Tennant 7200 User manual

330045
Rev. 02 (3--02)
Service Manual
7200

This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT
Model 7200 ride on scrubber.
The set is organized into four major groups: General Information, Chassis, Scrubbing, and Electrical.
General Information: Safety precautions, machine transport, machine jacking, machine storage, chassis
lubrication, machine specifications, and machine maintenance chart.
Chassis: Tire/wheel replacement, brake adjustment and replacement, steering adjustment and
replacement.
Scrubbing: Scrub head repair/replacement, brush repair/replacement, skirt/seal repair/replacement,
squeegee repair/replacement, solution and recovery tank repair/replacement, and scrubbing
troubleshooting.
Electrical: Battery maintenance and replacement, electric motor removal, electrical schematics,
diagnostics, and electrical troubleshooting.
Manual Number -- 330045
Revision: 02
Published: 3--02
Copyright E1999, 2002 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
1-1
7200 330045 (3--02)
CONTENTS
Page
SAFETY PRECAUTIONS 1-3..............
SPECIFICATIONS 1-5....................
GENERAL MACHINE
DIMENSIONS/CAPACITIES 1-5.........
GENERAL MACHINE PERFORMANCE 1-5..
POWER TYPE 1-6........................
TIRES 1-6...............................
MACHINE DIMENSIONS 1-7...............
MAINTENANCE 1-8......................
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE 1-10...................
PUSHING OR TOWING THE MACHINE 1-10
TRANSPORTING THE MACHINE 1-10......
MACHINE JACKING 1-13..................
TO JACK UP MACHINE 1-13..............
STORAGE INFORMATION 1-14............
FREEZE PROTECTION 1-14..............
HARDWARE INFORMATION 1-15..........
STANDARD BOLT TORQUE CHART 1-15...
METRIC BOLT TORQUE CHART 1-15......
BOLT IDENTIFICATION 1-15...............
THREAD SEALANT AND LOCKING
COMPOUNDS 1-15....................

GENERAL INFORMATION
1-2 7200 330045 (10--99)

GENERAL INFORMATION
1-3
7200 330045 (3--02)
SAFETY PRECAUTIONS
The following symbols are used throughout this
manual as indicated in their description:
WARNING: To warn of hazards or
unsafe practices that could result in
severe personal injury or death.
FOR SAFETY: To identify actions that
must be followed for safe operation of
equipment.
This machine is designed solely for scrubbing dirt
and dust in an indoor environment. Tennant does
not recommend using this machine in any other
environment.
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.
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 an explosion
or fire. Do not pickup.
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.
-- Check brakes and steering for proper
operation (if so equipped).
3. When using machine:
-- Go slow on inclines and slippery
surfaces.
-- Use care when backing machine.
-- Follow mixing and handling
instructions on chemical containers.
4. Before leaving or servicing machine:
-- Stop on level surface.
-- Set parking brake (if equipped).
-- 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 that will support the
weight of the machine.
-- Wear eye and ear protection when
using pressurized air or water.
-- Disconnect battery connections before
working on machine.
-- Avoid contact with battery acid.
-- Use Tennant supplied or equivalent
replacement parts.
6. When loading/unloading machine
onto/off truck or trailer.
-- Turn off machine.
-- Use truck or trailer that will support
the weight of the machine.
-- Use winch. Do not push the machine
onto/off the truck or trailer unless the
load height is 380 mm (15 in) or less
from the ground.
-- Set parking brake after machine is
loading (option).
-- Block machine tires.
-- Tie machine down to truck or trailer.

GENERAL INFORMATION
1-4 7200 330045 (10--99)
The safety labels appear on the machine in the
locations indicated. If these or any label becomes
damaged or illegible, install a new label in its
place.
BATTERY CHARGING LABEL -- LOCATED ON
AND UNDERNEATH THE SEAT SUPPORT.
FLAMMABLE SPILLS LABEL --
LOCATED ON THE SEAT SUPPORT.
FOR SAFETY LABEL -- LOCATED ON THE
SEAT SUPPORT.
FLAMMABLE MATERIALS LABEL -- LOCATED
ON THE UNDERSIDE OF THE TANK COVER
AND ON THE LEFT SIDE OF THE OPERATOR
COMPARTMENT.
350656

