Featuring. Service Information. The safe scrubbing alternativet. Hygenict. Fully Cleanable Tanks Rev. 00 *331045*

Transcription

1 Featuring The safe scrubbing alternatiet Hygenict Fully Cleanable Tanks T7 Serice Information 10 Re. 00 *10*

2 This manual proides serice information for the TENNANT Model T7. This machine will proide excellent serice. Howeer, the best results will be obtained at minimum costs if: D D D The machine is operated with reasonable care. The machine is maintained regularly -- per the maintenance instructions proided. The machine is maintained with TENNANT supplied or approed parts. Manual Number Reision: 00 Published: 1--0 Tennant Company PO Box 1 Minneapolis, MN 0 Phone: (800) --80 or (7) FaST Foam Scrubbing Technology logo is a United States registered trademark of Tennant Company. Copyright E 00 TENNANT, Printed in U.S.A.

3 Table of Contents Electrical Troubleshooting Information... 1 Commonly Used Electrical Symbols & Terms... Ladder Schematic... Wire Harness Group... Key OFF, Operator NOT on Seat... 9 Key OFF, Battery Charger Plugged In Key ON, Operator on Seat Tank Leel Sensors... 1 Horn & Hour Meter Systems... 1 Propel Forward System... 1 Propel Reerse System... 1 Braking System... 1 Scrub Head & Squeegee Actuator Systems Scrub Brush Motors System Vacuum Fan System... 0 FaST System... 1 Conentional Solution System... LED Locations & Descriptions... Operational Modes & Interlocks... Diagnostic & Fault Alarms... Alarm Codes... High Current Faults... Diagnostic & Configuration Modes... Display Software Reision Mode... 7 Self Test Mode... 8 Input Display Mode... 9 Manual Mode... 0 Propel / Brake Diagnostics... 1 Battery Select Mode & Voltage Leels... Battery Select Mode... Voltage Leels... Reerse Alarm & Propel Speed Select Modes... Reerse Alarm Select Mode... Propel Speed Select Mode... Inputs & Outputs Table... Torque Standard... Inch Fasteners... METRIC Fasteners... 7 Nylon Insert Lock Nuts... 9 Nut-Hex Light THIN... 9 Wheel Bolt and Nuts... 0 Wheel Bearing Adjustment... 0 Tightening Nuts on Tapered Shafts... 1 Shoulder Bolts... Taper Lockr Bushings... Sequence Tightening... i

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5 T7 ELECTRICAL Troubleshooting Information BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual * Always use an ESD (Electrostatic Discharge) strap when working near the Control Board * Be cautious when working near Control Board Battery oltage is always present, een with Key OFF * Always unplug Positie Battery Cable when remoing or replacing components DURING TESTS: * Call Technical Serices if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action NOTE:Troubleshooting charts may be shown with optional equipment. The optional equipment may not be specified in these charts. Some machines may not be equipped with all components shown T7ETI REV 00 1

6 Commonly Used Electrical Symbols & Terms NOTE: The term NORMALLY refers to the components at rest or de-energized position Wires Connected Together Wires Not Connected Together Plug-in Connection Battery Circuit Breaker Fuse Normally Open Switch Normally Open Limit Switch Normally Closed Limit Switch Normally Open Push-Button Switch Normally Closed Push-Button Switch Indicates Moement from Normal Position Normally Open Normally Closed M1 Relay Coil (Part 1 of Relay) Relay Contacts (Part of Relay) Diode Solenoid (Vale or Actuator) Indicates Component in Position Other than Normal X Motor Wiring Standoff (Connection Point) Lamp (Light Bulb) Horn or Alarm Indicates Component is Energized Terms & Abbreiations BDI Battery Discharge Indicator Dynamic Braking A method of using the generating nature of an electric motor to slow the machine Hall Effect A oltage deeloped as a result of current flow in the presence of a magnetic field LED Light Emitting Diode PM Permanent Magnet PWM (Pulse Width Modulation) A method of using controlled on/off times to regulate the oltage and current supplied to an electrical deice Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Example of Wiring Numbers & Colors: Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White 7 1 BLK

