Tennant 480 User manual

465
480
490
MM184
Rev. 12 (9–94)

This manual is furnished with each new TENNANT Model 465, 480, and 490. It provides necessary
operating and preventive maintenance instructions. Read this manual completely and understand the
machine before operating or servicing it.
This manual covers all machine variations and standard options. The instruction portion of the manual
consists of the Specification, Operation, Maintenance, and Appendix sections. The parts portion consists
of How to use this Manual; 465 Parts; 480 Parts; 480EE Parts; 490 Parts; Options; Breakdowns; and
Cross Reference.
All right side and left side references to the machine are determined by facing the direction of forward
travel. All hardware considered to be of a common nature or locally available has been omitted from the
parts sections. Be aware that this machine may contain metric hardware. Make sure you use equivalent
hardware when replacement becomes necessary.
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 maintenance instructions provided.
 The machine is maintained with TENNANT supplied or equivalent parts.
Parts and supplies may be ordered by phone or mail from any TENNANT parts and service center,
distributor, or from any of the TENNANT subsidiaries. Before ordering parts or supplies, be sure to have
your machine model number and serial number handy. Fill out the data block below for future reference.
The telephone numbers, telex numbers, mailing addresses, and locations of those outlets are listed in the
Customer Documents section of the manual.
MACHINE DATA
Please fill out at time of installation.
Machine Serial Number –
Engine Serial Number –
Sales Representative –
Customer Number –
Date of Installation –
Manual Number – MM184
Revision: 12
Published: 9–94
Trademark Registered in: Austria, Benelux, Denmark, England, France, Germany, Italy, Spain,
Switzerland, United States, Argentina, Australia, Canada, Japan, Mexico, Sweden, by TENNANT,
Minneapolis, Minnesota, U.S.A.
Copyright 1988, 1989, 1990, 1991, 1992, 1993, 1994 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
i
465/480/490MM184 (9–92)
SAFETY PRECAUTIONS
The following symbols are used throughout this
manual as indicated in their descriptions:
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.
The following information signals potentially
dangerous conditions to the operator or
equipment. Read this manual carefully. Know
when these conditions can exist. Locate all safety
devices on the machine. Then, take necessary
steps to train machine operating personnel.
Report machine damage or faulty operation
immediately. Do not use the machine if it is not in
proper operating condition.
FOR SAFETY:
1. Do Not Operate Machine:
–Unless Trained And Authorized.
–Unless Operation Manual Is Read And
Understood.
–In Flammable Or Explosive Areas
Unless Designed For Use In Those
Areas.
–In Areas With Possible Falling Objects
Unless Equipped With Overhead
Guard.
2. Before Starting Machine:
–Make Sure All Safety Devices Are In
Place And Operate Properly.
–Check Brakes And Steering For Proper
Operation (If So Equipped).
3. When Using Machine:
–Go Slow On Grades And Slippery
Surfaces.
–Use Care When Backing Machine.
–Do Not Carry Riders On Machine.
–Always Follow Safety And Traffic
Rules.
4. Before Leaving Or Servicing Machine:
–Stop On Level Surface.
–Set Parking Brake.
–Turn Off Machine And Remove Key.
5. When Servicing Machine:
–Avoid Moving Parts. Do Not Wear
Loose Jackets, Shirts, Or Sleeves
When Working On Machine.
–Block Machine Tires Before Jacking
Machine Up.
–Jack Machine Up At Designated
Locations Only. Block Machine Up
With Jack Stands.
–Use Hoist Or Jack Of Adequate
Capacity To Lift Machine.
–Disconnect Battery Connections
Before Working On Machine.
–Avoid Contact With Battery Acid.
- Use TENNANT Supplied Or Equivalent
Replacement Parts.
WARNING: Batteries Emit Hydrogen Gas.
Explosion Or Fire Can Result. Keep Sparks
And Open Flame Away. Keep Covers Open
When Charging.
WARNING: Flammable Materials Can Cause
An Explosion Or Fire. Do Not Use Flammable
Materials In Tank(s).
WARNING: Flammable Materials Or Reactive
Metals Can Cause Explosion Or Fire. Do Not
Pick Up.
WARNING: Hazardous Voltage. Shock Can
Result. Disconnect Batteries Before Working
On Machine. Only Qualified Personnel Should
Work Inside Panel.

GENERAL INFORMATION
465/480/490MM184 (9–91)
ii
The following safety labels are mounted on the
machine in the locations indicated. If these, or
any label becomes damaged or illegible, install a
new label in its place.
FOR SAFETY LABEL –LOCATED BELOW
THE CONTROL PANEL. BATTERY CHARGING WARNING LABEL – LOCATED NEXT TO THE MACHINE AND
BATTERY CONNECTORS.
CLEANING AGENTS WARNING LABEL–
LOCATED ON THE RECOVERY TANK.
FLAMMABLE MATERIALS LABEL –LOCATED
UNDER THE LEFT STEERING HANDLE
04385