GENERAL INFORMATION
1-5
7200 330045 (3--02)
SPECIFICATIONS
GENERAL MACHINE DIMENSIONS/CAPACITIES
Item Dimension/capacity
Length 1830 mm (72 in)
Length (with Pre--Sweept)2465 mm (97 in)
Width (less squeegee) 1020 mm (40.25 in)
Width (with squeegee) 1155 mm (45.5 in)
Height 1360 mm (53.5 in)
Height with overhead guard 2032 mm (80 in)
Disk brush diameter for side brush (option) 455 mm (18 in)
Disk brush diameter for Pre--Sweept(option) 380 mm (15 in)
Disk brush diameter for 700 mm (28 in) scrub head 355 mm (14 in)
Disk brush diameter for 900 mm (36 in) scrub head 455 mm (18 in)
Cylindrical sweep brush diameter for Pre--Sweept(option) 150 mm (6 in)
Cylindrical sweep brush length for Pre--Sweept(option) 810 mm (32 in)
Cylindrical scrub brush diameter 150 mm (6 in)
Cylindrical brush length for 700 mm (28 in) scrub head 700 mm (28 in)
Cylindrical brush length for 900 mm (36 in) scrub head 900 mm (36 in)
Squeegee width for 700 mm (28 in) scrub head 950 mm (37.5 in)
Squeegee width for 900 mm (36 in) scrub head 1155 mm (45.5 in)
Scrubbing path width for 700 mm (28 in) scrub head 700 mm (28 in)
Scrubbing path width for 900 mm (36 in) scrub head 900 mm (36 in)
Solution tank capacity 130 L (35 gallons)
Recovery tank capacity 210 L (55 gallons)
GVWR 1134 Kg (2500 lbs)
GENERAL MACHINE PERFORMANCE
Item Measure
Aisle turnaround width 2080 mm (82 in)
Aisle turnaround width (with Pre--Sweept)2770 mm (109 in)
Travel Speed 9.6 Km (6 mph)
Maximum rated climb and descent angle for transport 8_@ gross weight
Maximum rated climb and descent angle for scrubbing 4_
Maximum rated climb and descent angle for trailering 11_

GENERAL INFORMATION
1-6 7200 330045 (3--02)
POWER TYPE
Type Quantity Volts Ah Rating Weight
Batteries 66235 @ 20 hr rate 30 kg (67 lb)
66335 @ 20 hr rate 47 kg (104 lb)
Type Use VDC kW (hp)
Electric Motors Pre--Sweeptbrush (disk) 36 0.20 (0.25)
Pre--Sweeptbrush (cyl) 36 0.45 (0.60)
S
c
r
u
b
b
r
u
s
h
(
d
i
s
k
)
3
6
0
5
6
(
0
7
5
)
S
cru
b
b
rus
h
(
d
i
s
k
)
3
6
0
.
5
6
(
0
.
7
5
)
Scrub brush (cyl) 36 0.56 (0.75)
V
a
c
u
u
m
f
a
n
3
6
0
6
(
0
8
)
V
acuum
f
an
3
6
0
.
6
(
0
.
8
)
P
r
o
p
e
l
l
i
n
g
3
6
1
1
(
1
5
)
P
rope
l
l
i
ng
3
6
1
.
1
(
1
.
5
)
Type VDC amp Hz Phase VAC
Chargers (Smart) 36 20 60 1120
36 20 50 1230
36 20 50 1245
36 30 60 1120
36 30 50 1230
36 30 50 1245
TIRES
Location Type Size
Front (1) Solid 100 mm wide x 305 mm OD (4 in wide x 12 in OD)
Rear (2) Solid 90 mm wide x 305 mm OD (3.5 in wide x 12 in OD)

GENERAL INFORMATION
1-7
7200 330045 (3--02)
TOP VIEW
SIDE VIEW
2032 mm
(80.0 in)
1360 mm
(53.5 in)
+
--
921 mm
(36.25 in)
1155 mm
(45.5 in)
1092 mm
(43.0 in)
1830 mm
(72.0 in)
1020 mm
(40.25 in)
1025 mm
(40.35 in)
405 mm
(16.0 in)
810 mm
(32.0 in)
FRONT VIEW
915 mm
(36.0 in)
350790
MACHINE DIMENSIONS