7 T7 Ladder Schematic (page 1 of )

8 T7 Ladder Schematic (page of )

9 T7 Wire Harness Group (page 1 of ) 1

10 T7 Wire Harness Group (page of ) 1

11 T7 Wire Harness Group (page of ) 1 7

12 T7 Wire Harness Group (page of ) 8

13 T7 - Key OFF, Operator NOT on Seat 1 BLK CHARGER PLUG 1 BLK 1 BLK X STANDOFF M1B F1 100 A X STANDOFF 0 RED 0 RED D CB1 A EMERGENCY STOP SWITCH S1 KEYSWITCH MAIN CONTACTOR M1A CHARGER INTERLOCK 1 1 CB 1 A 0 RED SW1 D1 CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-7 PIN J- PIN J-1 POST J11 + POS NEG POST J7-7 1 BLK LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK RIBBON CABLE CONNECTOR P TOUCH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output 1 9

14 T7 - Key OFF, Battery Charger Plugged In 1 BLK CHARGER PLUG 1 BLK 1 BLK X STANDOFF M1B F1 100 A X STANDOFF 0 RED 0 RED D CB1 A EMERGENCY STOP SWITCH S1 KEYSWITCH MAIN CONTACTOR M1A 1 1 CB 1 A 0 RED D1 CHARGER SW1 INTERLOCK CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-7 PIN J- PIN J-1 POST J11 + POS NEG POST J7-7 1 BLK LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK RIBBON CABLE CONNECTOR P TOUCH PANEL RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output 1 10

15 T7 - Key ON, Operator on Seat 1 BLK CHARGER PLUG 1 BLK 1 BLK X STANDOFF M1B F1 100 A X STANDOFF 0 RED 0 RED D CB1 A EMERGENCY STOP SWITCH S1 KEYSWITCH MAIN CONTACTOR M1A CHARGER INTERLOCK 1 1 CB 1 A 0 RED SW1 D1 CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-7 PIN J- PIN J-1 POST J11 + POS NEG POST J7-7 1 BLK LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK RIBBON CABLE CONNECTOR P TOUCH PANEL Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output RIBBON CABLE 1 RIGHT SIDE DASH PANEL KEY SWITCH O I 11

16 T7 Tank Leel Switches CONDITIONS: key ON 1 BLK CHARGER PLUG 1 BLK 1 BLK X STANDOFF M1B F1 100 A X STANDOFF 0 RED 0 RED D CB1 A EMERGENCY STOP SWITCH S1 KEYSWITCH MAIN CONTACTOR M1A CHARGER INTERLOCK 1 1 CB 1 A 0 RED SW1 D1 CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J-0 PIN J- PIN J- PIN J-8 PIN J-1 POST J11 + POS NEG POST J7-8 LOGIC GROUND RECOVERY TANK FULL SWITCH SW 9 SW SOLUTION TANK LOW SWITCH 1 BLK 1 BLK RIBBON CABLE CONNECTOR P TOUCH PANEL Indicates Component is Energized RIBBON CABLE Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output Tank Leel Switches Logic Chart switch tank full tank empty switch OPEN switch CLOSED indicator Solution Tank Recoery Tank i Recoery Tank Full Switch closes when recoery tank is full Solution Tank Low Switch opens when solution tank is low Tank Leel Switches are ALWAYS in the OPEN position with low or empty tank 1 x x Solution Tank Empty LED OFF x x Solution Tank Empty LED ON x x Recoery Tank Full LED ON x x Recoery Tank Full LED OFF Tank Leel Switches are ALWAYS in the CLOSED position with full tank 1