GENERAL INFORMATION
iii
465/480/490MM184 (9–92)
CONTENTS
Page
GENERAL INFORMATION i. . . . . . . . . . . . . . .
SAFETY PRECAUTIONS i. . . . . . . . . . .
SPECIFICATIONS 1-1. . . . . . . . . . . . . . . . . . . . . .
MACHINE SPECIFICATIONS –465 1-3. .
POWER TYPE 1-3. . . . . . . . . . . . . . . . . .
POWER TRAIN 1-3. . . . . . . . . . . . . . . . .
STEERING 1-3. . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM 1-3. . . . . . . . . . . . .
SUSPENSION SYSTEM 1-3. . . . . . . . .
SYSTEM FLUID CAPACITIES 1-3. . . .
GENERAL MACHINE DIMENSIONS –
CAPACITIES 1-3. . . . . . . . . . . . . .
MACHINE WEIGHTS 1-3. . . . . . . . . . . .
GENERAL MACHINE
PERFORMANCE 1-3. . . . . . . . . . . . .
MACHINE DIMENSIONS –465 1-4. . . . . .
MACHINE SPECIFICATIONS –
480/480EE 1-5. . . . . . . . . . . . . . . . . . . . .
POWER TYPE 1-5. . . . . . . . . . . . . . . . . .
POWER TRAIN 1-5. . . . . . . . . . . . . . . . .
STEERING 1-5. . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM 1-5. . . . . . . . . . . . .
SUSPENSION SYSTEM 1-5. . . . . . . . .
SYSTEM FLUID CAPACITIES 1-5. . . .
GENERAL MACHINE DIMENSIONS –
CAPACITIES 1-5. . . . . . . . . . . . . .
MACHINE WEIGHTS 1-5. . . . . . . . . . . .
GENERAL MACHINE
PERFORMANCE 1-5. . . . . . . . . . . . .
MACHINE DIMENSIONS –480/480EE 1-6
MACHINE SPECIFICATIONS –490 1-7. .
POWER TYPE 1-7. . . . . . . . . . . . . . . . . .
POWER TRAIN 1-7. . . . . . . . . . . . . . . . .
STEERING 1-7. . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM 1-7. . . . . . . . . . . . .
SUSPENSION SYSTEM 1-7. . . . . . . . .
SYSTEM FLUID CAPACITIES 1-7. . . .
GENERAL MACHINE DIMENSIONS –
CAPACITIES 1-7. . . . . . . . . . . . . .
MACHINE WEIGHTS 1-7. . . . . . . . . . . .
GENERAL MACHINE
PERFORMANCE 1-7. . . . . . . . . . . . .
MACHINE DIMENSIONS –490 1-8. . . . . . .
Page
OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR OPERATION 2-3. . .
AFTER UNCRATING AND BEFORE
OPERATING MACHINE 2-3. . . . . . .
OPERATION OF CONTROLS 2-4. . . . . . .
MACHINE COMPONENTS 2-4. . . . . . .
HOW IT WORKS 2-5. . . . . . . . . . . . . . . .
INSTRUMENT PANEL SYMBOLS 2-5.
CONTROLS AND INSTRUMENTS 2-6
HOUR METER 2-7. . . . . . . . . . . . . . . . . .
ESSWITCH 2-7. . . . . . . . . . . . . . . . . .
BRUSH PRESSURE –
BATTERY INDICATOR 2-7. . . . . . . .
KEY-OPERATED ON-OFF SWITCH 2-7
SCRUB BRUSH SWITCH 2-7. . . . . . . .
VACUUM FAN SWITCH 2-7. . . . . . . . . .
STEERING HANDLES 2-7. . . . . . . . . . .
SOLUTION LEVER 2-8. . . . . . . . . . . . . .
AUTO STOP SWITCH 2-8. . . . . . . . . . .
POWER WAND SWITCH 2-8. . . . . . . . .
PRE-SWEEPBRUSH HANDLE 2-8.
ESSWITCH 2-7. . . . . . . . . . . . . . . . . .
PARKING BRAKE LEVER 2-9. . . . . . . .
SQUEEGEE LEVER 2-9. . . . . . . . . . . . .
CIRCUIT BREAKERS 2-9. . . . . . . . . . . .
MACHINE OPERATION 2-10. . . . . . . . . . . . .
NORMAL SCRUBBING OPERATION 2-10
PRE–START CHECKLIST 2-10. . . . .
TO START MACHINE 2-10. . . . . . . . .
TO FILL SOLUTION TANK 2-10. . . . .
TO SCRUB 2-11. . . . . . . . . . . . . . . . . .
TO DRAIN AND CLEAN RECOVERY
TANK 2-11. . . . . . . . . . . . . . . . . . . .
POST OPERATION CHECKLIST –
MACHINE ON 2-13. . . . . . . . . . . . .
TO STOP MACHINE 2-13. . . . . . . . . .
POST OPERATION CHECKLIST –
MACHINE OFF 2-14. . . . . . . . . . . .
DOUBLE SCRUBBING OPERATION 2-14
OPERATION ON GRADES 2-14. . . . . . .
MACHINE TROUBLESHOOTING 2-15.
OPTIONS OPERATION 2-16. . . . . . . . . . . . .
VACUUM WAND ATTACHMENT 2-16. .
TO OPERATE VACUUM WAND
ATTACHMENT 2-16. . . . . . . . . . . .
POWER WAND 2-17. . . . . . . . . . . . . . . . .
TO OPERATE THE POWER
WAND 2-17. . . . . . . . . . . . . . . . . . . .
PRE-SWEEP2-19. . . . . . . . . . . . . . . . . .
TO REMOVE PRE-SWEEP2-19. .
TO MOUNT THE PRE-SWEEP2-20
TRANSPORTING MACHINE 2-22. . . . . . . . .
PUSHING OR TOWING MACHINE 2-22
MACHINE JACKING 2-22. . . . . . . . . . . . .

