Tennant 5400 User manual

330735
Rev. 00 (3–01)
Service Manual
5400

This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT
Model 5400.
The set is organized into four major groups: General Information, Chassis, Scrubbing, and Electrical.
General Information: Machine safety, transport, jacking, lifting, and storage. Machine specifications,
Maintenance charts and Hardware information.
Chassis: Tire/wheel replacement, Caster replacement, Transaxle and Transaxle drive motor replacement.
Scrubbing: Squeegee assembly replace and adjust, Scrubber head replace and adjust, Scrubber brush
motor replacement, Vacuum fan replacement, Solution/recovery tank replacement, , Power wand pump
replacement, and Scrubbing troubleshooting chart.
Electrical: Battery maintenance and replacement, Charging instructions, Circuit breaker/relay
replacement, Instrument panel replacement, Vacuum fan motor brush replacement, Scrub brush brush
replacement, Electrical schematic, and Electrical troubleshooting.
Manual Number – 330735
Revision: 00
Published: 3–01
Copyright 2001 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
1-1
5400330735 (3–01)
CONTENTS
Page
SAFETY PRECAUTIONS 1–3. . . . . . . . . . . . . .
SPECIFICATIONS 1–5. . . . . . . . . . . . . . . . . . . .
MACHINE DIMENSIONS –610mm (24 in)
and 660mm (26 in) DISK MODELS 1–6
MACHINE DIMENSIONS –610mm (24 in)
CYLINDRICAL BRUSH MODEL 1–7. . .
TROUBLESHOOTING 1–8. . . . . . . . . . . . . . . . .
MACHINE JACKING 1–10. . . . . . . . . . . . . . . . . .
MACHINE TRANSPORTING 1–10. . . . . . . . . .
STORING MACHINE 1–11. . . . . . . . . . . . . . . . .
TO STORE MACHINE 1–11. . . . . . . . . . . . .
STORAGE INFORMATION 1–11. . . . . . . . . . . .
HARDWARE INFORMATION 1–12. . . . . . . . . .
STANDARD BOLT TORQUE CHART 1–12
METRIC BOLT TORQUE CHART 1–12. . .
BOLT IDENTIFICATION 1–12. . . . . . . . . . . .
THREAD SEALANT AND LOCKING
COMPOUNDS 1–12. . . . . . . . . . . . . . . . .

GENERAL INFORMATION
1-2 5400330735 (3–01)

GENERAL INFORMATION
1-3
5400330735 (3–01)
SAFETY PRECAUTIONS
This machine is intended for industrial and
commercial use. It is suited to scrub hard floors in
an indoor environment and is not constructed for
any other use. Use only recommended pads,
brushes and cleaning detergents.
The following safety alert symbols 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.
The following information signals potentially
dangerous conditions to the operator or
equipment:
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.
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.
–Use care when reversing machine.
–Do not carry riders on machine.
–Always follow safety and traffic rules.
–Report machine damage or faulty
operation immediately.
4.. Before leaving or servicing machine:
–Stop on level surface.
–Turn off machine.
–Set parking brake, if equipped.
5.. When servicing machine:
–Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
–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.
–Wear eye and ear protection when
using pressurized air or water.
–Disconnect battery connections before
working on machine.
–Wear protective gloves when handling
batteries or battery cables.
–Avoid contact with battery acid.
–Use manufacturer supplied or
approved 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: Moving parts. Turn off power
before working on machine.
WARNING: Actuator pinch point. Stay
clear of head lift area.

GENERAL INFORMATION
1-4 5400330735 (3–01)
The safety labels appear on the machine in the
locations indicated. Replace labels if they become
damaged or illegible.
FOR SAFETY LABEL –LOCATED
ON THE SOLUTION FLOW PANEL.
FOR SAFETY: Do not operate
machine unless operation manual
is read and understood. MOVING PARTS LABEL –LOCATED
ON THE SCRUB HEAD SHROUD.
WARNING: Moving parts. Turn off
power before working on machine.
FLAMMABLE MATERIALS LABEL –
LOCATED ON THE RECOVERY TANK
COVER.
WARNING: Flammable materials
can cause an explosion or fire. Do
not use flammable materials in
tank(s). Flammable materials or
reactive metals can cause explosion
or fire. Do not pick up.
BATTERY CHARGE LABEL –
LOCATED ON THE RECOVERY TANK
COVER AND BOTTOM SIDE OF
RECOVERY TANK.
WARNING: Batteries emit
hydrogen gas. Explosion or fire
can result. Keep sparks and open
flame away. Keep covers open
when charging.
GENERAL HAZZARD
LABEL –LOCATED ON
THE ACTUATOR
MOUNTING BRACKET
WARNING: Actuator
pinch point. Stay clear
of head lift area.