17 T7 Horn & Hour Meter Systems CONDITIONS: key ON, operator on seat, in motion OR Vacuum Fan running (for Hour Meter) 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A 1 EMERGENCY STOP SWITCH S1 KEYSWITCH MAIN CONTACTOR M1A SW1 CHARGER INTERLOCK D1 1 0 RED CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-10 PIN J- PIN J-1 POST J11 + POS NEG POST J7-0 1 BLK STANDOFF X LOGIC GROUND S HORN SWITCH 1 BLK NOTE: Hour Meter is actie only when propelling (forward or reerse), OR anytime Squeegee/ Vacuum Fan is actie 1 1 LS1 HORN PIN J PIN J-1 H1 HOUR METER RIBBON CABLE CONNECTOR P Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output i TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE RIGHT SIDE DASH PANEL HORN SWITCH Horn pulses ON & OFF when Directional Switch is in REVERSE Hour Meter is ON only when propelling (forward or reerse), or anytime Squeegee/Vacuum Fan is ON Horn pulses when a fault is detected (Directional Switch must be in FORWARD Position) refer to Diagnostic/Beep Code chart 1

18 T7 Propel Forward System CONDITIONS: key ON, operator on seat, propel pedal depressed 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A NOTE: Refer to the Propel/Brake Diagnostics page for more information NOTE: Brake Solenoid is energized to release parking brake. Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output = Output that can Change Polarity EMERGENCY STOP SWITCH BLK S1 KEYSWITCH MAIN CONTACTOR M1A MTR1A SW1 PROPEL MOTOR FORWARD 1 1 MTR1B BRAKE SOLENOID CHARGER INTERLOCK WHT D1 0 RED TOUCH PANEL 1 1 PIN J-17 PIN J- PIN J- PIN J- PIN J-1 CONTROL BOARD POST J11 + LEFT SIDE DASH PANEL 7 1 BLK FORWARD X LOGIC GROUND SW SEAT SWITCH 1 BLK PROPEL PEDAL POSITION SENSOR U GND HALL 1 PROPEL EFFECT SIGNAL POWER SENSOR 1 1 i DIRECTIONAL SWITCH RIGHT SIDE DASH PANEL PIN J10- PIN J10-1 PIN J-7 POS RIBBON CABLE CONNECTOR P RIBBON CABLE FORWARD REVERSE PIN J- PIN J-7 POST J7 NEG - PIN J- PIN J- 7 GRN REVERSE STANDOFF X ORG SW PROPEL DIRECTION SWITCH Typical Propel Motor Current Draw: 1 to 0 Amps in motion, higher at start-up Propel Motor Voltage: 0 to VDC - FORWARD Approx. 0 to 17 VDC - REVERSE Propel Motor is controlled by PWM (Pulse Width Modulation) The Propel Pedal Position HALL EFFECT Sensor sends a arying oltage signal (1 to Volts) to control board, based upon position of the propel pedal 1 1

19 T7 Propel Reerse System CONDITIONS: key ON, operator on seat, propel pedal depressed 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A NOTE: Refer to the Propel/Brake Diagnostics page for more information NOTE: Brake Solenoid is energized to release parking brake. Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output = Output that can Change Polarity EMERGENCY STOP SWITCH BLK S1 KEYSWITCH MAIN CONTACTOR M1A MTR1A SW1 CHARGER INTERLOCK PROPEL MOTOR REVERSE 1 1 MTR1B BRAKE SOLENOID D1 0 RED TOUCH PANEL 1 1 PIN J-17 PIN J- PIN J- PIN J- PIN J-1 CONTROL BOARD POST J11 + PIN J10- PIN J10-1 LEFT SIDE DASH PANEL 7 1 BLK FORWARD X LOGIC GROUND SW SEAT SWITCH 1 BLK PROPEL PEDAL POSITION SENSOR U GND HALL 1 PROPEL EFFECT SIGNAL POWER SENSOR 1 1 i DIRECTIONAL SWITCH WHT RIGHT SIDE DASH PANEL PIN J-7 POS RIBBON CABLE CONNECTOR P RIBBON CABLE FORWARD REVERSE PIN J- PIN J-7 POST J7 NEG - PIN J- PIN J- 7 GRN REVERSE STANDOFF X ORG Typical Propel Motor Current Draw: 1 to 0 Amps in motion, higher at start-up Propel Motor Voltage: 0 to VDC - FORWARD Approx. 0 to 17 VDC - REVERSE Propel Motor is controlled by PWM (Pulse Width Modulation) The Propel Pedal Position HALL EFFECT Sensor sends a arying oltage signal (1 to Volts) to control board, based upon position of the propel pedal SW PROPEL DIRECTION SWITCH 1 1