GENERAL INFORMATION
465/480/490MM184 (9–93)
iv
Page
TO JACK UP MACHINE 2-22. . . . . . .
MACHINE TIE–DOWNS 2-23. . . . . . . . . .
MACHINE STORAGE 2-24. . . . . . . . . . . . . . .
STORING MACHINE 2-24. . . . . . . . . . . . . .
MAINTENANCE 3-1. . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED FIRST 50-HOUR
MACHINE INSPECTION 3-3. . . . . . . . .
MAINTENANCE CHART 3-4. . . . . . . . . . . .
LUBRICATION 3-5. . . . . . . . . . . . . . . . . . . . .
REAR CASTERS 3-5. . . . . . . . . . . . . . . .
WHEEL DRIVE CHAIN 3-5. . . . . . . . . . .
ELECTRICAL SYSTEM 3-6. . . . . . . . . . . . .
BATTERIES 3-6. . . . . . . . . . . . . . . . . . . .
TO CHARGE BATTERIES 3-7. . . . .
ELECTRIC MOTORS 3-8. . . . . . . . . . . .
PROPELLING CIRCUIT 3-8. . . . . . . . . .
ELECTRICAL SCHEMATIC
(465/480/490) 3-9. . . . . . . . . . . . . . . .
ELECTRICAL SCHEMATIC
(480EE) 3-10. . . . . . . . . . . . . . . . . . . . .
BELTS AND CHAINS 3-11. . . . . . . . . . . . . . .
WHEEL DRIVE CHAIN 3-11. . . . . . . . . . .
STATIC DRAG CHAIN 3-11. . . . . . . . . . .
VACUUM FAN DRIVE BELT
(480EE) 3-11. . . . . . . . . . . . . . . . . . . . .
SCRUB HEAD 3-12. . . . . . . . . . . . . . . . . . . . .
SCRUB HEAD 3-12. . . . . . . . . . . . . . . . . .
TO LEVEL SCRUB HEAD 3-12. . . . .
SCRUB BRUSHES 3-13. . . . . . . . . . . . . .
TO REPLACE SCRUB BRUSHES 3-13
SCRUB HEAD FLOOR SKIRTS 3-14. . .
SOLUTION AND RECOVERY TANKS 3-15
SOLUTION TANK 3-15. . . . . . . . . . . . . . .
SOLUTION VALVE 3-15. . . . . . . . . . . . . .
RECOVERY TANK 3-16. . . . . . . . . . . . . .
TO DRAIN AND CLEAN
RECOVERY TANK 3-16. . . . . . . . .
SQUEEGEES 3-18. . . . . . . . . . . . . . . . . . . . . .
REAR SQUEEGEE 3-18. . . . . . . . . . . . . .
TO REMOVE SQUEEGEE
ASSEMBLY 3-18. . . . . . . . . . . . . . .
TO INSTALL SQUEEGEE
ASSEMBLY 3-19. . . . . . . . . . . . . . .
TO REPLACE OR ROTATE
BLADE 3-19. . . . . . . . . . . . . . . . . . .
TO LEVEL REAR SQUEEGEE
(for 465 with serial number
below 010216, or 480 with
serial numberbelow 020294) 3-20. .
Page
TO LEVEL REAR SQUEEGEE
(for 465 serial number 010216
and above, 480 serial
number 020294 and above,
and 490 machines) 3-20. . . . . . . . .
TO ADJUST SQUEEGEE
DEFLECTION (for 465 with
serial number below 010216,
or 480 with serial number
below 020294) 3-21. . . . . . . . . . . . .
TO ADJUST SQUEEGEE
DEFLECTION (for 465 serial
number 010216 and above,
480 serial number 020294 and
above, and 490 machines) 3-21. .
SQUEEGEE ASSEMBLY STOP
ADJUSTMENT (for 465 serial
number 010216 and above,
480 serial number 020294 and
above, and 490 machines) 3-22. .
BRAKES AND TIRES 3-23. . . . . . . . . . . . . . .
PARKING BRAKE 3-23. . . . . . . . . . . . . . .
TIRES 3-23. . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS 3-24. . . . . . . . . . . . . . . . . . . . . . . . .
PRE-SWEEP3-24. . . . . . . . . . . . . . . . . .
PRE-SWEEPBRUSH 3-24. . . . . . .
TO REPLACE PRE-SWEEP
BRUSH 3-24. . . . . . . . . . . . . . . . . . .
TO ADJUST PRE-SWEEP
BRUSH PATTERN 3-25. . . . . . . . .
PRE-SWEEPBRUSH
SIDE SKIRTS 3-25. . . . . . . . . . . . .
PRE-SWEEPBRUSH
DRIVE BELT 3-25. . . . . . . . . . . . . .
TO REPLACE AND ADJUST THE
BRUSH DRIVE BELT 3-25. . . .
PRE-SWEEPREAR SKIRT 3-26. .
DEBRIS HOPPER SLIT SKIRT 3-26.
PRE- SWEEPHOPPER SEALS 3-26
APPENDIX 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HARDWARE INFORMATION 4-3. . . . . . . .
STANDARD BOLT TORQUE CHART 4-3
METRIC BOLT TORQUE CHART 4-3.
BOLT IDENTIFICATION 4-3. . . . . . . . . .
THREAD SEALANT AND LOCKING
COMPOUNDS 4-3. . . . . . . . . . . . . . .
HOW TO USE THIS MANUAL 5-1. . . . . . . . . . . .
IMPORTANT INFORMATION 5-1. . . . . . . .
FINDING A TENNANT PART NUMBER 5-2
PLACING AN ORDER 5-3. . . . . . . . . . . . . . .