GENERAL INFORMATION
1-5
5400330735 (3–01)
SPECIFICATIONS
MODEL 610mm (24 in)
Disk Head 660mm (26 in) Disk Head 610mm (24 in) Cylindrical Head
LENGTH 1270mm (50 in) 1289mm (50.75 in) 1359mm (53.50 in)
WIDTH / WIDTH WITH SCRUB HEAD 559mm (22 in) /
641mm (25.25 in) 559mm (22 in) / 699mm (27.5 in) 559mm (22 in) / 667mm (26.25 in)
HEIGHT 1041mm (41 in) 1041mm (41 in) 1041mm (41 in)
WEIGHT 142 kg (314 lb) / 260
Kg (570 lb) with bat-
teries
142 kg (314 lb) / 260
Kg (570 lb) with bat-
teries
142 kg (314 lb) / 260
Kg (570 lb) with bat-
teries
RECOVERY TANK CAPACITY 80 L (21 Gal) 80 L (21 Gal) 80 L (21 Gal)
SOLUTION TANK CAPACITY 80 L (21 Gal) 80 L (21 Gal) 80 L (21 Gal)
ESOPTION SOLUTION FILL CAPACITY 117 L (31 Gal) 117 L (31 Gal) 117 L (31 Gal)
DRIVE SYSTEM Transaxle, 24 V, 19
kw (.25 hp) Transaxle, 24 V, 19 kw (.25 hp) Transaxle, 24 V, 19 kw (.25 hp)
CLEANING RATE 2415 m2per hour
(26,000 sq ft) 2601 m2per hour (28,000 sq ft) 2415 m2per hour (26,000 sq ft)
CLEANING PATH WIDTH 610mm (24 in) 660mm (26 in) 610mm (24 in)
PAD PRESSURE Variable 0–54 kg
(0–120 lb) Variable 0–54 kg (0–120 lb) Variable 0–41 kg (0–90 lb)
SQUEEGEE WIDTH 839mm (33 in) 839mm (33 in) 839mm (33 in)
TOTAL POWER CONSUMPTION 60 Amp nominal 60 Amp nominal 60 Amp nominal
BRUSH MOTOR Two –.75 h.p., 270
rpm, 24 V, 33 A Two –.75 h.p., 270 rpm, 24 V, 33 A Two –.63 h.p., 1700 rpm, 670 brush rpm,
24 V, 23 A
VACUUM MOTOR .75 h.p., 3–stage 5.7
in, 24 V, 21 A .75 h.p., 3–stage 5.7 in, 24 V, 21 A .75 h.p., 3–stage 5.7 in, 24 V, 21 A
WATER LIFT 1829mm (72 in) 1829mm (72 in) 1829mm (72 in)
BATTERIES Four –6 V, 235 AH Four –6 V, 235 AH Four –6 V, 235 AH
RUN TIME PER CHARGE Up to 2.5 hours Up to 2.5 hours Up to 2.5 hours
DECIBEL RATING AT OPERATOR’S EAR,
INDOORS ON TILE. 74 dB(A) 74 dB(A) 74 dB(A)

GENERAL INFORMATION
1-6 5400330735 (3–01)
MACHINE DIMENSIONS –610mm (24 in) and 660mm (26 in) DISK MODELS
641mm (25.25 in)
559mm (22 in)
1041mm (41 in)
839mm (33 in)
*699mm (27.5 in)
* Dimensions apply to 660 mm (26 in) disk models only
1270mm (50 in)
*1289mm (50.75 in)

GENERAL INFORMATION
1-7
5400330735 (3–01)
MACHINE DIMENSIONS –610mm (24 in) CYLINDRICAL BRUSH MODEL
667 mm
(26.25 in)
559 mm
(22 in)
1359 mm
(53.5 in)
1041 mm (41 in)
839 mm (33 in)