20 T7 Braking System CONDITIONS: key ON, operator on seat, brake pedal depressed 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A NOTE: Refer to the Propel/Brake Diagnostics page for more information NOTE: Brake Solenoid is DEenergized to apply parking brake. Dynamic Braking will occur before Brake Solenoid is de-energized EMERGENCY STOP SWITCH BLK S1 KEYSWITCH MAIN CONTACTOR M1A CHARGER INTERLOCK MTR1A SW1 PROPEL MOTOR 1 1 MTR1B BRAKE SOLENOID WHT D1 1 0 RED 1 PIN J-17 PIN J- PIN J- PIN J- PIN J-1 CONTROL BOARD POST J11 + PIN J10- PIN J10-1 PIN J-7 POS PIN J- PIN J-7 POST J7 NEG - PIN J- RIBBON CABLE CONNECTOR P 7 1 BLK STANDOFF X LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK BRAKE PEDAL POSITION SENSOR U GND HALL BRAKE EFFECT SIGNAL POWER SENSOR 1 Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE 1 1 i The brake pedal position HALL EFFECT sensor sends a arying oltage signal (1 to Volts) to control board, based upon position of the brake pedal Brake Solenoid is DE-energized to apply brake. Dynamic Braking will occur before Brake Solenoid is de-energized. 1

21 T7 Scrub Head & Squeegee Actuator Systems (page 1 of ) CONDITIONS: key ON, operator on seat, forward trael, propel pedal depressed, One Step Scrub Button pressed 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A 1 EMERGENCY STOP SWITCH S1 KEYSWITCH MAIN CONTACTOR M1A SW MTR CHARGER INTERLOCK D1 1 0 RED 17 CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-7 PIN J- PIN J-1 POST J11 + PIN J-1 POS NEG POST J7-7 1 BLK STANDOFF X LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK NOTE: Actuator oltage switches polarity when direction of actuator trael changes (see next page for more information) SQUEEGEE ACTUATOR 0 19 MTR SCRUB HEAD ACTUATOR PIN J-9 PIN J- PIN J-1 RIBBON CABLE CONNECTOR P Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output = Output that can Change Polarity One Step Scrub Button i Vacuum Fan/ Squeegee Button TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE Pressing the One Step Scrub Button will lower the squeegee and scrub head Only one actuator will be energized at any gien time squeegee is lowered first, then the scrub head Squeegee actuator uses internal limit switches to stop trael in upward and downward trael Scrub head actuator trael is controlled by monitoring actuator current in upward trael and brush motor current in downward trael Squeegee actuator can also be operated by pressing the Vacuum Fan/ Squeegee Button, without operating scrub brushes 17

22 T7 Scrub Head & Squeegee Actuator Systems (page of ) Actuator Voltage Data Actuator Trael Direction Wire # Color Polarity Notes Squeegee Scrub Head DOWN UP DOWN UP 17 Purple 18 Gray "+" 17 Purple "+" 18 Gray 19 White 0 Tan "+" 19 White "+" 0 Tan Voltage at actuator connector will be approx. VDC for seconds, then approx. 1 VDC for seconds for both UP & DOWN trael Voltage at actuator connector will be approx. VDC for seconds Voltage at actuator connector will be approx. VDC for seconds, then approx. 11 to 1 VDC for to seconds i Pressing the One Step Scrub Button will lower the squeegee and scrub head Only one actuator will be energized at any gien time squeegee is lowered first, then the scrub head Squeegee actuator uses internal limit switches to stop trael in upward and downward trael Scrub head actuator trael is controlled by monitoring actuator current in upward trael and brush motor current in downward trael Squeegee actuator can also be operated by pressing the Vacuum Fan/ Squeegee Button, without operating scrub brushes 18

