid.
Battery Specifications:
Four 6 volt, deep cycle, 305 amp hour batteries. Part
Number #606991. Maximum battery dimensions are
178mm (7 in.) W x 308mm (12.13 in.) L x 356mm
(14 in.) H.
1. Turn all switches to the off position and pull out the
main (10 amp) circuit breaker button as shown
(Figure 1).
FIG. 1
ATTENTION: To prevent motors from accidental
starting, be certain to pull out the main circuit
breaker button before installing batteries.
2. Carefully hinge open recovery tank to access
battery compartment. Remove loose battery
cables from compartment (Figure 2).
FIG. 2
3. Carefully install batteries into compartment and
arrange battery posts as shown (Figure 3).
ATTENTION: Do not drop the batteries into the
compartment, battery and machine housing
damage may result.
FRONT
FIG. 3
4. Before connecting the battery cables, make sure
the terminals and posts are clean. Use a post
cleaner and wire brush if necessary.

OPERATION
8Tennant 5540/5560 (08--05)
NOTE: Apply a light coating of non-metallic grease or
protective spray on the cable connections to prevent
battery corrosion.
5. Connect cables to battery posts in numerical order
as labeled, RED TO POSITIVE & BLACK TO
NEGATIVE (Figure 3).
6. Double check cable connections before closing up
battery compartment.
7. Reset the main circuit breaker button.
8. Turn main switch on, and check battery meter
charge level to ensure batteries are fully charged.
If batteries need charging, see CHARGING
BATTERIES.
MACHINE SETUP
ATTACHING SQUEEGEE ASSEMBLY
1. Turn main switch to the off position.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
2. Pull back on squeegee lift lever to raise squeegee
mount bracket (Figure 4).
FIG. 4
3. Loosen two thumb knobs on squeegee and slide
squeegee into slots at rear of squeegee mount
bracket (Figure 5).
FIG. 5
4. Tighten thumb knobs securely.
5. Connect the vacuum hose from the machine to the
squeegee assembly (Figure 6).
FIG. 6
INSTALLING BRUSHES OR PAD DRIVERS
1. Turn main switch to the off position and pull out
the main circuit breaker button.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
ATTENTION: To prevent accidental starting, pull
out the main circuit breaker button before
installing brush or pad drivers. Circuit breaker
button is located at rear of control housing.
2. Raise scrub head. Step down firmly on bottom
brush lift foot pedal to raise (Figure 7).
FIG. 7

OPERATION
Tennant 5540/5560 (08--05) 9
3. Unfasten black latch at front of machine and hinge
open skirt housing to access motor hub (Figure 8).
FIG. 8
4. Select recommended pad or brush that best
meets your cleaning needs.
NOTE: Consult your authorized distributor for pad and
brush recommendations.
5. (For Pad Installation) Attach pads to pad drivers
before connecting drivers to motor hub. To attach
pad to driver, remove plastic centerlock ring from
pad driver. Position pad on pad driver and replace
centerlock ring (Figure 9).
FIG. 9
6. Attach brush/pad drivers to motor hubs. Align (3)
mounting studs with slots in motor hub. Give driver
a quick turn toward spring clip located on motor
hub. Be certain pad driver is securely fastened
and spring clip locks into one of the studs before
operating machine (Figure 10).
FIG. 10
NOTE: Always make sure pad driver and motor hub
surfaces are clean before installing drivers. Keeping
surfaces clean will make it easier when removing pad
drivers.
7. Close skirt housing and refasten latch.
FILLING SOLUTION TANK
1. Transport machine to filling station. Raise
squeegee and brush when transporting.
2. Turn off machine.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
3. Shut off solution flow. Pull solution flow lever
completely back to shut off (Figure 11).
FIG. 11
4. Open solution fill door at front of machine and fill
solution tank with clean water, 60°C (140°F)
maximum temperature. Or you can fill solution
tank using hose fill port at rear of machine. Pull off
plug and insert hose to fill. The clear tube below
the fill port has 19L (5 gallon) increment markers
to indicate amount of water in tank (Figure 12).
NOTE: The water must not be hotter than 60_C
(140_F) or tank damage may occur.
FIG. 12
NOTE: If filling with a bucket be certain that bucket is
clean. This will prevent possible solution line clogs.

