Tennant 5680 User manual

Drive Module Replacement Kit
KIT NO. 9011905 Page1of7
Model: 5680
9011904 Rev. 05 (04- 2018) Tennant Company www.tennantco.com
The original controller board p/n 397785 has been discontinued and replaced by this kit. The kit includes additional
parts for proper installation. Carefully follow the installation instructions as described below.
INSTALLATION INSTRUCTIONS:
Installation Time: 1.5 Hours
Special Tools Required: Ohmmeter to adjust
potentiometer
FOR SAFETY: Before servicing machine, stop
on level surface, turn off machine, and
remove key.
1. Disconnect the black (- ) battery cable from
battery pack.
2. Remove the two screws and the height
adjustment knob from the control console housing.
Lower housing to access control board (Figure 1).
Fig. 1
3. Remove electrical cover from control board.
Discard cover, it’s not required with new module
(Figure 2).
Disconnect the wire connections from old board
and remove board from machine (two screws).
Discard old board (Figure 2).
Fig. 2
9011905 Kit Contents
Ref Part No. Description Qty.
1 1212548 Module, Drive [D515113] 1
2 1206698 Harness, Drive, Adapter [5680] 1
3 1213069 Harness, Potentiometer 1
4 392894 Gauge, Discharge, Battery, 36v, w/gasket 1
5 1073600 Screw, Pan, m4 x 0.7 x 25, fmg 2
1
4
3
5
2
4. Mount the new module to panel. Using a 9/64”
drill bit, drill the top mounting hole location as
described. For the bottom hole, use the module
as a drill template (Figure 3).
Drill
bottom
hole
21/8in
[54 mm]
81/4in
[209.5 mm]
Attach
module
using
M4x25
Pan
Screw (2)
Old
board
hole
location
Drill top
hole
Use caution when drilling not to drill into tank.
Fig. 3

Drive Module Replacement Kit
INSTALLATION INSTRUCTIONS - Continued
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KIT NO. 9011905
9011904 Rev. 05 (04- 2018) Tennant Company www.tennantco.com
5. Reconnect the existing harness wires to the
new drive module as shown (Figure 4).
23A/Orange
13D/Black
21/Pink
22/Brown
Fig. 4
6. Connect the new wire harness to the new
drive module as shown (Figure 5)
Fig. 5
7. Disconnect the three potentiometer wire
connections (6/Blue, 5/Green and 4D/Yellow)
and remove the old potentiometer from machine
(Figure 6).
Remove Potentiometer
Potentiometer
Wires
Fig. 6
8. Connect wires (36/Blue, 35/Green &
44/Yellow) from the new wire harness to the wire
terminals that were disconnected in step 7
(Figure 7)
Fig. 7
9. Install the new potentiometer as shown
(Figure 8). Do not tighten the nut at this time.
The potentiometer will need to be properly
adjusted before tightening nut. Continue on next
page.
Potentiometer
Set
Screw
Nut
Star
Washers
(2)
Use second star washer from old potentiometer
Fig. 8

Drive Module Replacement Kit
INSTALLATION INSTRUCTIONS - Continued
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KIT NO. 9011905
9011904 Rev. 05 (04- 2018) Tennant Company www.tennantco.com
To properly adjust the potentiometer, measure the
potentiometer’s maximum ohm value using an
ohmmeter then divide the max. value by two to
find the center (neutral) position (Figure 9).
Example: Maximum value 5.0K ohms
 2=
2.5K ohms (+/- 10%) center position.
With the machine’s control grips at the neutral
position, rotate the body of the potentiometer up
or down until the reading on the ohmmeter is at
the center (neutral) position. Tighten nut.
2.5K (+/- 10%)
Center Position
Fig. 9
10. Connect the new potentiometer wire harness
to the new wire harness wires (white to 39/white,
red to1B/red and black to13AA/black) (Figure
10).
Fig. 10
11. Depending on when the machine was
manufactured, the PROPEL circuit breaker may
be positioned and identified as CB2 or CB3 as
shown below (Figure 11). Follow the below
instructions according to CB Panel configuration.
CB1
CB3 PROPEL
CB2
VAC
CB3
PROPEL
CB1
CB3
VAC
CB2
PROPEL
CB2 PROPEL
(Early Models)
Fig. 11
For models with CB3 PROPEL, disconnect wire
2/Brown from the propel circuit breaker (CB3) and
replace it with wire 1C/Red from the new wire
harness as shown (Figure 12). The disconnected
brown wire is not required for this kit. Wrap
electrical tape around the unused terminal.
Disconnect
wire 2/Brown Connect wire
1C/Red
Fig. 12
For early models with CB2 PROPEL, remove
wire 2A/Brown from propel circuit breaker (CB2)
and replace it with wire 1C/Red from new harness
(figure not shown). Also disable CB1 by removing
wires 3A/3C/Orange. CB1 is no longer needed
with new drive module.

Drive Module Replacement Kit
INSTALLATION INSTRUCTIONS - Continued
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KIT NO. 9011905
9011904 Rev. 05 (04- 2018) Tennant Company www.tennantco.com
12. Cut cable- tie to locate the charger interlock
wire connections within the machine’s wire
harness as shown (Figure 13). Remove the
electrical tape and disconnect the orange wire
from blue wires.
The disconnected orange wire is not required for
this kit. Wrap electrical tape around the unused
terminal. The disconnected orange wire disables
the 10A circuit breaker (CB1). CB1 is not
required for this kit.
NOTE: For early models, if harness is not
equipped with charger interlock wires as shown,
refertoStep13NOTE.
Disconnect orange
wire from blue wires
Charger interlock wires
Cut cable- tie and locate
charger interlock wires
Fig. 13
13. Connect wire 33/Orange from the new wire
harness to the blue charger interlock wires as
shown below (Figure )14. Re- wrap wire
connections with electrical tape. Re- secure the
machine harness wires with cable- tie.
NOTE: For early models, disconnect wire
3B/Orange from key switch and connect wire
33/Orange from new wire harness to key switch
(Figure not shown).
Connect wire
33/Orange
Fig. 14
14. Connect wire 13AC/Black from the new wire
harness to the contactor terminal (Figure 15).
Connect wire
13AC/Black
Fig. 15
15. Connect wire 1C/Red from the new wire
harness to the main contactor terminal as shown
(Figure 16).
Connect
wire 1C/Red
Fig. 16
16. Remove the old battery discharge indicator
(BDI) from control housing (Figure 17). Save
screws.
Fig. 17

Drive Module Replacement Kit
INSTALLATION INSTRUCTIONS - Continued
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KIT NO. 9011905
9011904 Rev. 05 (04- 2018) Tennant Company www.tennantco.com
17. Connect wires 13AB/Black and 34/Yellow from
the new wire harness to the yellow and black
wires that were disconnected from the old BDI
(Figure 18).
NOTE: The orange wire is no longer required
and can be removed from the machine.
Fig. 18
18. Install the new battery discharge indicator
(BDI) and connect the new wire harness as shown
(Figure 19). Discard the wire harness that is
packaged with the new BDI. It’s not required.
From new
wire harness
Fig. 19
19. Test machine for proper operation.

Drive Module Replacement Kit
INSTALLATION INSTRUCTIONS - Continued
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KIT NO. 9011905
9011904 Rev. 05 (04- 2018) Tennant Company www.tennantco.com
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KIT NO. 9011905
9011904 Rev. 05 (04- 2018) Tennant Company www.tennantco.com
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