23 T7 Scrub Brush Motors System CONDITIONS: key ON, operator on seat, forward trael, propel pedal depressed, One Step Scrub Button pressed 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A 1 EMERGENCY STOP SWITCH S1 KEYSWITCH MAIN CONTACTOR M1A SW1 CHARGER INTERLOCK 8 7 MTR D1 1 0 RED 7 CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-7 PIN J- PIN J-1 POST J11 + PIN J8-1 POS NEG POST J7-7 1 BLK STANDOFF X LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK LEFT SCRUB BRUSH MOTOR 10 9 MTR 8 9 PIN J8- PIN J8- Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output One Step Scrub Button i RIGHT SCRUB BRUSH MOTOR Brush Pressure Buttons TOUCH PANEL 10 PIN J8- LEFT SIDE DASH PANEL RIBBON CABLE CONNECTOR P RIBBON CABLE Brush Motor Current Draw: Approx. 10 to 0 Amps per motor, arying upon selected brush pressure setting Brush Motor Voltage: Approx. 18 VDC in Economy Mode Approx. 1. VDC in All Other Modes Scrub Brush Motors are controlled by PWM (Pulse Width Modulation) Pressing the One Step Scrub Button will turn on the Scrub Brush Motors (after lowering squeegee and scrub head) Scrub Brush Motors will function only when propelling either forward or reerse Scrub Brush Pressure is controlled by monitoring brush motor current 19

24 T7 Vacuum Fan System CONDITIONS: key ON, operator on seat, forward trael, One Step Scrub Button pressed 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A 1 EMERGENCY STOP SWITCH S1 KEYSWITCH MAIN CONTACTOR M1A SW1 CHARGER INTERLOCK D1 1 0 RED CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-7 PIN J- PIN J-1 POST J11 + POS NEG POST J7-7 1 BLK STANDOFF X LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK 1 11 MTR 11 PIN J9-1 VACUUM FAN 1 PIN J9- RIBBON CABLE CONNECTOR P Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output One Step Scrub Button i Vacuum Fan/ Squeegee Button TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE Vacuum Fan Motor Current Draw: Approx. 18 to 1 Amps Vacuum Fan Motor Voltage: Approx. 18 VDC in Economy Mode Approx. 1. VDC in All Other Modes Vacuum Fan Motor is controlled by PWM (Pulse Width Modulation) Pressing the One Step Scrub Button will actiate Vacuum Fan Vacuum Fan can also be operated by pressing the Vacuum Fan/Squeegee Button, without operating scrub brushes 0

25 T7 FaST System CONDITIONS: key ON, operator on seat, forward trael, propel pedal depressed, One Step Scrub Button pressed 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A 1 EMERGENCY STOP SWITCH S1 KEYSWITCH 1 MAIN CONTACTOR M1A SW1 CHARGER INTERLOCK D1 1 0 RED CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-7 PIN J- PIN J-1 POST J11 + POS NEG POST J7-7 1 BLK STANDOFF X LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK 1 MTR7 PIN J- FaST PUMP MOTOR FaST Button RIBBON CABLE CONNECTOR P Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output One Step Scrub Button i TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE Pressing the One Step Scrub Button will actiate FaST Pump Motor OR Solution Solenoid Vale as Scrub Brush Motors engage Pressing the FaST button will toggle from FaST scrubbing to Conentional scrubbing FaST system will operate ONLY if FaST LED is ON Solution Volume Control Buttons will NOT operate & Solution Volume Control LED s will be OFF during FaST scrubbing 1