GENERAL INFORMATION
v
465/480/490MM184 (9–94)
Page
465 MODEL PARTS 6-1. . . . . . . . . . . . . . . . . . . . .
Fig. 1 –Recommended General
Maintenance Items 6-2. . . . . . . . .
Fig. 2 –Replacement Brushes 6-3. . . . . . . . . .
Fig. 3 –Hood and Bumper Group 6-4. . . . . . .
Fig. 4 –Hood and Bumper Group 6-6. . . . . . .
Fig. 5 –Main Frame Group 6-8. . . . . . . . . . . . .
Fig. 6 –Main Frame Group 6-9. . . . . . . . . . . . .
Fig. 7 –Side Skirt Support Group 6-10. . . . . .
Fig. 8 –Front Shroud Group 6-12. . . . . . . . . . .
Fig. 9 –Scrub Head Lift Group 6-14. . . . . . . . .
Fig. 10 –Scrub Head Group 6-16. . . . . . . . . . .
Fig. 11 –Tire and Rim Assembly 6-17. . . . . . .
Fig. 12 –Single Drive Group 6-18. . . . . . . . . . .
Fig. 13 –Solution and Recovery
Tanks Group 6-20. . . . . . . . . . . . .
Fig. 14 –Recovery Tank Float Group 6-22. . . .
Fig. 15 –Solution Control Group 6-24. . . . . . . .
Fig. 16 –Battery Group 6-26. . . . . . . . . . . . . . .
Fig. 17 –Battery Group 6-28. . . . . . . . . . . . . . .
Fig. 18 –Steering Control Group 6-30. . . . . . .
Fig. 19 –Rear Electric Panel Group 6-32. . . . .
Fig. 20 –Electrical Controller Group 6-34. . . . .
Fig. 21 –Rear Electrical Group 6-35. . . . . . . . .
Fig. 22 –Rear Squeegee Link Group 6-36. . . .
Fig. 23 –Rear Squeegee Link Group 6-38. . . .
Fig. 24 –Rear Squeegee Group 6-40. . . . . . . .
Fig. 25 –Wire Harness Group 6-42. . . . . . . . . .
Fig. 26 –Label Group 6-44. . . . . . . . . . . . . . . . .
480 MODEL PARTS 7-1. . . . . . . . . . . . . . . . . . . . .
Fig. 1 –Recommended General
Maintenance Items 7-2. . . . . . . . .
Fig. 2 –Replacement Brushes 7-3. . . . . . . . . .
Fig. 3 –Hood and Bumper Group 7-4. . . . . . .
Fig. 4 –Hood and Bumper Group 7-6. . . . . . .
Fig. 5 –Main Frame Group 7-8. . . . . . . . . . . . .
Fig. 6 –Main Frame Group 7-9. . . . . . . . . . . . .
Fig. 7 –Side Skirt Support Group 7-10. . . . . .
Fig. 8 –Front Shroud Group 7-12. . . . . . . . . . .
Fig. 9 –Scrub Head Lift Group 7-14. . . . . . . . .
Fig. 10 –Scrub Head Group 7-16. . . . . . . . . . .
Fig. 11 –Tire and Rim Assembly 7-17. . . . . . .
Fig. 12 –Single Drive Group 7-18. . . . . . . . . . .
Fig. 13 –Solution and Recovery
Tanks Group 7-20. . . . . . . . . . . . .
Fig. 14 –Recovery Tank Float Group 7-22. . . .
Fig. 15 –Solution Control Group 7-24. . . . . . . .
Fig. 16 –Battery Group 7-26. . . . . . . . . . . . . . .
Fig. 17 –Battery Group 7-28. . . . . . . . . . . . . . .
Fig. 18 –Steering Control Group 7-30. . . . . . .
Fig. 19 –Rear Electric Panel Group 7-32. . . . .
Fig. 20 –Electrical Controller Group 7-34. . . . .
Fig. 21 –Rear Electrical Group 7-35. . . . . . . . .
Fig. 22 –Rear Squeegee Link Group 7-36. . . .
Fig. 23 –Rear Squeegee Link Group 7-38. . . .
Fig. 24 –Rear Squeegee Group 7-40. . . . . . . .
Fig. 25 –Wire Harness Group 7-42. . . . . . . . . .
Fig. 26 –Label Group 7-44. . . . . . . . . . . . . . . . .
Page
480EE MODEL PARTS 8-1. . . . . . . . . . . . . . . . . .
Fig. 1 –Recommended General
Maintenance Items 8-2. . . . . . . . .
Fig. 2 –Replacement Brushes 8-3. . . . . . . . . .
Fig. 3 –Hood and Bumper Group 8-4. . . . . . .
Fig. 4 –Main Frame Group 8-6. . . . . . . . . . . . .
Fig. 5 –Front Shroud Group 8-8. . . . . . . . . . . .
Fig. 6 –Scrub Head Lift Group 8-10. . . . . . . . .
Fig. 7 –Scrub Head Group 8-12. . . . . . . . . . . .
Fig. 8 –Tire and Rim Assembly 8-13. . . . . . . .
Fig. 9 –Single Drive Group 8-14. . . . . . . . . . . .
Fig. 10 –Solution and Recovery
Tanks Group 8-16. . . . . . . . . . . . .
Fig. 11 –Vacuum Fan Group 8-18. . . . . . . . . . .
Fig. 12 –Solution Control Group 8-20. . . . . . . .
Fig. 13 –Battery Group 8-22. . . . . . . . . . . . . . .
Fig. 14 –Steering Control Group 8-24. . . . . . .
Fig. 15 –Rear Electric Panel Group 8-26. . . . .
Fig. 16 –Electrical Box Group, EE 8-28. . . . . .
Fig. 17 –Rear Squeegee Link Group 8-30. . . .
Fig. 18 –Rear Squeegee Group 8-32. . . . . . . .
Fig. 19 –Wire Harness Group 8-34. . . . . . . . . .
Fig. 20 –Label Group 8-36. . . . . . . . . . . . . . . . .
490 MODEL PARTS 9-1. . . . . . . . . . . . . . . . . . . . .
Fig. 1 –Recommended General
Maintenance Items 9-2. . . . . . . . .
Fig. 2 –Replacement Brushes 9-3. . . . . . . . . .
Fig. 3 –Hood and Bumper Group 9-4. . . . . . .
Fig. 4 –Main Frame Group 9-6. . . . . . . . . . . . .
Fig. 5 –Front Shroud Group 9-8. . . . . . . . . . . .
Fig. 6 –Scrub Head Lift Group 9-10. . . . . . . . .
Fig. 7 –Scrub Head Group 9-12. . . . . . . . . . . .
Fig. 8 –Tire and Rim Assembly 9-13. . . . . . . .
Fig. 9 –Single Drive Group 9-14. . . . . . . . . . . .
Fig. 10 –Solution and Recovery
Tanks Group 9-16. . . . . . . . . . . . .
Fig. 11 –Vacuum Fan Group 9-18. . . . . . . . . . .
Fig. 12 –Solution Control Group 9-20. . . . . . . .
Fig. 13 –Battery Group 9-22. . . . . . . . . . . . . . .
Fig. 14 –Steering Control Group 9-24. . . . . . .
Fig. 15 –Rear Electrical Panel Group 9-26. . .
Fig. 16 –Electrical Controller Group 9-28. . . . .
Fig. 17 –Rear Electrical Group 9-29. . . . . . . . .
Fig. 18 –Rear Squeegee Link Group 9-30. . . .
Fig. 19 –Rear Squeegee Group 9-32. . . . . . . .
Fig. 20 –Label Group 9-33. . . . . . . . . . . . . . . . .
Fig. 21 –Wire Harness Group 9-34. . . . . . . . . .

