Tennant 5680 User manual

Drive Module Replacement Kit
KIT NO. 9011905 Page1of4
Model: 5680
9011904 Rev. 02 (02- 2015) 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.
3. Remove electrical cover from control board.
Discard cover, it’s not required with new module.
Disconnect the wire connections from old board
and remove board from machine (two screws).
Discard old board.
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.
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.

Drive Module Replacement Kit
INSTALLATION INSTRUCTIONS - Continued
Page2of4
KIT NO. 9011905
9011904 Rev. 02 (02- 2016) Tennant Company www.tennantco.com
5. Reconnect the existing harness wires to the
new drive module as shown.
23A/Orange
13D/Black
21/Pink
22/Brown
6. Connect the new wire harness to the new
drive module as shown.
7. Disconnect the three potentiometer wire
connections (6/Blue, 5/Green and 4D/Yellow)
and remove the old potentiometer from machine.
Remove Potentiometer
Potentiometer
Wires
8. Connect wires (36/Blue, 35/Green &
44/Yellow) from the new wire harness to the wire
terminals that were disconnected in step 7.
9. Install the new potentiometer as shown. 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

Drive Module Replacement Kit
INSTALLATION INSTRUCTIONS - Continued
Page3of4
KIT NO. 9011905
9011904 Rev. 02 (02- 2016) 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.
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
10. Connect the new potentiometer wire harness
to the new wire harness wires (white to 39/white,
red to1B/red and black to13AA/black).
11. Disconnect wire 2/Brown from the propel
circuit breaker (CB3) and replace with wire
1C/Red from the new wire harness as shown.
NOTE: For early models, remove wire 2A/Brown
from propel circuit breaker (CB2) and replace with
wire 1C/Red from new harness (not shown). Also
disable CB1 by removing wires 3A/3C/Orange.
CB1 is no longer needed with new drive module.
Disconnect
wire 2/Brown Connect wire
1C/Red
12. Cut cable- tie to locate the charger interlock
wire connections within the machine’s wire
harness as shown. Remove the electrical tape
and disconnect the orange wire from blue wires.
NOTE: For early models, if harness is not
equipped with charger interlock wires as shown,
refertoStep13NOTE.
Disconnect
Charger
interlock
wires

Drive Module Replacement Kit
INSTALLATION INSTRUCTIONS - Continued
Page4of4
KIT NO. 9011905
9011904 Rev. 02 (02- 2016) Tennant Company www.tennantco.com
13. Connect wire 33/Orange from the new wire
harness to the blue charger interlock wires as
shown below. Re- wrap wire connections with
electrical tape.
NOTE: For early models, disconnect wire
3B/Orange from key switch and connect wire
33/Orange from new wire harness to key switch
(not shown).
Connect wire
33/Orange
14. Connect wire 13AC/Black from the new wire
harness to the contactor terminal as shown.
Connect wire
13AC/Black
15. Connect wire 1C/Red from the new wire
harness to the main contactor terminal as shown.
Connect
wire 1C/Red
16. Remove the old battery discharge indicator
(BDI) from control housing. Save screws.
17. Connect wires 13AB/Black and 3A/Yellow from
the new wire harness to the yellow and black
wires that were disconnected from the old BDI.
NOTE: The orange wire is no longer required
and can be removed from the machine.
18. Install the new battery discharge indicator
(BDI) and connect the new wire harness as
shown. Discard the wire harness that is packaged
with the new BDI. It’s not required.
From new
wire harness
19. Test machine for proper operation.