OPERATION
10 Tennant 5540/5560 (08--05)
5. Pour a recommended cleaning detergent into the
solution tank according to mixing instructions on
the bottle.
ATTENTION: Only use recommended cleaning
detergents. Machine damage due to improper
detergent usage will void the manufacturer’s
warranty.
WARNING: Fire or Exposion Hazard.
Never Use Flammable Liquids.
FOR SAFETY: When using machine, follow mixing
and handling instructions on chemical containers.
MACHINE OPERATION
FOR SAFETY: Do not operate machine unless
operator manual is read and understood.
WARNING: Fire or Explosion Hazard. Never
Operate Machine In Or Near Flammable Liquids,
Vapors Or Combustible Dusts.
PRE--OPERATION CHECKS
1. Sweep and dust mop the floor.
2. Check battery meter charge level to ensure
batteries are fully charged (See CHARGING
BATTERIES).
3. Check that pads or brushes are installed.
4. Check that squeegee is installed.
OPERATING THE MACHINE
1. Adjust control grips to a comfortable operating
height (three settings). Squeeze two levers
together, located under console, to raise and lower
control grips (Figure 13).
FIG. 13
2. Lower squeegee. Depress thumb lever on
squeegee lift lever to lower (Figure 14).
FIG. 14
3. Lower scrub head. Depress top brush lift foot
pedal forward to lower (Figure 15).
FIG. 15
4. Turn on the main, vacuum and brush switches.
NOTE: The brush motors will not start until control
grips are rotated.
5. Activate solution flow. Push solution flow lever
slightly forward to activate. The further the lever is
pushed forward the more solution will flow. Push
completely forward for maximum flow. Solution will
immediately begin to flow once lever is activated
(Figure 16).
FIG. 16

OPERATION
Tennant 5540/5560 (08--05) 11
NOTE: To increase or decrease the maximum solution
flow, turn solution flow adjustment knob (for
conventional scrubbing only). Turn knob clockwise to
decrease solution flow or counterclockwise to increase
(Figure 17).
FIG. 17
6. Slowly rotate control grips forward to begin
scrubbing. The machine will continue to gain
speed the further you rotate grips. To drive
machine in reverse, simply rotate control grips
backwards.
ATTENTION: Always start machine out slowly to
prevent machine from leaping forward.
7. View amount of solution flow on floor and adjust
solution control lever to desired solution flow (for
conventional scrubbing only).
8. To stop machine, release control grips.
WHILE OPERATING MACHINE
FOR SAFETY: When using machine, go slow on
inclines and slippery surfaces.
WARNING: Fire Or Explosion Hazard. Do Not
Pick Up Flammable Materials Or Reactive Metals.
1. Overlap each scrubbing path by 2 inches (5 cm).
2. Pour a recommended foam control solution into
the recovery tank if excessive foam appears.
ATTENTION: Do not allow foam or water to enter
the float shut-off screen, vacuum motor damage
will result. Foam will not activate the float shut-off
screen.
3. If more scrubbing pressure is needed for small
heavily soiled areas, follow steps below:
a. Lower brush.
b. Lift brush pressure lever to the locked position
(Figure 18).
NOTE: Brush MUST be down to allow brush pressure
lever to be lifted to the locked position. Do not leave
lever in the lock position when brushes are raised.
FIG. 18
4. If squeegee leaves streaks, raise and wipe blades
with a cloth. Pre--sweep area to prevent streaking.
5. Before stopping or turning machine around, pull
back on solution control lever to shut off solution
flow.
6. During brief stops, you do not have to turn off
brush switch, the brush will automatically stop
when control grips are released.
7. While cleaning, view clear tube gallon marker for
remaining cleaning solution. Each mark on hose
indicates 19 liters (5 gal).
8. Periodically check battery meter discharge level.
When needle drops to the red zone, recharge
batteries.
ATTENTION: Do not continue to run machine
when battery meter needle is in the red zone,
battery damage will result.
9. When solution tank runs dry, turn off brush switch,
shut off solution control lever and continue to
vacuum until all dirty water is consumed. Then
drain recovery tank (See DRAINING TANKS).