GENERAL INFORMATION
1-8 7200 330045 (3--02)
MAINTENANCE
1
2
23
4
1
15
5
6
7
8
9
10
10
11
13
12
14
350790

GENERAL INFORMATION
1-9
7200 330045 (3--02)
MAINTENANCE CHART
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 1Side and rear squeegees Check for damage and wear -- 3
y
2Scrub brushes Check for damage, wear, debris -- 2
8Recovery tank Clean tank -- 1
8Recovery tank, EStmode Clean EStfilter -- 1
7Solution tank, EStmode Clean solution supply filter -- 1
9Vacuum fan inlet filter Clean -- 1
-- Machine Check for leaks -- 3
11 Cylindrical brushes only:
debris trough
Clean -- 1
12 Pre--Sweeptbrushes Check for damage and wear -- 2
12 Pre--Sweeptdebris hop-
per
Clean -- 1
50 Hours 15 Pre--Sweeptcylindrical
brushes
Check taper -- 1
5Cylindrical scrub brushes Check taper and rotate front to
rear
-- 2
10 Squeegee caster wheels
and pivot points
Lubricate SPL 4
4Battery cells Check electrolyte level DW 3
1Side and rear squeegees Check deflection and leveling -- 6
14 Pre--Sweeptskirts
and seals
Check for damage and wear -- 4
100 Hours 5Cylindrical scrub brush
drive belts
Check tension and wear -- 2
13 Pre--Sweept
brush drive belts
Check tension and wear -- 2
3Steering caster pivot bear-
ing
Lubricate SPL 1
200 Hours 4Battery terminals and
cables
HCheck and clean -- 12
6Steering gear chain Lubricate GL 1
500 Hours 9Vacuum fan motor(s) Check motor brushes -- 1
Steering gear chain HCheck deflection -- 1
1000 5Brush drive motors Check motor brushes -- 2(4)
Hours 6Propelling motor Check motor brushes -- 1
6Rear wheel nuts Torque wheel nuts -- 3
LUBRICANT/FLUID
DW Distilled water....
SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)...
GL SAE 90 weight gear lubricant....
NOTE: Also check procedures indicated (H) after the first 50 hours of operation.

GENERAL INFORMATION
1-10 7200 330045 (3--02)
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE
PUSHING OR TOWING THE MACHINE
If the machine becomes disabled, it can be
pushed or towed from the front or rear.
Only push or tow the machine for a very short
distance and do not exceed 3.2 kp/h (2 mph). It is
NOT intended to be pushed or towed for a long
distance or at a high speed.
ATTENTION! Do not push or tow
machine for a long distance or damage
may occur to the propelling system.
TRANSPORTING THE MACHINE
1. Position the rear of the machine at the
loading edge of the truck or trailer.
FOR SAFETY: Use truck or trailer that
will support the weight of the machine.
NOTE: Empty the recovery and solution tanks
before transporting the machine.

GENERAL INFORMATION
1-11
7200 330045 (3--02)
2. If the loading surface is not horizontal or is
higher than 380 mm (15 in) from the ground,
use a winch to load machine.
If the loading surface is horizontal AND is
380 mm (15 in) or less from the ground, the
machine may be driven onto the truck or
trailer.
3. To winch the machine onto the truck or
trailer, attach the winching chains to the rear
tie down locations. The rear tie-down
locations are the holes in the sides of the
machine frame near the rear bumper.
FOR SAFETY: When loading machine
onto truck or trailer, use winch. Do not
drive the machine onto the truck or
trailer unless the loading surface is
horizontal AND is 380 mm (15 in) or less
from the ground.
4. Position the machine onto the truck or trailer
as far as possible. If the machine starts to
veer off the centerline of the truck or trailer,
stop and turn the steering wheel to center
the machine.
5. Set the parking brake, lower the scrub head
and block the machine tires. Tie down the
machine to the truck or trailer before
transporting.
The front tie-down locations are the holes in
the front side of the machine frame.

GENERAL INFORMATION
1-12 7200 330045 (3--02)
The rear tie-down locations are the holes in
the sides of the machine frame near the rear
bumper.
6. If the loading surface is not horizontal or is
higher than 380 mm (15 in) from the ground,
use a winch to unload machine.
If the loading surface is horizontal AND is
380 mm (15 in) or less from the ground, the
machine may be driven off the truck or
trailer.
FOR SAFETY: When unloading machine
off truck or trailer, use winch. Do not
drive the machine off the truck or trailer
unless the loading surface is horizontal
AND 380 mm (15 in) or less from the
ground.