GENERAL INFORMATION
1-8 5400330735 (3–01)
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Machine will not Faulty key switch Contact Service Center
turn on Batteries need charging See CHARGING BATTERIES
Faulty battery(s) Replace battery(s)
Loose battery cable Tighten loose cable
MAIN circuit breaker has tripped Determine cause and reset breaker
Optional power kill button activated Turn button clockwise to reset
Brush motors will not Faulty brush switch Contact Service Center
turn on Control grips not rotated Rotate grips
Brush circuit breaker has tripped Replace pad or adjust pad pressure
and reset brush circuit breaker button
Faulty brush motor or wiring Contact Service Center
Worn carbon brushes Contact Service Center
Faulty brush solenoid Contact Service Center
Vacuum motor will not Faulty vacuum switch Contact Service Center
turn on Squeegee is raised off floor Lower squeegee
Main circuit breaker has tripped Remove obstruction and reset circuit
breaker button
Vacuum motor circuit breaker has
tripped Determine cause and reset circuit breaker button
Faulty vacuum motor or wiring Contact Service Center
Worn carbon brushes Contact Service Center
Little or no solution Solution switch is not activated Turn on solution switch
flow Clogged solution line or solution tank
filter Remove hose and blow compressed air through it. Flush solution tank after
each use
Clogged solution valve or solenoid Remove valve or solenoid and clean.
Do not scratch inside of valve
Faulty solution switch or solenoid Contact Service Center
Solution flow knob not activated Turn solution flow knob
Loose set screw on solution knob Calibrate knob and tighten screw
Poor Scrubbing Brushes/pads out of adjustment See ADJUSTING SCRUB HEAD
Performance Worn Brushes/pads Replace brushes/pads
Debris caught in brushes/pads Remove debris
Low tire pressure Increase tire pressure
Low battery charge Charge batteries
Incorrect brush/pad pressure Readjust brush/pad pressure
Broken Brush belt (cylindrical brush) Replace belts
Poor Drive Traction Pad pressure set too high Decrease brush pressure
Tires slipping Contact distributor for advice
Uneven brush pressure Level scrub head
Broken brush belt (cylindrical brush) Replace belt

GENERAL INFORMATION
1-9
5400330735 (3–01)
TROUBLESHOOTING –Continued
PROBLEM CAUSE SOLUTION
Poor water pickup Recovery tank is full and ball float has
been activated Empty recovery tank
Ball float screen inside recovery tank
is clogged Remove screen and clean
Clogged squeegee Clean squeegee
Worn squeegee blades Replace squeegee blades
Loose squeegee thumbscrews Tighten thumbscrews
Vacuum hose connections are loose
or hose has a hole Push hose cuffs firmly on connections. Replace hose if damaged
Clogged vacuum hose Remove clogged debris
Recovery tank inlet hole is obstructed Empty recovery tank and tilt tank side-
ways to access inlet hole, remove ob-
struction
Worn tank lid gasket Replace gasket
Loose drain hose plug Tighten plug
Recovery tank lid not in place Properly position lid
Loose vacuum motor Contact Service Center
Battery charge level is low Charge batteries. Do not run machine
when battery meter is in the red zone
ESoption not ESfilter is clogged Remove and clean ESfilter
operating Faulty ESpump Contact Service Center
Faulty ESON/OFF switch Contact Service Center
ESfloat switch is dirty Rinse off float switch located in
recovery tank
Faulty ESfloat switch Contact Service Center
Short run time Batteries not fully charged Charge batteries
Defective batteries Replace battery
Batteries need maintenance See BATTERY MAINTENANCE
Faulty charger Repair or replace battery charger

GENERAL INFORMATION
1-10 5400330735 (3–01)
MACHINE JACKING
Use designated locations under the solution tank
for jacking up machine. Use a piece of wood to
distribute machine weight load.
Always stop machine on a flat level surface and
block machine tires before jacking up machine.
FOR SAFETY: When servicing machine, block
machine tires before jacking machine up.
FOR SAFETY: When servicing machine, jack
machine up at designated locations only.
Block machine up with jack stands.
MACHINE TRANSPORTING
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
FOR SAFETY: When using machine, go slow
on inclines and slippery surfaces.
When transporting machine by use of trailer or
truck, be certain to follow tie–down procedures
below:
1. Raise squeegee and scrub head.
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 scrub head and squeegee.
4. Set parking brake, if equipped, and place a
block behind each drive wheel to prevent
machine from rolling.

GENERAL INFORMATION
1-11
5400330735 (3–01)
STORING MACHINE
Before storing the machine for an extended period
of time, the machine needs to be prepped to
lessen the chance of rust, sludge, and other
undesirable deposits from forming. Contact
TENNANT service personnel.
TO STORE MACHINE
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Set Parking
Brake, Turn Off Machine And Remove Key.
1. Make sure the tanks are drained and rinsed
out.
2. Un–plug the batteries and charge them
properly.
STORAGE INFORMATION
The following steps should be taken when storing
the machine for extended periods of time.
1. Drain and clean the solution and recovery
tanks.
2. Park the machine in a cool, dry area.
3. Remove the batteries, or charge them after
every three months.