OPERATION
12 Tennant 5540/5560 (08--05)
CIRCUIT BREAKERS
The machine is equipped with (4) circuit breakers to
protect motors from damage. If circuit breakers trip,
they cannot be reset immediately. Determine reason
why breaker tripped, allow motor to cool and then
reset. Brush motor circuit breakers will trip due to
excessive overload on pad. Clean or change pad if
breaker should trip. Circuit breaker buttons are
located at rear of machine as shown (Figure 19).
-- 10A Main Circuit Breaker
-- 35A Drive Motor/Vacuum Circuit Breaker
-- 35A Brush Motor Circuit Breaker (2)
FIG. 19
NOTE: When servicing machine or when machine is
left unattended, pull out the Main circuit breaker
button. This will shut off all power to machine.
DRAINING TANKS
The recovery tank should be drained and cleaned out
after every use. The solution tank should be cleaned
out periodically to remove any corrosion.
Transport the machine to a draining site, turn the key
off and follow the draining instructions below:
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
DRAINING RECOVERY TANK
1. Remove drain hose from holder, position hose
over floor drain and twist off drain hose cap. To
completely drain recovery tank, hinge open tank
and flip up tank support stand to rest tank on
(Figure 20).
NOTE: If using a bucket to drain machine, do not use
same bucket for filling solution tank. This will prevent
possible solution line clogs.
FIG. 20
2. Rinse out recovery tank after each use. This will
prevent foul odor buildup. Use a hose to rinse out
the recovery tank. Be careful not to spray water
into shut--off float screen.
DRAINING SOLUTION TANK
1. Pull clear hose off hose barb at rear of machine
and drain solution into floor drain or bucket
(Figure 21).
FIG. 21
2. Rinse out solution tank with clean water after each
use and flush out solution flow system by pushing
solution flow lever forward. This will prevent
clogging due to chemical buildup. Use clear hose
to drain solution tank.
3. Reconnect clear hose to hose barb. Be certain
hose is completely pushed onto hose barb.

OPERATION
Tennant 5540/5560 (08--05) 13
CHARGING BATTERIES
ATTENTION: To prolong the life of the batteries
and to provide optimum machine performance,
ONLY recharge the batteries after a total of 30
minutes of use or more. Do not leave batteries
discharged for lengthy periods.
The following charging instructions are intended for
battery chargers supplied with the machine. Only use
a battery charger with the following specifications to
prevent battery damage.
BATTERY CHARGER SPECIFICATIONS:
SCHARGER TYPE: FOR LEAD ACID BATTERIES
SOUTPUT VOLTAGE -- 24 VOLTS
SOUTPUT CURRENT -- 25 AMPS
SAUTOMATIC SHUT--OFF CIRCUIT
SFOR DEEP CYCLE BATTERY CHARGING
1. Transport machine to a well ventilated area for
charging.
WARNING: Fire Or Explosion Hazard.
Batteries Emit Hydrogen Gas. Keep Sparks And
Open Flame Away. Keep Battery Compartment
Open When Charging.
2. Before charging the batteries, check the
electrolyte level in each battery cell (Figure 22).
FIG. 22
FOR SAFETY: When servicing machine, wear
protective gloves and eye protection when
handling batteries and battery cables. Avoid
contact with battery acid.
The electrolyte level (A) should slightly cover the
battery plates (B). Add distilled water as needed.
DO NOT OVERFILL, the fluid may expand and
overflow while charging. Replace cell caps before
charging (Figure 23).
A
B
FIG. 23
3. Connect the charger’s AC power supply cord to a
properly grounded receptacle (Figure 24).
Grounded
3HoleOutlet
Ground Pin
FIG. 24
4. Plug charger’s DC output connector to battery
connector located near battery compartment
(Figure 25).
FIG. 25
5. The charger will automatically begin charging and
shut off when fully charged.