26 T7 Conentional Solution System CONDITIONS: key ON, operator on seat, forward trael, propel pedal depressed, One Step Scrub Button pressed 1 BLK M1B D F1 100 A X STANDOFF 0 RED 0 RED CB1 A CB 1 A 1 EMERGENCY STOP SWITCH S1 KEYSWITCH 1 MAIN CONTACTOR M1A SW1 CHARGER INTERLOCK D1 1 0 RED CONTROL BOARD PIN J-17 PIN J- PIN J- PIN J- PIN J-7 PIN J- PIN J-1 POST J11 + POS NEG POST J7-7 1 BLK STANDOFF X LOGIC GROUND 7 GRN ORG SW SEAT SWITCH 1 BLK SOL PIN J- SOLUTION SOLENOID VALVE Indicates Component is Energized Wiring Color Codes (Unless otherwise marked) Right Most Digit of Wire Number Color of Wire Tan Pink Brown Orange Yellow Green Blue Purple Gray White = Battery Negatie or Logic Ground = Battery Positie or Positie Output One Step Scrub Button i Solution Volume Control Buttons TOUCH PANEL LEFT SIDE DASH PANEL RIBBON CABLE CONNECTOR P RIBBON CABLE Pressing the One Step Scrub Button will actiate FaST Pump Motor OR Solution Solenoid Vale as Scrub Brush Motors engage Pressing the FaST button will toggle from FaST scrubbing to Conentional scrubbing Conentional Solution system will operate ONLY if FaST LED is OFF Solution Volume Control Buttons & LED s will operate ONLY during Conentional scrubbing

27 T7 LED Locations & Descriptions

28 T7 Operational Modes & Interlocks Mode Entry Sequence Indicator Function Forward Directional Switch Forward Propel Pedal Depressed Directional Switch in Forward position Forward moement of machine Reerse Directional Switch Reerse Propel Pedal Depressed Directional Switch in Reerse position Horn Sounding continuously ON & OFF (except in "Hospital" mode) Reerse moement of machine Scrub Mode Press One Step Scrub Button (ON) One Step Scrub LED ON Actiate Scrub Brush, Squeegee, Vacuum Fan & Solution Flow operations FaST Mode Press One Step Scrub Button (ON) Press FaST Button (ON) One Step Scrub & FaST LED's ON Solution Flow LED's OFF Actiate FaST foam solution flow when scrub and propel are engaged Conentional Solution Mode Press One Step Scrub Button (ON) Press FaST Button (OFF) One Step Scrub & Solution Flow LED(s) ON FaST LED OFF Actiate Conentional solution flow when scrub and propel are engaged Double Scrub (no water pickup) Water pickup (no Scrub) Press One Step Scrub Button (ON) Press Vacuum Fan/Squeegee Button (OFF) Press Vacuum Fan/Squeegee Button (ON) One Step Scrub LED ON Vacuum Fan/Squeege LED OFF One Step Scrub LED OFF Vacuum Fan/Squeegee LED ON Apply cleaning solution with no water pickup Collect solution on floor with squeegee, without scrubbing floor Low Power Mode Low Power Mode w/ FaST Solution Tank Empty Recoery Tank Full Battery Discharged Accessory Motor High Current Fault Press Brush Pressure Lower Brush Pressure (#1) LED ON; Middle (#) & Decrease (-) to one LED Upper (#) LED's OFF Press Solution Flow Decrease Lower Solution Flow (#1) LED ON; Middle (#) & (-) to one LED Upper (#) LED's OFF Press Brush Pressure Decrease (-) to one LED Press FaST Button (ON) Solution Tank Empty (Float Switch Open) Recoery Tank Full (Float Switch Closed) Battery oltage at or below full discharge oltage Controller sensed an Oer Current condition in the Scrub Brush Motors or Vacuum Fan Motor Lower Brush Pressure (#1) LED ON; Middle (#) & Upper (#) LED's OFF FaST LED ON (Solution Flow LED's OFF) Solution Tank Empty LED ON Recoery Tank Full LED ON Red LED (on Battery Gauge) blinking Fault LED ON and any one or more of the following: Lower Brush Pressure (#1) LED ON (Right Motor) Upper Brush Pressure (#) LED ON (Left Motor) Upper Solution Flow (#) LED ON (Vacuum Fan) Reduce Scrub Brush and Fan speeds (to prolong battery life, reduce noise, lower water usage) Reduce Scrub Brush and Fan speeds (to prolong battery life, reduce noise, lower water usage) Disable Scrub function (Operator can get an additional minute of operation by re-engaging scrub system with One Step button) Disable Scrub function (Operator can get an additional minute of operation by re-engaging scrub system with One Step button) Disable Scrub function (Operator can get an additional minute of operation by re-engaging scrub system with One Step button) Preent damage to Scrub Brush Motors or Vacuum Fan Motor Scrub function shuts off

