Tennant 7400 User manual

7400
Service Manual
MM428
Rev. 04 (3--02)

This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT
Model 7400.
This manual is organized into seven major groups: General Information, Chassis, Scrubbing, Electrical,
Hydraulics, Engine--G/LPG and Engine--D.
General Information: Machine transport, machine jacking, machine storage, machine specifications, and
machine maintenance chart.
Chassis: Tire/wheel replacement, brake adjustment and replacement, chassis lubrication, steering
adjustment and replacement.
Scrubbing: Scrubber head repair/replacement, brush repair/replacement. squeegee repair/replacement,
and scrubber troubling shooting.
Electrical: Battery maintenance and replacement, instrument panel replacement, and electrical
troubleshooting.
Hydraulics: Valve replacement/repair, motor replacement/repair, cylinder replacement/repair, pump
replacement/repair, filter replacement, and hydraulics troubleshooting.
Engine -- G/LPG: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system
maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine
repairs.
Engine -- D: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system
maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine
repairs.
Manual Number -- MM428
Revision: 04
Published: 3--02
CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Copyright E1996, 1998, 2001, 2002 TENNANT, Printed in U.S.A.

GENERAL INFORMATION
1-1
7400 MM428 (6--01)
CONTENTS
Page
SAFETY PRECAUTIONS 1--3..............
SPECIFICATIONS 1--6....................
GENERAL MACHINE
DIMENSIONS/CAPACITIES 1--6......
GENERAL MACHINE PERFORMANCE1--6
POWER TYPE 1--7.....................
STEERING 1--7........................
HYDRAULIC SYSTEM 1--8..............
BRAKING SYSTEM 1--8................
TIRES 1--8.......................
MACHINE DIMENSIONS 1--9...............
MAINTENANCE 1--10.....................
MAINTENANCE CHART / G/LP 1--10.....
MAINTENANCE CHART / DIESEL 1--12..
PUSHING, TOWING, AND
TRANSPORTING THE MACHINE 1--14...
PUSHING OR TOWING
THE MACHINE 1--14.................
TRANSPORTING THE MACHINE 1--15...
MACHINE JACKING 1--17...............
STORING MACHINE 1--18..............
HARDWARE INFORMATION 1--19..........
STANDARD BOLT TORQUE CHART 1--19
METRIC BOLT TORQUE CHART 1--19...
BOLT IDENTIFICATION 1--19............
THREAD SEALANT AND LOCKING
COMPOUNDS 1--19.................
HYDRAULIC FITTING INFORMATION1--20
HYDRAULIC TAPERED PIPE FITTING (NPT)
TORQUE CHART 1--20..............
HYDRAULIC TAPERED SEAT FITTING (JIC)
TORQUE CHART 1--20..............
HYDRAULIC O--RING FITTING TORQUE
CHART 1--20......................

GENERAL INFORMATION
1-2 7400 MM428 (6--01)

GENERAL INFORMATION
1-3
7400 MM428 (6--01)
SAFETY PRECAUTIONS
The following precautions 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 machine is suited to sweep disposable
debris. Do not use the machine other than
described in this Operator Manual. The machine
is not designed for use on public roads.
The following information signals potentially
dangerous conditions to the operator or
equipment:
FOR SAFETY:
1. Do not operate machine:
-- Unless trained and authorized.
-- Unless operator manual is read and
understood.
-- If it is not in proper operating
condition.
-- 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:
-- Check for fuel, oil, and liquid leaks.
-- Keep sparks and open flame away
from refueling area.
-- Make sure all safety devices are in
place and operate properly.
-- Check brakes and steering for proper
operation.
3. When starting machine:
-- Keep foot on brake and directional
pedal in neutral.
4. When using machine:
-- Use brakes to stop machine.
-- Go slow on inclines and slippery
surfaces.
-- Use care when reversing machine.
-- Do not carry passengers on machine.
-- Always follow safety and traffic rules.
-- Report machine damage or faulty
operation immediately.
5. Before leaving or servicing machine:
-- Stop on level surface.
-- Set parking brake.
-- Turn off machine and remove key.
6. 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.
-- Avoid contact with battery acid.
-- Avoid contact with hot engine coolant.
-- Allow engine to cool.
-- Keep flames and sparks away from
fuel system service area. Keep area
well ventilated.
-- Use cardboard to locate leaking
hydraulic fluid under pressure.
-- Use Tennant supplied or approved
replacement parts.
WARNING: Engine emits toxic gases.
Severe respiratory damage or
asphyxiation can result. Provide
adequate ventilation. Consult with your
regulatory authorities for exposure
limits. Keep engine properly tuned.
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 belt and fan. Keep
away.
WARNING: Strong Vacuum. Keep Away
From Fan Inlet When Fan Is Running.