OPERATION
14 Tennant 5540/5560 (08--05)
6. Rest the recovery tank on the support stand to
promote ventilation during charging (Figure 26).
FIG. 26
ATTENTION: Do not disconnect the charger’s DC
cord from the machine’s receptacle when the
charger is operating. Arcing may result. If the
charger must be interrupted during charging,
disconnect the AC power supply cord first.
WARNING: Fire Or Explosion Hazard.
Batteries Emit Hydrogen Gas. Keep Sparks And
Open Flame Away. Keep Battery Compartment
Open When Charging.
7. Lead Acid Batteries: After charging, check the
electrolyte level (A) again. The level should be
approximately 1 cm from the bottom of the fill--port
(B) (Figure 27). Add distilled water if needed. DO
NOT OVERFILL.
A
B
FIG. 27
MACHINE MAINTENANCE
To keep the machine in good working condition, simply
follow the daily, monthly and quarterly maintenance
procedures.
WARNING: Electrical Hazard. Disconnect
Battery Cables Before Servicing Machine.
DAILY MAINTENANCE
(After Every Use)
1. Remove and clean pads or brushes. Never use
soiled pads when cleaning. Replace pads when
they become loaded with residue.
2. Remove and clean lint from float shut--off screen
located in recovery tank (Figure 28).
FIG. 28
3. Drain and rinse tanks thoroughly. After draining
tanks, hinge recovery tank until you can see
vacuum intake hole at rear of tank. Remove any
clogging debris in hole if necessary.
4. Raise squeegee and wipe it down with a dry cloth.
Store squeegee in the up position to prevent
squeegee damage.
5. Clean machine housing with a nonabrasive,
non--solvent cleaner.
FOR SAFETY: When cleaning machine, do not
power spray or hose off machine. Electrical
malfunction may occur.
6. Recharge the batteries after a total of 30 minutes
of use or more (See CHARGING BATTERIES).

OPERATION
Tennant 5540/5560 (08--05) 15
MONTHLY MAINTENANCE
(Every80HoursofUse)
1. Check water level in battery cells (See BATTERY
MAINTENANCE).
2. Clean battery tops to prevent corrosion
(See BATTERY MAINTENANCE).
3. Check for loose or corroded battery cables.
4. Check drive chain for excess slack and lubricate
with a water resistant grease. If chain needs
tightening, see DRIVE CHAIN MAINTENANCE.
5. Lubricate axle and caster grease fittings with a
water resistant grease.
6. Lubricate all linkage pivot points with silicone
spray then coat with a water resistant grease to
maintain a smooth operation.
7. Check machine for water leaks and loose nuts and
bolts.
QUARTERLY MAINTENANCE
(Every 250 Hours of Use)
Inspect motors for carbon brush wear. Replace
brushes when worn to a length of 10mm (0.38 in.) or
less. Contact an Authorized Service Center for carbon
brush inspection.
Contact an Authorized Service Center for motor
maintenance.
BATTERY MAINTENANCE
WARNING: Fire Or Explosion Hazard.
Batteries Emit Hydrogen Gas. Keep Sparks And
Open Flame Away. Keep Battery Compartment
Open When Charging.
FOR SAFETY: When servicing machine, wear
protective gloves and eye protection when
handling batteries and battery cables. Avoid
contact with battery acid.
1. Check the specific gravity using a hydrometer to
determine the charge level and the condition of the
batteries (Figure 29). If one or more of the battery
cells read lower than the other battery cells (0.050
or more), the cell is damaged, shorted, or is about
to fail. Check the hydrometer readings against the
following chart to determine the remaining battery
charge level.
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.
FIG. 29
SPECIFIC GRAVITY
at 27_C(80_F) BATTERY
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(43_F) above or below 27_C(80_F).
2. Always follow proper charging instructions
(See CHARGING BATTERIES).
3. Check the electrolyte level (A) in each battery cell
after charging batteries. The level should be
approximately 1 cm from the bottom of the fill--port
(B). Add distilled water if needed (Figure 30).
DO NOT OVERFILL.
A
B
FIG. 30
4. Keep the battery tops clean to prevent battery
corrosion.
To clean batteries:
FOR SAFETY: When servicing machine, wear
protective gloves and eye protection when
handling batteries and battery cables. Avoid
contact with battery acid.