GENERAL INFORMATION
465/480/490MM184 (9–94)
vi
Page
OPTIONS 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 1 –Heavy Duty Bumper Kit, 465 10-2. . .
Fig. 2 –Heavy Duty Bumper Kit, 465 10-3. . .
Fig. 3 –Heavy Duty Bumper Kit, 480 10-4. . .
Fig. 4 –Heavy Duty Bumper Kit, 480 10-5. . .
Fig. 5 –Heavy Duty Bumper Kit, 490 10-6. . .
Fig. 6 –Demo Group, 465 10-7. . . . . . . . . . . . .
Fig. 7 –Demo Group, 480 10-8. . . . . . . . . . . . .
Fig. 8 –Demo Group, 490 10-9. . . . . . . . . . . . .
Fig. 9 –Vacuum Wand Kit 10-10. . . . . . . . . . . .
Fig. 10 –Pre-SweepMounting Group,
465 10-12. . . . . . . . . . . . . . . . . . . .
Fig. 11 –Pre-SweepMounting Group,
480 10-13. . . . . . . . . . . . . . . . . . . .
Fig. 12 –Pre-SweepDrive Group,
465 10-14. . . . . . . . . . . . . . . . . . . .
Fig. 13 –Pre-SweepDrive Group,
480 10-16. . . . . . . . . . . . . . . . . . . .
Fig. 14 –Pre-SweepFrame Group,
465 10-18. . . . . . . . . . . . . . . . . . . .
Fig. 15 –Pre-SweepFrame Group,
480 10-20. . . . . . . . . . . . . . . . . . . .
Fig. 16 –Extended Scrub Group, 465 10-22. .
Fig. 17 –Extended Scrub Group, 480 10-24. .
Fig. 18 –Extended Scrub Group, 490 10-26. .
Fig. 19 –Extended Scrub Electrical
Group 10-28. . . . . . . . . . . . . . . . . .
Fig. 20 –Single Parking Brake Group 10-30. .
Fig. 21 –GS Group, 465 10-32. . . . . . . . . . . . .
Fig. 22 –GS Group, 480 10-34. . . . . . . . . . . . .
Fig. 23 –Battery Charger Group,
60 Hz (220 Ah batteries) 10-36. .
Fig. 24 –Battery Charger Group,
50 Hz (220 Ah batteries) 10-37. .
Fig. 25 –Battery Charger Group,
40A, 36V, 50 Hz
(305 Ah batteries) 10-38. . . . . . . .
Fig. 26 –Battery Charger Group,
36A, 36V, 115V
(305 Ah batteries) 10-39. . . . . . . .
Fig. 27 –Battery Charger Group,
60 Hz (220 Ah batteries) 10-40. .
Fig. 28 –Battery Charger Group, 50 Hz,
230V (220 Ah batteries) 10-41. . .
Fig. 29 –Battery Charger Group, 50 Hz,
245V (220 Ah batteries) 10-41. .
Fig. 30 –Battery Charger Group,
60 Hz (305 Ah batteries) 10-42. .
Fig. 31 –Battery Charger Group,
50 Hz (305 Ah batteries) 10-43. .
Fig. 32 –Heavy Duty Battery Kit, Wet,
480 10-44. . . . . . . . . . . . . . . . . . . .
Fig. 33 –Heavy Duty Battery Kit, Dry,
480 10-45. . . . . . . . . . . . . . . . . . . .
Fig. 34 –Battery Tray Group, 465 10-46. . . . .
Fig. 35 –Battery Tray Group, 480, 490 10-47.
Fig. 36 –Heavy Duty Battery Tray
Group, 480, 490 10-48. . . . . . . . .
Page
Fig. 37 –Wheel Cover Group 10-49. . . . . . . . .
Fig. 38 –Foam Filled Tire Group 10-50. . . . . .
Fig. 39 –Power Wand Hose Assembly 10-51.
Fig. 40 –Power Wand Assembly 10-52. . . . . .
Fig. 41 –Power Wand Pump and
Electrical Group 10-54. . . . . . . . . .
Fig. 42 –Power Wand Mount Group 10-56. . .
BREAKDOWNS 11-1. . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 1 –Electric Motor Breakdown,
10914 11-2. . . . . . . . . . . . . . . . . . .
Fig. 2 –Electric Motor Breakdown,
28386 11-4. . . . . . . . . . . . . . . . . . .
Fig. 3 –Electric Motor Breakdown,
04742 11-6. . . . . . . . . . . . . . . . . . .
Fig. 4 –Electric Motor Breakdown,
05680 11-7. . . . . . . . . . . . . . . . . . .
Fig. 5 –Electric Motor Breakdown,
04656 11-8. . . . . . . . . . . . . . . . . . .
Fig. 6 –Electric Motor Breakdown,
27851 11-9. . . . . . . . . . . . . . . . . . .
Fig. 7 –Water Pump Breakdown,
10916 11-10. . . . . . . . . . . . . . . . . .
Fig. 8 –Water Pump Breakdown,
27839 11-11. . . . . . . . . . . . . . . . . .
Fig. 9 –Electric Motor Breakdown,
04922 11-12. . . . . . . . . . . . . . . . . .
Fig. 10 –Water Pump Breakdown,
65590 11-13. . . . . . . . . . . . . . . . . .
CROSS REFERENCE 12-1. . . . . . . . . . . . . . . . . . .

