Tennant CS5 Operating manual

PLDC04318
REVISION DATE
July 31, 2020
DATE
July 31, 2020
TECHNICAL OFFICE
CS 5
TECHNICAL SERVICE MANUAL
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PLDC04318
REVISIONE 00
July 31, 2019
UFF. TECNICO
Contents
A1.1 Checking brush motor current draw..............................................................................7
A1.2 Checking and replacing the centre brush motor carbon brushes .................................8
A1.3 Disassembling and replacing the centre brush motor...................................................11
B1.1 Checking suction motor current draw............................................................................15
B1.2 Removing the suction fan..............................................................................................17
B2.1 Testing and/or replacing the solution pump...................................................................19
B3.1 Replacing the suction diverter valve .............................................................................22
B4.1 Replacing the rear squeegee cable ..............................................................................25
B4.2 Adjusting the rear squeegee cable................................................................................27
B4.3 Removing the splitter bracket........................................................................................28
B4.4 Replacing the splitter bracket control cable “A”.............................................................30
B4.5 Adjusting the splitter bracket control cable “A”..............................................................31
B4.6 Replacing the diverter valve control cable “B”...............................................................32
B4.7 Replacing the front squeegee control cable “C”............................................................33
B4.8 Adjusting the front squeegee control cable “C”.............................................................34
C1.1 Replacing the idle wheels.............................................................................................37
C2.1 Replacing the carrying handle ......................................................................................39
C2.2 Replacing rear squeegee activation lever.....................................................................41
C2.3 Disassembling the hand grip.........................................................................................42
C2.4 Disassembling the handle adjustment and squeegee inversion levers..... 43
C2.5 Disassembling and replacing the complete handle ......................................................46
D1.1 Disassembling and replacing hand grip components ...................................................50
D1.2 Checking and replacing the main switch.......................................................................54
D2.1 Disassembling and replacing the power board.............................................................57
D2.2 Checking and replacing the fuses.................................................................................59
D3.1 Wiring diagram..............................................................................................................60
E1.1 Error codes on the instrument panel.............................................................................62
E1.2 FW Version Control.......................................................................................................64
E2.1 Troubleshooting.............................................................................................................65
TECHNICAL SERVICE MANUAL REVISIONS-UPDATES....................................................66
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PLDC04318
REVISIONE 00
July 31, 2019
UFF. TECNICO
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*IMPORTANT
Move the machine to the tank draining area, and empty the
solution tank and the dirty water tank.
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necessary, place chocks under the wheels.
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partment on the machine.
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In this Service Manual, the terms RIGHT and LEFT are used
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A BRUSH UNIT
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A1 BRUSH MOTOR
The brush motor is 36 V, with a maximum power of 100 W. It is powered by the batteries via the
electronic board, with softstart. The brush axis rotation speed after the mechanical reduction
drive is 160 rpm. The electric motor connected the brush via the reduction drive attached to
the motor features IP 44 protection. It is therefore is protected against foreign bodies larger
than 1 mm and from water spray in all directions
i
The motor carbon brushes and rotor should be checked for wear every 400 - 500 operating
hours.
*
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A1.1 Checking brush motor current draw
Carry out the test with the machine off, as testing with the machine in movement (forwards
gear) may cause an increase in the current reading.
*
1Make sure that the batteries on the machine are charged (36 V ± 1 V).
2Use a clamp-on ammeter with a full scale reading of at least 100 A (amperes).
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4Make sure that there is enough room around the machine to perform the checks safely.
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6Remove the tank, identify the Red wire on the brush motor and connect the clamp-on ammeter to it.
7On the control panel, disable the suction motor.
8Activate the brush using the corresponding brush control lever on the handle.
9Carry out a test with the brush and without the tank and a second test without the brush.
10 Read the value and compare it against those shown in the table.
11 If the readings are between the values shown in the table, disconnect the clamp-on ammeter.
12 If on the other hand the readings do not correspond to the values shown in the table, perform the following
checks.
13 Remove the brush and check that the no-load current is within the values shown in the table.
13a If the reading is outside of the values shown in the table (usually higher), check motor carbon brush wear.
13b If the reading is within the range of values shown in the table, check that the brush is not rubbing on the brush
cover or the rear squeegee, and that the brush motor reduction drive does not produce abnormal noise.