OPERATION
16 Tennant 5540/5560 (08--05)
a. Mix a strong solution of baking soda and water
(Figure 31).
FIG. 31
b. Brush the solution sparingly over the battery
tops and cable connectors.
NOTE: Do not allow baking soda solution to enter
battery cells.
c. Use a wire brush to clean the battery terminals
and cable connectors.
d. After cleaning, apply a coating of clear battery
post protectant to the terminals and cable
connectors.
5. Check for loose or worn cables. Replace if worn.
DRIVE CHAIN MAINTENANCE
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
Inspect drive chain for proper tension. Chain should
flex between 6.35mm (0.25 in.) and 12.7mm (0.50 in.)
from center. If chain flexes more than 12.7mm
(0.50 in.), chain should be tightened. To tighten chain,
follow steps below:
1. Turn main switch to the off position and pull out
the main circuit breaker button.
2. From operators right side of machine, locate and
loosen 4 motor mount bolts, do not remove bolts.
3. Loosen locking nut on tension bolt (Figure 32).
FIG. 32
4. Turn tension bolt clockwise until chain is taut.
5. Retighten locking nut and 4 motor mount screws.
6. Lubricate chain with a water resistant oil.
TRANSPORTING MACHINE
When transporting machine by use of trailer or truck,
be certain to follow tie--down procedures below:
FOR SAFETY: When using machine, go slow on
inclines and slippery surfaces.
1. Remove squeegee from machine and raise brush
head. Leave pad or brush installed.
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 brush
head.
4. Place a block behind the drive wheel and the rear
casters.
5. Place tie--down straps over top of machine and
secure straps to floor. It may be necessary to
install tie--down brackets to the floor of your trailer
or truck.
STORING MACHINE
1. Before storing machine, be certain to flush tanks
and drain machine of all water.
2. Store machine in a dry area with squeegee
removed and pad driver in the raised position.
3. Remove recovery lid to promote air circulation.
4. When storing machine for short periods, raise pad
driver and squeegee off floor to prevent damage.
ATTENTION: If storing machine in freezing
temperatures, be certain to drain machine of all
water. Damage due to freezing temperatures is not
covered by warranty.
ATTENTION: Do not expose machine to rain; store
indoors.

OPERATION
Tennant 5540/5560 (08--05) 17
RECOMMENDED STOCK ITEMS
Refer to the Parts List section for recommended stock
items. Stock Items are clearly identified with a bullet
preceding the parts description. See example below:
TROUBLE SHOOTING
PROBLEM CAUSE SOLUTION
No power, nothing runs. Batteries need charging. See CHARGING BATTERIES.
Faulty battery(s). Replace battery(s).
Loose battery cable. Tighten loose cable.
Battery connection is improper. See INSTALLING BATTERIES.
Faulty Main switch Contact Service Center.
Main circuit breaker has tripped. Determine cause and reset circuit
breaker button.
Brush motor does not run. Brush circuit breakers have
tripped, or has been pulled out. Clean or change to a less aggres- sive pad. Also, release brush
pressure lever if it’s in the up posi-
tion. Reset breaker button.
Control grips are not twisted. Control grips must be twisted to
activate brushes.
Faulty brush motor or wiring. Contact Service Center.
Faulty brush switch. Contact Service Center.
Carbon brushes worn. Contact Service Center.
Faulty solenoid. Contact Service Center.
Vacuum motor does not run. Vacuum circuit breaker has
tripped. Remove obstruction and reset breaker.
Faulty vacuum switch. Contact Service Center.
Faulty vacuum motor or wiring. Contact Service Center.
Faulty solenoid. Contact Service Center.
Carbon brushes worn. Contact Service Center.
Short run time. Batteries not fully charged. Charge batteries.
Bad cell in one or more batteries. Replace battery.
Batteries need maintenance. See BATTERY MAINTENANCE.
Faulty charger. Replace battery charger.