SPECIFICATIONS
1Ć1
465/480/490 MM184 (10–90)
SECTION 1
CONTENTS
Page
MACHINE SPECIFICATIONS –465 1-3. . . . . . .
POWER TYPE 1-3. . . . . . . . . . . . . . . . . . . . . . .
POWER TRAIN 1-3. . . . . . . . . . . . . . . . . . . . . .
STEERING 1-3. . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM 1-3. . . . . . . . . . . . . . . . . .
SUSPENSION SYSTEM 1-3. . . . . . . . . . . . . .
SYSTEM FLUID CAPACITIES 1-3. . . . . . . . .
GENERAL MACHINE DIMENSIONS –
CAPACITIES 1-3. . . . . . . . . . . . . . . . . . . . . .
MACHINE WEIGHTS 1-3. . . . . . . . . . . . . . . . .
GENERAL MACHINE PERFORMANCE 1-3.
MACHINE DIMENSIONS –465 1-4. . . . . . . . . . .
MACHINE SPECIFICATIONS –480/480EE 1-5.
POWER TYPE 1-5. . . . . . . . . . . . . . . . . . . . . . .
POWER TRAIN 1-5. . . . . . . . . . . . . . . . . . . . . .
STEERING 1-5. . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM 1-5. . . . . . . . . . . . . . . . . .
SUSPENSION SYSTEM 1-5. . . . . . . . . . . . . .
SYSTEM FLUID CAPACITIES 1-5. . . . . . . . .
GENERAL MACHINE DIMENSIONS –
CAPACITIES 1-5. . . . . . . . . . . . . . . . . . . . . .
MACHINE WEIGHTS 1-5. . . . . . . . . . . . . . . . .
GENERAL MACHINE PERFORMANCE 1-5.
MACHINE DIMENSIONS –480/480EE 1-6. . . . .
MACHINE SPECIFICATIONS –490 1-7. . . . . . .
POWER TYPE 1-7. . . . . . . . . . . . . . . . . . . . . . .
POWER TRAIN 1-7. . . . . . . . . . . . . . . . . . . . . .
STEERING 1-7. . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM 1-7. . . . . . . . . . . . . . . . . .
SUSPENSION SYSTEM 1-7. . . . . . . . . . . . . .
SYSTEM FLUID CAPACITIES 1-7. . . . . . . . .
GENERAL MACHINE DIMENSIONS –
CAPACITIES 1-7. . . . . . . . . . . . . . . . . . . . . .
MACHINE WEIGHTS 1-7. . . . . . . . . . . . . . . . .
GENERAL MACHINE PERFORMANCE 1-7.
MACHINE DIMENSIONS –490 1-8. . . . . . . . . . .

SPECIFICATIONS
465/485/490 MM184 (9–90)
1Ć2

SPECIFICATIONS
1Ć3
465/480/490 MM184 (9–92)
MACHINE SPECIFICATIONS –465
POWER TYPE
Electric propelling motor –nominal voltage
36 VDC, 0.50 hp (0.37 kW) @ 320 rpm
Electric vacuum fan motor –nominal voltage
36 VDC, 0.85 hp (0.63 kW) @ 14000 rpm
Electric scrub brush motors, (2)
nominal voltage 36 VDC,
0.84 hp (0.63 kW) @ 230 rpm maximum
0.50 hp (0.37 kW) @ 320 rpm continuous
Electric Pre-Sweepmotor (option) –nominal
voltage 36 VDC, 0.20 hp (0.15 kW) @ 250
rpm
Batteries (6) –6 V, 220 A/h @ 20 hour rate
Battery charger options –36 VDC 20 A,
115 VAC, 60 hz
36 VDC 20 A, 230 VAC, 50 hz
POWER TRAIN
Propelling –electric motor to differential driven
Scrub brushes –electric motor direct driven
Vacuum fan –electric motor direct driven
Pre-Sweepbrush (option) –electric motor belt
driven
STEERING
Type –manual
BRAKING SYSTEM
Parking brakes (option) –disc type, cable
actuated
SUSPENSION SYSTEM
Front (2) –4.10/3.50–6 pneumatic tires
Rear (2) –5 in (130 mm) solid casters
SYSTEM FLUID CAPACITIES
Solution tank capacity –22.1 gal (83.7 L)
Recovery tank capacity –27 gal (102.2 L)
GENERAL MACHINE DIMENSIONS –
CAPACITIES
Length –63.5 in (1615 mm)
Length with Pre-Sweep–82.4 in (2095 mm)
Width –27.9 in (710 mm)
Width with squeegee –31.9 in (810 mm)
Height –44.3 in (1125 mm)
Track, front –20.38 in (520 mm)
Track, rear –17.06 in (435 mm)
Wheel base –17.68 in (450 mm)
Scrub brush diameter –14 in (355 mm)
Pre-Sweepbrush (option) diameter –5.5 in
(140 mm)
Pre-Sweepbrush (option) length –20 in
(510 mm)
Scrubbing path width –26 in (650 mm)
Pre-Sweephopper capacity –1 cu ft (0.03 m)
Rear squeegee path width –31.9 in (810 mm)
MACHINE WEIGHTS
GVWR –1150 lb (520 kg)
GENERAL MACHINE PERFORMANCE
Maximum forward speed –2.8 mph (4.5 km/h)
Maximum reverse speed –1.5 mph (2.4 km/h)
Aisle turnaround width –64.75 in (1645 mm)
Aisle turnaround width with Pre-Sweep–
82.00 in (2080 mm)
Maximum rated ramp climb angle –6
Maximum rated ramp descent angle –6

SPECIFICATIONS
465/485/490MM184 (9–90)
1Ć
SIDE VIEW
TOP VIEW
31.9 in
(810 mm) 27.9 in
(710 mm)
82.4 in
(2095 mm)
63.5 in
(1615 mm)
44.3 in
(1125 mm)
04340
MACHINE DIMENSIONS –465