GENERAL INFORMATION
1-12 5400330735 (3–01)
HARDWARE INFORMATION
The following charts state standard plated
hardware tightening ranges for normal assembly
applications. Decrease the specified torque by
20% when using a thread lubricant. Do not
substitute lower grade hardware for higher grade
hardware. If higher grade hardware than specified
is substituted, tighten only to the specified
hardware torque value to avoid damaging the
threads of the part being threaded into, as when
threading into speed nuts or weldments.
STANDARD BOLT TORQUE CHART
Thread
Size
SAE Grade 5
Torque ft lb
(Nm)
SAE Grade 8
Torque ft lb
(Nm)
0.25 in 7–10 (9–14) 10–13 (14–38)
0.31 in 15–20 (20–27) 20–26 (27–35)
0.38 in 27–35 (37–47) 36–47 (49–64)
0.44 in 43–56 (58–76) 53–76 (72–103)
0.50 in 65–85 (88–115) 89–116
(121–157)
0.62 in 130–170
(176–231) 117–265 (159–359)
0.75 in 215–280
(291–380) 313–407 (424–552)
1.00 in 500–650
(678–881) 757–984 (1026–1334)
NOTE: Decrease torque by 20% when using a
thread lubricant.
METRIC BOLT TORQUE CHART
Thread
Size
Class 8.8
Torque ft lb
_Nm)
Class 10.9
Torque ft lb
(Nm)
M4 2 (3) 3 (4)
M5 4 (5) 6 (8)
M6 7 (9) 10 (14)
M8 18 (24) 25 (34)
M10 32 (43) 47 (64)
M12 58 (79) 83 (112)
M14 94 (127) 133 (180)
M16 144 (195) 196 (265)
M20 260 (352) 336 (455)
M24 470 (637) 664 (900)
NOTE: Decrease torque by 20% when using a
thread lubricant.
Exceptions to the above chart:
Check the machine for exceptions!
BOLT IDENTIFICATION
Identification
Grade Marking Specification and Grade
SAE–Grade 5
SAE–Grade 8
ISO–Grade 8.8
ISO–Grade 10.9
01395
THREAD SEALANT AND LOCKING
COMPOUNDS
Thread sealants and locking compounds may be
used on this machine. They include the following:
Locktite 515 sealant –gasket forming
material. TENNANT Part No. 75567,15 oz
(440 ml) cartridge.
Locktite 242 blue –medium strength thread
locking compound. TENNANT Part No.
32676, 0.5 ml tube.
Locktite 271 red –high strength thread
locking compound. TENNANT Part No.
19857, 0.5 ml tube.

CHASSIS
2-1
5400330735 (3–01)
CONTENTS
Page
INTRODUCTION 2–3. . . . . . . . . . . . . . . . . . . . . .
DRIVE TRANSAXLE 2–4. . . . . . . . . . . . . . . . . .
TO REMOVE DRIVE TRANSAXLE 2–4. . .
TO INSTALL THE TRANSAXLE 2–6. . . . . .
TO REPLACE DRIVE WHEEL/TIRE
ASSEMBLY 2–7. . . . . . . . . . . . . . . . . . . . .
REAR CASTER 2–9. . . . . . . . . . . . . . . . . . . . . . .
TO REPLACE REAR CASTER 2–9. . . . . . .

CHASSIS
2-2 5400 330735 (3–01)

CHASSIS
2-3
5400 330735 (3–01)
INTRODUCTION
This section includes information on the main
chassis related components for example the
transaxle, casters, and tires.
The transaxle drive motor and transaxle must be
replaced as one unit.

CHASSIS
2-4 5400330735 (3–01)
DRIVE TRANSAXLE
The drive transaxle on the 5400 provides the
forward and reverse movement for the machine.
The drive transaxle is powered by a 24V electric
motor.
TO REMOVE DRIVE TRANSAXLE
1. Lower the scrub head all the way to the
floor.
FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.
2. Turn the machine power off.
3. Lift the rear of the machine until the
transaxle drive wheels are off the ground.

CHASSIS
2-5
5400330735 (3–01)
4. Place a jackstand under the machine frame.
5. Remove the four 0.250 in. hex nuts and
washers holding each drive wheel to the
transaxle. Remove the drive wheels from the
machine.
6. Un–plug the transaxle drive motor from the
main harness.
7. Remove the four M8 hex screws and
washers holding the two transaxle mount
brackets to the machine frame.
8. The transaxle can now be removed from the
machine.

CHASSIS
2-6 5400330735 (3–01)
TO INSTALL THE TRANSAXLE
1. Position the new transaxle under the
machine frame. Make sure the drive motor
electric lead is positioned on the left hand
side of the machine.
2. Lift the transaxle up into the machine frame
until the mount brackets and M8 hex screws
can be reinstalled. Tighten to 18 –24 Nm
(15 –20 ft lb).
3. Plug the drive motor into the main harness.
See schematic in the ELECTRICAL section
of this manual.
4. Reinstall the drive wheels onto the transaxle
using the four 0.250 in. hex nuts and
washers. Tighten to 11 –14 Nm
(7 –10 ft lb).
5. Remove the jack stands and lower the
machine to the ground.
6. Raise the scrubber head.
7. Operate the machine, checking for proper
operation of the transaxle.