13c Replace the brush motor with a new one.
Current draw A (amperes) Min Max
No load (without brushes) 0.05 A 0.10 A
Load applied (brushes operating) 0.18 A 0.30 A
69
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A1.2 Checking and replacing the centre brush motor carbon brushes
Disassembly
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2Make sure that there is enough room around the machine to perform the dismantling operations safely.
3If necessary, clean the working area with a jet of compressed air.
4Release the dirty water tank using the two locking levers and remove it together with the solution tank.
5Identify the brush motor and unscrew the two self-locking nuts that secure the cap to the motor housing.
6Remove the cap by pulling it upwards and at the same time tapping it lightly with a plastic mallet.
7To simplify removal, jiggle it slightly to release it from the bearing and the studs.
8Move the spring that presses on one of the carbon brushes and remove it from its housing.
The carbon brushes can be checked only by removing the motor cover, as the motor does not
have openings for carbon brush inspection, as may be the case with other motors.
i
5
8
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Checks
9Measure the carbon brush to determine wear, and then compare the values against those shown below.
10 The length of the carbon brush must be no less than 9 mm / 0.35 in.
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four at the same time.
12 Check the sliding contact surface of the carbon brushes for signs of abnormal wear or burning.
13 Blow the inside of the motor clean with a jet of compressed air, paying particular attention to the area around the
carbon brushes and the rotor where the carbon brushes slide.
14 Check wear in the places where the carbon brushes slide before replacement. A damaged rotor would cause
premature wear of the new carbon brushes.
8.7 ± 0.1 mm
0.34 ± 0.004 in
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1 5 . 6 ± 0 . 1 m m
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0.23 ± 0.004 in
0.61 ± 0.004 in
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Always replace all four brush motor carbon brushes at the same time.
*
Always check that the new carbon brushes are the same shape and size as those being
replaced (naturally apart from the length) and that they slide freely in their seats.
*
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Reassembling the carbon brushes
15 Reassemble four new carbon brushes, positioning them so that they remain secured in their housings by the
springs, and when assembling the cap they do not interfere with the rotor.
16 Assemble the cap, screw the nuts on a few threads until the bearing is partially inserted. Keeping the cap slightly
raised, slowly push each carbon brush against the rotor with a thin screwdriver.
17 Tap the centre of the cap with a rubber mallet to move the bearing into position.
18 Tighten the self-locking nuts to a maximum torque of 5.5 Nm / 48.68 lbf in.
15
15
Reassembly
1Continue reassembly by repeating the disassembly operations in reverse order.
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A1.3 Disassembling and replacing the centre brush motor
If removing the motor cap to check and/or replace the motor carbon brushes, it is
recommended to mark the position of the cap on the motor housing with a marker.
*
Disassembly
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2Make sure that there is enough room around the machine to perform the dismantling operations safely.
3If necessary, clean the working area with a jet of compressed air, or a vacuum cleaner.
4Remove the battery and put it in a safe place, away from liquids; release and remove the brush.
5Press the two tank locking levers to release them, remove the dirty water tank and the solution tank and identify
the brush motor.
6Position the handle vertically and tilt the machine backwards until the handle rests on the ground.
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8Unscrew the four screws that secure the motor to its support, leaving one of the two screws at the top to last, so
as to prevent the motor from falling, while holding it with one hand.
7
8
6
8
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9Lift the electronics cover casing and then remove the electronics compartment cover to reach the power board.
10 Disconnect the motor electrically from the power board and then remove the cable from the plastic guides that
anchor it to the plastic chassis; remove the motor.
11 Replace the motor with a new one.
10-11
Reassembly
1For assembly, repeat the steps for dismantling in reverse order.
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*IMPORTANT
Move the machine to the tank draining area, and empty the
solution tank and the dirty water tank.
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necessary, place chocks under the wheels.
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partment on the machine.
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In this Service Manual, the terms RIGHT and LEFT are used
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B SUCTION UNIT
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B1 SUCTION MOTOR
The electric fan used for suction during the drying phase is maintenance-free, and therefore in
the event of problems it will be replaced completely.
*
The suction motor is a single-stage centrifugal-tangential 36 V DC motor, powered directly via
the functions board; it is activated on the instrument panel using the button provided, with the
suction start signal sent via the functions board using a MOS-FET for ramped starting.