GENERAL INFORMATION
1-4 7400 MM428 (6--01)
The following safety labels are mounted on the
machine in the locations indicated. If these or any
labels become damaged or illegible, install a new
label in its place.
EMISSIONS LABEL -- LOCATED ON THE SIDE
OF THE OPERATOR COMPARTMENT.
10783
FOR SAFETY LABEL -- LOCATED ON THE
SIDE OF THE OPERATOR COMPARTMENT.
FLAMMABLE SPILLS LABEL -- LOCATED ON
THE SIDE OF THE OPERATOR
COMPARTMENT.

GENERAL INFORMATION
1-5
7400 MM428 (6--01)
FAN AND BELT LABEL -- LOCATED ON THE
ENGINE COMPARTMENT LINTEL.
10783
STRONG VACUUM LABEL -- LOCATED ON
THE VACUUM FAN HOUSING.
FLAMMABLE MATERIALS LABEL -- LOCATED
NEXT TO THE SOLUTION TANK COVERS AND
ON THE DETERGENT TANK.

GENERAL INFORMATION
1-6 7400 MM428 (6--01)
SPECIFICATIONS
GENERAL MACHINE DIMENSIONS/CAPACITIES
Item Dimension/capacity
Length 2460 mm (97 in)
Width 1525 mm (60 in)
Width with optional side brush 1590 mm (62.5 in)
Height 1475 mm (58 in)
Height with overhead guard 2045 mm (80.5 in)
Main scrub brush diameter 280 mm (11 in)
Main scrub brush length 1140 mm (45 in)
Side scrub brush diameter (option) 410 mm (16 in)
Squeegee width 1525 mm (60 in)
Scrubbing path width 1140 mm (45 in)
Scrubbing path width with optional side brush 1450 mm (57 in)
Debris tray volume capacity 42L(1.5 ft
3)
Solution tank 265 L (70 gal)
Recovery tank 272 L (72 gal)
Detergent tank (option) 25 L (6.7 gal)
Total capacity with ESt(option) 397 L (105 gal)
GVWR 2087 kg (4600 lb)
GENERAL MACHINE PERFORMANCE
Item Measure
Maximum forward speed 12.9 kmh (8 mph)
Maximum reverse speed 6.4 kmh (4 mph)
Minimum aisle turn width 3190 mm (125.5 in)
Minimum turning radius, right 2660 mm (104.75 in)
Minimum turning radius, left 2030 mm (79.75 in)
Maximum rated incline for scrubbing 6_
Maximum rated incline for transport of machine 8_