OPERATION
18 Tennant 5540/5560 (06--01)
TROUBLE SHOOTING --continued
PROBLEM CAUSE SOLUTION
Poor squeegee pick up. Recovery tank is full. Empty recovery tank.
Ball float shutoff screen inside
recovery tank is clogged. Remove screen and clean.
Squeegee is clogged with debris. Clean squeegee.
Squeegee blades are worn. Replace squeegee blades.
Squeegee thumbscrews are loose. Tighten thumbscrews.
Vacuum hose connections are
loose or hose has a hole. Push hose cuffs firmly on connec- tions. Replace hose if damaged.
Vacuum hose is clogged with
debris. Remove clogged debris.
Recovery tank water inlet is
plugged. Inlet is located at bottom
of recovery tank.
Empty recovery tank and tilt it
sideways to locate inlet hole,
remove clogged debris.
Tank gasket is defective. Replace gasket.
Drain hose plug is loose. Tighten drain plug.
Clear recovery tank lid is loose. Tighten lid.
Vacuum motor is loose. Contact Service Center.
Battery charge is low. Charge batteries. Do not run
machine when battery meter is in
the red zone.
Drive motor does not run. Main circuit breaker has tripped or
is pulled. Determine cause and reset breaker.
Faulty Main switch. Contact Service Center.
Faulty speed control circuit board
or connection. Contact Service Center.
Faulty solenoid. Contact Service Center.
Faulty wiring. Contact Service Center.
Faulty drive motor. Contact Service Center.
Worn carbon brushes. Contact Service Center.
Drive motor runs, but not correctly. Faulty potentiometer or speed
control board. Contact Service Center.
Faulty resistor. Contact Service Center.
Little or no solution flow. Solution flow lever in not activated. Push solution flow lever forward.
Solution line or filter is clogged. Remove hose and blow com-
pressed air through it. Flush solu-
tion tank after each use.
Solution valve is clogged. Remove valve and clean. Do not
scratch or damage inside of valve.
Solution flow adjustment knob
needs adjusting. Turn solution flow knob clockwise to increase flow.
Safety lights do not work. Flasher is burned out. Contact Service Center.

OPERATION
Tennant 5540/5560 (06--01) 19
SPECIFICATIONS
MODEL 5540 5560
LENGTH 1500 mm (59 in.) 1500 mm (59 in.)
WIDTH 740 mm (29 in.) 890 mm (35 in.)
HEIGHT 1040 mm (41 in.) 1040 mm (41 in.)
WEIGHT -- WITH BATTERIES 352kg (760 lbs) 355kg (765 lbs)
TANKS CAPACITY 102L (27 Gal) 102L (27 Gal)
SPEED CONTROL VARIABLE FWD/REV VARIABLE FWD/REV
CLEANING SPEED (MAX.) 2787 sq. m.(30,000 sq. ft.)/hr. 3251 sq. m. (35,000 sq. ft.)/hr.
CLEANING PATH WIDTH 680 mm (27 in.) 830 mm (33 in.)
PAD DIAMETER 2 -- 355 mm (14 in.) 2 -- 430 mm (17 in.)
SQUEEGEE WIDTH 965 mm (38 in.) 1067 mm (42 in.)
DRIVE MOTOR .5 h.p., 0--1800 rpm, 24V, 10A .5 h.p., 0--1800 rpm, 24V, 10A
BRUSH MOTOR 2 -- .75 h.p., 220 rpm, 24V, 20A, 550W 2 -- .75 h.p., 220 rpm, 24V, 20A, 550W
VACUUM MOTOR .75 h.p., 3--stage 5.7”, 24V, 21A, 550W .75 h.p., 3--stage 5.7”, 24V, 21A, 550W
WATER LIFT 1720 mm (68 in.) 1720 mm (68 in.)
BATTERIES 4--305A/hr, 6V deep cyc 4--305A/hr, 6V deep cyc
RUN TIME on full charge 4.76 Hours 4.76 Hours
DECIBEL RATING AT OPERATOR’S
EAR, INDOORS ON TILE. <70dB(A) <70dB(A)

OPERATION
20 Tennant 5540/5560 (08--05)