The maximum power consumption is 160 W, with a suction capacity of 18.7 litres/s - 4.95
gal/s, and a vacuum capacity of 120 mm H20 - 4.72 in H20 - 0.17 psi.
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routine maintenance is needed, therefore no carbon brushes need to be replaced.
It is however recommended to measure current draw so as to check that there are no
problems, or that the motor needs to be replaced.
i
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B1.1 Checking suction motor current draw
1Make sure that the batteries on the machine are charged (36 V ± 1 V).
2Use a clamp-on ammeter with a full scale reading of at least 100A (amperes).
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4Make sure that there is enough room around the machine to perform the checks safely.
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7Locate the two suction motor power wires and remove them.
8Connect the clamp-on ammeter to one of the white wires.
6
7
8
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9Activate the suction motor from the control panel.
10 Wait for current draw to stabilise before reading the value for comparison against the table below.
11 If the reading is between the values shown in the table, disconnect the clamp-on ammeter and return the
machine to operating conditions.
12 If on the other hand the reading does not correspond to the value shown in the table, perform the following
checks.
12a Make sure that the wiring that powers the suction motor is intact and that the connections are tight.
12b Replace the suction motor with a new one.
Current draw A (amperes) Min Max
No-load 0.14 A 0.62 A
9
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B1.2 Removing the suction fan
Disassembly
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2Make sure that there is enough room around the machine to perform the dismantling operations safely.
3If necessary, clean the working area with a jet of compressed air.
4Remove the battery and put it in a safe place, away from liquids.
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7Disconnect the fast-ons that connect the motor to the electrical system and replace the suction motor.
8Remove the gasketfrom the suction motor, clean it and use it again for the new suction motor.
6
Reassembly
1For assembly, repeat the steps for dismantling in reverse order.
2Tighten the screws on the plastic parts gently.
If the gasket mounted on the suction motor is still in good condition, use it again for the new
motor, otherwise if it shows signs of abrasion or cuts, replace it with a new one.
*
8
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B2 SOLUTION PUMP
The electric pump is powered at 24 VAC (alternating current); it is therefore necessary to use
this power supply voltage for any tests.
However, electrical operation can be checked using a 24 VDC battery (direct current).
*
The electric pump used to deliver the solution is a vibration pump, operating at 24 VAC with a
frequency of 50 Hz and a maximum power consumption of 20 W.
It has a suction capacity of 100 mbars = 0.1 bars = 1019.74 mm H2O = 1.45 psi.
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is 0.45 l/min - 15.21 oz/min at 0 pressure.
The pump is powered by the electronic board, which in addition to converting from direct to
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maximum, medium, minimum.
Due to the type of operation via valves that open and close intermittently, the pump must be
mounted in one direction only; see to the arrow shown on the pump.
If used as indicated, the pump does not require maintenance; in the event of malfunction or
breakages it cannot be repaired and therefore must be replaced completely.
It should only be used with water or a water-detergent solution.
i
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Disassembly
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2Make sure that there is enough room around the machine to perform the dismantling operations safely.
3Remove the dirty water tank and the solution tank and identify the solution pump.
4If necessary, clean the working area with a jet of compressed air.
B2.1 Testing and/or replacing the solution pump
3
5Using a Phillips-head screwdriver, Undo the screw that secures the plastic cover on the solution pump.
6Remove the cover and disconnect the two fast-ons on the solution pump.
5 6
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Disassembly
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chassis.
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Checking electrical operation
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2Connect one of the two cables between one pole of the battery and a fast-on on the solution pump.
3Connect the other cable either to the battery pole or the fast-on on the solution pump (one end only).
4Touch the other end of the cable to the remaining contact a series of times; each time the solution pump will
make a “CLICK” noise.
4a This “CLICK” means that the pump is working electrically; proceed to the next check.
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4c If the hoses are free and not crushed, check the power board.
4d If no “CLICK” noise is heard, replace the solution pump with a new one.
Reassembly
1For assembly, repeat the steps for dismantling in reverse order.
2Tighten the screws on the plastic parts gently.
2 - 3 - 4
7 - 8
12 V - 24 V
1 - 2 - 3 - 4
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