GENERAL INFORMATION
1-7
7400 MM428 (6--01)
POWER TYPE
Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke
Kubota
V1505--B (E)
Piston Diesel 4Natural 478 mm
(3.07 in)
78.4 mm
(3.08 in)
Displacement Net power, governed Net power, maximum
1500 cc (91.4 cu in) 24.6 kw (34 hp) @ 2400 rpm 27.2 kw (37.5 hp) @
3000 rpm
Fuel Cooling system Electrical system
Diesel
Fuel tank: 42 L (11.2 gal)
Water/ethylene glycol
antifreeze
12 V nominal
Total: 7.5 L (2 gal) 37 A alternator
Radiator: 3.8 L (1 gal)
Idle speed, no load (Fast) governed speed, under
load
Engine lubricating oil
without filter
950 +50 rpm 2400 +50 rpm 6 L (6.35 qt)
SAE--CC/CD rated
engine oil
Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke
Ford VSG 1.3 Piston Distributorless-
type spark
4Natural 474 mm
(2.91 in)
75 mm
(2.97 in)
Displacement Net power, governed Net power, maximum
1300 cc (79 cu in) 23.2 kw (32 hp) @ 2400 rpm 39.5 kw (53 hp) @
4000 rpm
Fuel Cooling system Electrical system
Gasoline, 87 octane
minimum, unleaded.
Fuel tank: 42 L (11.2 gal)
Water/ethylene glycol
antifreeze
12 V nominal
LPG,
F
l
t
k
1
5
k
(
3
3
l
b
)
Total: 7.5 L (2 gal) 50 A alternator
Fuel tank: 15 kg (33 lb) Radiator: 3.8 L (1 gal)
Idle speed, no load (Fast) governed speed, under
load
Firing order
1350 + 250 rpm 2400 + 50 rpm 1--2--4--3,
counterclockwise
rotation
Spark plug gap Valve clearance, cold Engine lubricating oil
with filter
1 mm (0.04 in) 0.20 mm (0.008 in) intake
0.50 mm (0.002 in) exhaust
3.3 L (3.5 qt) 10W30
SAE--SG/SH

GENERAL INFORMATION
1-8 7400 MM428 (6--01)
STEERING
Type Power source Emergency steering
Front wheel, hydraulic cylinder
and rotary valve controlled
Hydraulic accessory pump Manual
HYDRAULIC SYSTEM
System Capacity Fluid Type
Hydraulic reservoir 38 L (10 gal) TENNANT part no. 65869 -- above 7_C(45_F)
Hydraulic total 74 L (19.5 gal) TENNANT part no. 65870 -- below 7_C(45_F)
BRAKING SYSTEM
Type Operation
Service brakes Mechanical drum brakes (2), one per rear wheel,
cable actuated
Parking brake Utilize service brakes, cable actuated
TIRES
Location Type Size Pressure
Front (1) Solid 460 x 130 mm (5 x 18 in) --
Rear (2) Solid 460 x 130 mm (5 x 18 in) --

GENERAL INFORMATION
1-9
7400 MM428 (6--01)
1327 mm
(52.25 in)
2460 mm
(97 in)
2045 mm
(80.5 in)
1475 mm
(58 in)
1525 mm
(60 in)
1260 mm
(49.6 in)
1610 mm
(63.4 in)
1483 mm
(58.4 in)
1686 mm
(66.4 in)
10919
MACHINE DIMENSIONS

GENERAL INFORMATION
1-10 7400 MM428 (6--01)
MAINTENANCE
1
2
3
4
5
6
7
8
10
11 12
9
5
13
13
13
13
MAINTENANCE CHART / G/LP
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 4Engine air filter Check indicator -- 1
y
g
Empty dust cap -- 1
4Engine crankcase Check oil level EO 1
8Rear Squeegee Check for damage and wear -- 1
q
g
Check deflection -- 1
11 Side Squeegees Check for damage and wear -- 2
10 Scrub brushes Check for damage and wear -- 1
7Recovery tank Clean -- 1
7Recovery tank, EStmode Clean EStfilter -- 1
5Solution tank, EStmode Clean -- 1
50 Hours 10 Scrub brushes Rotate end-for-end or front-to-
rear
-- 1
100 Hours 6Radiator Clean core exterior -- 1
Check coolant level WG 1
4Engine crankcase Change oil and filter element EO 1
13 Cover seals Check for damage and wear -- 4
4Engine Check fan belt tension -- 1
g
Check and adjust idle speed -- 1
Check and adjust idle mixture -- 1
3Hydraulic fluid reservoir Check fluid level HYDO 1
-- Tires Check for damage -- 3
8Rear squeegee Check leveling -- 1
8Rear squeegee casters Lubricate SPL 2