SPECIFICATIONS
1Ć5
465/480/490MM184 (9–92)
MACHINE SPECIFICATIONS –480/480EE
POWER TYPE
Electric propelling motor –nominal voltage
36 VDC, 0.50 hp (0.37 kW) @ 320 rpm
Electric vacuum fan motor(480) –nominal
voltage
36 VDC, 0.85 hp (0.63 kW) @ 14000 rpm
Electric vacuum fan drive motor(480EE)
nominal voltage 36 VDC,
1.00 hp (0.74 kw) @ 2800
Electric scrub brush motors, (2)
nominal voltage 36 VDC,
0.84 hp (0.63 kW) @ 230 rpm maximum
0.50 hp (0.37 kW) @ 320 rpm continuous
Electric Pre-Sweepmotor (option) –nominal
voltage 36 VDC, 0.20 hp (0.15 kW) @ 250
rpm
Batteries (480) (6) –6 V,
220 A/h @ 20 hour rate
Batteries (480EE and heavy duty option) (6) –
6 V, 305 A/h @ 20 hour rate
Battery charger options –36 VDC 20 A,
115 VAC, 60 hz
36 VDC 20 A, 230 VAC, 50 hz
POWER TRAIN
Propelling –electric motor to differential driven
Scrub brushes –electric motor direct driven
Vacuum fan (480) –electric motor direct driven
Vacuum fan (480EE) –electric motor belt driven
Pre-Sweepbrush (option) –electric motor belt
driven
STEERING
Type –manual
BRAKING SYSTEM
Parking brakes (option) –disc type, cable
actuated
SUSPENSION SYSTEM
Front (2) –4.10/3.50–6 pneumatic tires
Rear (2) –5 in (130 mm) solid casters
SYSTEM FLUID CAPACITIES
Solution tank capacity –27.5 gal (104.1 L)
Recovery tank capacity –31 gal (117.4 L)
GENERAL MACHINE DIMENSIONS –
CAPACITIES
Length –66.5 in (1690 mm)
Length with Pre-Sweep–86.1 in (2190 mm)
Width –35.1 in (890 mm)
Width with squeegee –37.6 in (955 mm)
Height –44.3 in (1125 mm)
Track, front –20.38 in (520 mm)
Track, rear –17.06 in (435 mm)
Wheel base –17.68 in (450 mm)
Scrub brush diameter –16 in (405 mm)
Pre-Sweepbrush (option) diameter –5.5 in
(140 mm)
Pre-Sweepbrush (option) length –26 in
(660 mm)
Scrubbing path width –32 in (800 mm)
Pre-Sweephopper capacity –1.25 cu ft
(0.04 m)
Rear squeegee path width –37.5 in (955 mm)
MACHINE WEIGHTS
GVWR (480) –1450 lb (658 kg)
GVWR (480EE) –1459 lb (662 kg)
GENERAL MACHINE PERFORMANCE
Maximum forward speed –2.8 mph (4.5 km/h)
Maximum reverse speed –1.5 mph (2.4 km/h)
Aisle turnaround width –68.80 in (1750 mm)
Aisle turnaround width with Pre-Sweep–
86.40 in (2200 mm)
Maximum rated ramp climb angle –6
Maximum rated ramp descent angle –6

SPECIFICATIONS
465/485/490MM184 (10–90)
1Ć6
SIDE VIEW
TOP VIEW
37.6 in
(955 mm) 35.1 in
(890 mm)
86.1 in
(2190 mm)
66.5 in
(1690 mm)
44.3 in
(1125 mm)
04340
MACHINE DIMENSIONS –480/480EE

SPECIFICATIONS
1Ć7
465/480/490MM184 (9–92)
MACHINE SPECIFICATIONS –490
POWER TYPE
Electric propelling motor –nominal voltage
36 VDC, 0.50 hp (0.37 kW) @ 320 rpm
Electric vacuum fan motor –nominal voltage
36 VDC, 1.25 hp (0.93 kW) @ 10500 rpm
Electric scrub brush motors, (2)
nominal voltage 36 VDC,
1.20 hp (0.89 kW) @ 250 rpm maximum
0.80 hp (0.60 kW) @ 320 rpm continuous
Batteries (6) –6 V, 220 A/h @ 20 hour rate
Batteries (heavy duty option) (6) –6 V,
305 A/h @ 20 hour rate
Battery charger options –36 VDC 30 A,
115 VAC, 60 hz
36 VDC 30 A, 230 VAC, 50 hz
POWER TRAIN
Propelling –electric motor to differential driven
Scrub brushes –electric motor direct driven
Vacuum fan –electric motor direct driven
STEERING
Type –manual
BRAKING SYSTEM
Parking brakes (option) –disc type, cable
actuated
SUSPENSION SYSTEM
Front (2) –4.10/3.50–6 pneumatic tires
Rear (2) –5 in (130 mm) solid casters
SYSTEM FLUID CAPACITIES
Solution tank capacity –27.5 gal (104.1 L)
Recovery tank capacity –31 gal (117.4 L)
GENERAL MACHINE DIMENSIONS –
CAPACITIES
Length –67.3 in (1710 mm)
Width –39.0 in (990 mm)
Width with squeegee –42.8 in (1090 mm)
Height –44.3 in (1125 mm)
Track, front –20.38 in (520 mm)
Track, rear –17.06 in (435 mm)
Wheel base –17.68 in (450 mm)
Scrub brush diameter –18 in (455 mm)
Scrubbing path width –36 in (914 mm)
Rear squeegee path width –42.8 in (1090 mm)
MACHINE WEIGHTS
GVWR –1554 lb (705 kg)
GENERAL MACHINE PERFORMANCE
Maximum forward speed –2.8 mph (4.5 km/h)
Maximum reverse speed –1.5 mph (2.4 km/h)
Aisle turnaround width –70.9 in (1801 mm)
Maximum rated ramp climb angle –6
Maximum rated ramp descent angle –6

SPECIFICATIONS
465/485/490MM184 (9–90)
1Ć8
SIDE VIEW
TOP VIEW
42.8 in
(1090 mm) 39.0 in
(990 mm)
67.3 in
(1710 mm)
44.3 in
(1125 mm)
06311
MACHINE DIMENSIONS –490