GENERAL INFORMATION
1-13
7200 330045 (10--99)
MACHINE JACKING
TO JACK UP MACHINE
FOR SAFETY: Before Leaving Or
Servicing Machine; Stop On Level
Surface, Set Parking Brake.
The model 7200 can be jacked up from any of the
four corners. Always empty the solution and
recovery tanks before jacking.
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.
7. TO JACK UP THE FRONT: Place blocks
behind the rear tires when jacking up the
front of the machine. Place jack stands
under the machine frame after the machine
is at the desired level.
8. TO JACK UP THE REAR: The front of the
machine must be placed on jack stands
before the rear of the machine can be
jacked up. If this is not done the machine will
tip or rock on the jack because of the single
front tire. Place jack stands under the rear of
the machine after lifting.

GENERAL INFORMATION
1-14 7200 330045 (10--99)
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.
EStmachines: Run clean water through
the solution system and the EStsolution
pump.
2. Park the machine in a cool, dry area.
3. Remove the batteries, or charge them every
three months.
FREEZE PROTECTION
1. Be sure the solution tank is empty.
2. Pour 3.8 L (1 gal) of pre-mixed
automotive-type windshield washer solution
into the solution tank.
3. Turn the machine power on.
4. Start the solution flow. Start the power wand
solution system and EStsystem to
circulate the washer solution through the
components.
5. The washer solution does not need to be
drained from the solution tank.

GENERAL INFORMATION
1-15
7200 330045 (10--99)
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.

GENERAL INFORMATION
1-16 7200 330045 (3--02)

CHASSIS
2-1
7200 330045 (10--99)
CONTENTS
Page
INTRODUCTION 2--3......................
SEAT 2--4................................
OPERATOR SEAT 2--4.................
TO REMOVE SEAT ASSEMBLY 2--4..
TO INSTALL SEAT ASSEMBLY 2--6...
TO ADJUST SEAT POSITION 2--7....
STATIC DRAG CHAIN 2--7.................
BRAKES AND TIRES 2--8..................
SERVICE BRAKES 2--8.................
PARKING BRAKE 2--8..................
TO ADJUST SERVICE BRAKES 2--9..
TO ADJUST PARKING BRAKE 2--10..
TO REPLACE DRIVE ASSEMBLY
BRAKE SHOES 2--11.............
REAR TIRES AND WHEELS 2--15..........
TO REMOVE REAR TIRE 2--15..........
TO INSTALL REAR TIRE 2--16...........
TO REPLACE REAR WHEEL
BEARINGS 2--17....................
FRONT TIRE AND WHEEL, AND WHEEL
DRIVE SUPPORT 2--19.................
FRONT WHEEL SUPPORT CASTER
BEARING ASSEMBLY 2--19..........
TO REMOVE FRONT DRIVE
ASSEMBLY 2--20....................
TO INSTALL FRONT DRIVE
ASSEMBLY 2--22....................
TO REPLACE DRIVE ASSEMBLY
CASTER BEARING AND
THRUST WASHERS 2--24.........
TO REPLACE DRIVE ASSEMBLY
PIVOT CONE BEARING 2--29........
Page
PLANETARY GEAR BOX 2--32.............
TO REMOVE PLANETARY GEAR
BOX 2--32..........................
TO INSTALL PLANETARY GEAR
BOX 2--34..........................
TO REPLACE FRONT TIRE AND
WHEEL ASSEMBLY 2--36............
TO REPLACE FRONT DRIVE
ASSEMBLY OUTER WHEEL
BEARING 2--40..................
TO REPLACE FRONT DRIVE
ASSEMBLY INNER WHEEL
BEARING 2--42..................
STEERING 2--46..........................
TO ADJUST STEERING CHAIN 2--46....
TO REPLACE STEERING CHAIN 2--47...
TO REPLACE LARGE STEERING
SPROCKET 2--48...................
TO REPLACE SMALL STEERING
SPROCKET 2--50...................
TO REPLACE STEERING HOUSING
BEARINGS 2--52....................
TO REPLACE STEERING U--JOINT 2--56.

CHASSIS
2-2 7200 330045 (10--99)