GENERAL INFORMATION
1-11
7400 MM428 (6--01)
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
100 Hours 10 Scrub brush idlers Lubricate SPL 2
10 Scrub head skirts Check for damage and wear -- 2
-- Side brush skirt Check for damage and wear -- 1
200 Hours 6Radiator hoses and clamps Check for tightness and wear -- 2
4Engine fan belt Check tension -- 1
2 Parking brake Check adjustment -- 1
2Brake pedal Check and adjust travel -- 1
1Front wheel
support bearings
Lubricate SPL 2
400 Hours 9Rear wheel bearings Check, lubricate, and adjust SPL 2
4Engine Clean or replace and adjust -- 4
g
p
j
spark plugs
HCheck and adjust valve -- 8
j
clearance
Check and adjust idle speed -- 1
Check and adjust carburetor -- 1
j
idle mixture
Replace PCV valve. Clean PCV -- 1
p
hoses, tubes, and fittings
Fuel filter, gasoline -- 1
800 Hours 3Hydraulic reservoir Replace filler cap -- 1
y
Replace suction strainer -- 1
Change hydraulic fluid HYDO 1
4Hydraulic fluid filter Change filter element -- 1
-- Hydraulic hoses Check for wear and damage -- All
6 Cooling system Flush WG 1
1Propelling motor HTorque shaft nut -- 1
1Front wheel HTorque wheel nuts -- 1
12 Battery HClean and tighten battery cable -- 1
y
g
y
connections
NOTE: Also check procedures indicted (H) after
the first 50-hours of operation.
NOTE: More frequent intervals may be required
in extremely dusty conditions.
LUBRICANT/FLUID
EO Engine oil, SAE--SG/SH rated....
HYDO Tennant or approved hydraulic fluid.
WG Water and permanent-type ethylene glycol anti-freeze, --34_C(--30_F)...
SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)...
DW Distilled water....

GENERAL INFORMATION
1-12 7400 MM428 (6--01)
1
2
3
4
5
6
7
8
10
11 12
9
5
13
1
3
13
13
09076
MAINTENANCE CHART / DIESEL
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
Daily 4Engine air filter Check indicator -- 1
y
g
Empty dust cap -- 1
4Engine crankcase Check oil level EO 1
8Rear Squeegee Check for damage and wear -- 1
q
g
Check deflection -- 1
11 Side Squeegees Check for damage and wear -- 2
10 Scrub brushes Check for damage and wear -- 1
7Recovery tank Clean -- 1
7Recovery tank, EStmode Clean EStfilter -- 1
5Solution tank, EStmode Clean -- 1
50 Hours 10 Scrub brushes Rotate end-for-end or front-to-
rear
-- 1
4Fuel pipes and clamps Check for tightness and wear -- 1
100 Hours 6Radiator Clean core exterior -- 1
Check coolant level WG 1
4Engine crankcase Change oil and filter EO 1
4Engine fan belt Check tension -- 1
3Hydraulic fluid reservoir Check fluid level HYDO 1
-- Tires Check for damage -- 3
8Rear squeegee Check leveling -- 1
8Rear squeegee casters Lubricate SPL 2