OPERATION
2Ć1
465/480/490MM184 (9–92)
SECTION 2
CONTENTS
Page
PREPARATION FOR OPERATION 2-3. . . . . . . .
AFTER UNCRATING AND BEFORE
OPERATING MACHINE 2-3. . . . . . . . . . . .
OPERATION OF CONTROLS 2-4. . . . . . . . . . . .
MACHINE COMPONENTS 2-4. . . . . . . . . . . .
HOW IT WORKS 2-5. . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL SYMBOLS 2-5. . . . . .
CONTROLS AND INSTRUMENTS 2-6. . . . .
HOUR METER 2-7. . . . . . . . . . . . . . . . . . . . . . .
ESSWITCH 2-7. . . . . . . . . . . . . . . . . . . . . . .
BRUSH PRESSURE –
BATTERY INDICATOR 2-7. . . . . . . . . . . . .
KEY-OPERATED ON-OFF SWITCH 2-7. . . .
SCRUB BRUSH SWITCH 2-7. . . . . . . . . . . . .
VACUUM FAN SWITCH 2-7. . . . . . . . . . . . . . .
STEERING HANDLES 2-7. . . . . . . . . . . . . . . .
SOLUTION LEVER 2-8. . . . . . . . . . . . . . . . . . .
AUTO STOP SWITCH 2-8. . . . . . . . . . . . . . . .
POWER WAND SWITCH 2-8. . . . . . . . . . . . . .
PRE-SWEEPBRUSH HANDLE 2-8. . . . . .
ESSWITCH 2-7. . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE LEVER 2-9. . . . . . . . . . . . .
SQUEEGEE LEVER 2-9. . . . . . . . . . . . . . . . . .
CIRCUIT BREAKERS 2-9. . . . . . . . . . . . . . . . .
MACHINE OPERATION 2-10. . . . . . . . . . . . . . . . . .
NORMAL SCRUBBING OPERATION 2-10. . .
PRE–START CHECKLIST 2-10. . . . . . . . . .
TO START MACHINE 2-10. . . . . . . . . . . . . .
TO FILL SOLUTION TANK 2-10. . . . . . . . .
TO SCRUB 2-11. . . . . . . . . . . . . . . . . . . . . . .
TO DRAIN AND CLEAN RECOVERY
TANK 2-11. . . . . . . . . . . . . . . . . . . . . . . . .
POST OPERATION CHECKLIST –
MACHINE ON 2-13. . . . . . . . . . . . . . . . . .
TO STOP MACHINE 2-13. . . . . . . . . . . . . . .
POST OPERATION CHECKLIST –
MACHINE OFF 2-14. . . . . . . . . . . . . . . . .
DOUBLE SCRUBBING OPERATION 2-14. . .
OPERATION ON GRADES 2-14. . . . . . . . . . . .
MACHINE TROUBLESHOOTING 2-15. . . . . .
OPTIONS OPERATION 2-16. . . . . . . . . . . . . . . . . .
VACUUM WAND ATTACHMENT 2-16. . . . . . .
TO OPERATE VACUUM WAND
ATTACHMENT 2-16. . . . . . . . . . . . . . . . .
Page
POWER WAND 2-17. . . . . . . . . . . . . . . . . . . . . .
TO OPERATE THE POWER WAND 2-17.
PRE-SWEEP2-19. . . . . . . . . . . . . . . . . . . . . .
TO REMOVE PRE-SWEEP2-19. . . . . . .
TO MOUNT THE PRE-SWEEP2-20. . . .
TRANSPORTING MACHINE 2-22. . . . . . . . . . . . .
PUSHING OR TOWING MACHINE 2-22. . . . .
MACHINE JACKING 2-22. . . . . . . . . . . . . . . . . .
TO JACK UP MACHINE 2-22. . . . . . . . . . . .
MACHINE TIE–DOWNS 2-23. . . . . . . . . . . . . .
MACHINE STORAGE 2-24. . . . . . . . . . . . . . . . . . .
STORING MACHINE 2-24. . . . . . . . . . . . . . . . .

OPERATION
465/480/490 MM184 (9–90)
2Ć2

OPERATION
2Ć3
465/480/490 MM184 (9–91)
PREPARATION FOR OPERATION
AFTER UNCRATING AND BEFORE
OPERATING MACHINE:
1. Check the machine for shipping damage.
2. Read this manual carefully before operating
or servicing the machine.
FOR SAFETY: Do Not Operate The Machine
Unless Operation Manual Is Read And
Understood.
3. Lift open the machine hood, then tilt the rear
cover forward.
OPEN BATTERY COVERS
B
A
C04342
A. Machine Hood
B. Rear Cover
C. Batteries
4. Check the batteries electrolyte level as
described in BATTERIES in the
MAINTENANCE section.
CHECKING BATTERY ELECTROLYTE LEVEL
A
B
00879
A. Battery
B. Electrolyte Indicator Ring
FOR SAFETY: When Servicing Machine, Avoid
Contact With Battery Acid.
5. Check the battery specific gravity to
determine the state of charge as described
in BATTERIES in the MAINTENANCE
section. Charge the batteries if necessary.
6. Connect the battery connector to the
machine connector.
MACHINE BATTERY CONNECTORS
A
B
04343
A. Machine Connector
B. Battery Connector
7. Install scrub brushes as described in
SCRUB BRUSHES in the MAINTENANCE
section.
8. Pre-Sweepmachines: Install Pre-Sweep
assembly as described in TO MOUNT
PRE-SWEEP.

OPERATION
465/480/490MM184 (10–90)
2Ć
OPERATION OF CONTROLS
MACHINE COMPONENTS
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
S
T
U
V
W
J
T
Q
R
P
04341
04344
04378
06342
06449
A. Machine Hood M. Batteries
B. Rear Cover N. Recovery Tank
C. Control Panel O. Vacuum Fan (465/480)
D. Squeegee P. Vacuum Fan (490)
E. Rear Caster Q. Vacuum Fan (480EE)
F. Front Wheel R. Vacuum Fan Drive Motor (480EE)
G. Soap Basket S. Solution Lever
H. Recovery Tank Drain Hose T. Parking Brake Lever
I. Squeegee Lever U. Pre-Sweep
J. Steering Handle V. Squeegee Suction Hose
K. Solution Tank Drain Hose W. Scrub Head Cover
L. Solution Tank