GENERAL INFORMATION
1-13
7400 MM428 (6--01)
Interval Key Description Procedure
Lubricant/
Fluid
No. of
Service
Points
100 Hours 13 Cover seals Check for damage and wear -- 4
10 Scrub brush idlers Lubricate SPL 2
10 Scrub head skirts Check for damage and wear -- 2
-- Side brush skirt Check for damage and wear -- 1
200 Hours 6Radiator hoses and clamps Check for tightness and wear -- 2
2 Parking brake Check adjustment -- 1
2Brake pedal Check and adjust travel -- 1
1Front wheel Lubricate SPL 2
support bearings
400 Hours 9Rear wheel bearings Check, lubricate, and adjust SPL 2
4Fuel filter Replace cartridge -- 1
6 Cooling system Flush WG 1
800 Hours 3Hydraulic reservoir Replace filler cap -- 1
y
Replace suction strainer -- 1
Change hydraulic fluid HYDO 1
4Hydraulic fluid filter Change filter element -- 1
-- Hydraulic hoses Check for wear and damage -- All
1Propelling motor HTorque shaft nut -- 1
1Front wheel HTorque wheel nuts -- 1
12 Battery HClean and tighten battery cable -- 1
y
g
y
connections
NOTE: Also check procedures indicted (H) after
the first 50-hours of operation.
NOTE: More frequent intervals may be required
in extremely dusty conditions.
LUBRICANT/FLUID
EO Engine oil, SAE--CC/CD rated....
HYDO Tennant Company or approved hydraulic fluid.
WG Water and permanent-type ethylene glycol anti-freeze, --34_C(--30_F)...
SPL Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1)...
DW Distilled water....

GENERAL INFORMATION
1-14 7400 MM428 (6--01)
PUSHING, TOWING, AND TRANSPORTING
THE MACHINE
PUSHING OR TOWING THE MACHINE
If the machine becomes disabled, it can be
pushed from the front or rear, but towed only from
the rear.
The propelling pump has a bypass valve to
prevent damage to the hydraulic system when the
machine is being pushed or towed. This valve
allows a disabled machine to be moved for a very
short distance and at a speed to not exceed 1.6
kp/h (1 mph). The machine is NOT intended to be
pushed or towed a long distance or at a high
speed.
ATTENTION! Do not push or tow
machine for a long distance and without
using the bypass valve, or the machine
hydraulic system may be damaged.
Turn the bypass valve 90_from the normal
position before pushing or towing the machine.
The illustration shows the bypass valve in the
pushing or towing position.

GENERAL INFORMATION
1-15
7400 MM428 (6--01)
TRANSPORTING THE MACHINE
1. Position the rear of the machine at the
loading edge of the truck or trailer.
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 in the
holes at the bottom of the rear bumper.
If the machine has the optional rear tie down
brackets, attach the winching chains to
them.
4. Turn the bypass valve 90_from the normal
position before winching the machine onto
the truck or trailer. See PUSHING OR
TOWING THE MACHINE section of this
manual. Make sure the machine is centered.
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.

GENERAL INFORMATION
1-16 7400 MM428 (6--01)
5. 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.
6. Set the parking brake and block the machine
tires. Tie down the machine to the truck or
trailer before transporting.
The front tie down locations are in the holes
at the bottom of the front bumper. If the
machine has the optional tie down brackets,
use them to tie down the machine.
The rear tie down locations are in the holes
at the bottom of the rear bumper. If the
machine has the optional rear tie down
brackets, use them to tie down the machine.
7. 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
1-17
7400 MM428 (6--01)
MACHINE JACKING
Empty the recovery and the solution tanks before
jacking the machine.You can jack up the machine
for service at the designated locations. Use a
hoist or jack that will support the weight of the
machine. Always stop the machine on a flat, level
surface and block the tires before jacking the
machine up.
FOR SAFETY: Before leaving or
servicing machine; stop on level
surface, set parking brake, turn off
machine and remove key.
The front jacking location is the left front corner of
the machine frame.
The rear jacking locations are the two rear
corners of the machine frame.
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.

GENERAL INFORMATION
1-18 7400 MM428 (6--01)
STORING MACHINE
When storing the machine for extended periods of
time, the following procedures must be followed to
lessen the chance of rust sludge, or other
undesirable deposits from forming.
1. Drain and clean the solution and recovery
tanks.
2. EStmachines: Run clean water through
the solution system and the EStsolution
pump.
3. Raise the rear squeegee and the scrub
head.
4. Park the machine in a cool, dry area.
5. Remove or charge the battery every three
months.