29 T7 Diagnostic & Fault Alarms Mode Back-Up Alarm Propel Interlock: Seat Switch Released Propel interlock: High Pedal Disable Propel Interlock: Throttle Fault Propel Interlock: Parking Brake Fault Propel Interlock: Parking Brake Unplugged Directional Switch REVERSE FORWARD FORWARD FORWARD FORWARD Alarm Codes Entry Sequence Alarm Sequence Function Directional switch placed in REVERSE Propel Pedal depressed with operator NOT on seat Key switch turned ON with Propel Pedal engaged Controller sensed an out-of range Throttle signal Controller sensed an outof range Brake signal FORWARD Controller sensed open circuit on parking brake Controller sensed open Propel Interlock: E-STOP Switch Actiated FORWARD circuit on Emergency Stop Switch circuit Horn sounds 1 beep cycle (repeats) Horn sounds beep cycle (repeats) Horn sounds beep cycle (repeats) Horn sounds beep cycle (repeats) (Also FAULT and FaST LED's blink) Horn sounds beep cycle (repeats) (Also FAULT and Vacuum Fan/ Squeegee LED's blink) Horn sounds 7 beep cycle (repeats) (Also FAULT and Lower Solution Flow LED's blink) Horn sounds 8 beep cycle (repeats) (When in Input Display Mode, FAULT LED will also blink) Alerts nearby persons of machine backward moement (Note: Backup alarm will not sound when machine is placed in "Hospital" mode) Preents moement of machine when operator not in place Preents moement of machine when key switched ON while throttle depressed Preents moement of machine with inalid throttle oltage. Scrub function shuts off. Preents moement of machine with inalid brake oltage. Scrub function shuts off. Preents moement of machine with ineffectie parking brake. Scrub function shuts off. Disables all functions (Note: To reset, key switch must be cycled OFF and ON after the E-STOP switch has closed) Propel Interlock: Charger Plugged In FORWARD Battery charger plugged into machine with Key Switch ON Horn sounds 9 beep cycle (repeats) Preents moement of the machine with charger plugged in High Current Faults Fault Entry Sequence Indicator Excessie Propel Motor Current Propel Motor Current Higher than 0 Amps for 1 min. OR Higher than Amps for min. OR Higher than 8 Amps for min. Blinking FAULT LED, Propel disabled Excessie Left Brush Motor Current Excessie Right Brush Motor Current Excessie Vacuum Fan Motor Current Left brush motor current higher than 0 Amps Right brush motor current higher than 0 Amps Vacuum Fan Motor current higher than 7 Amps Blinking FAULT LED, Blinking Brush Pressure LED # Blinking FAULT LED, Blinking Brush Pressure LED #1 Blinking FAULT LED, Blinking Vacuum Fan/Squeegee LED

30 T7 Diagnostic & Configuration Modes Mode Entry Sequence Indicator Function Display Software Reision Mode Press and hold One Step Button, turn key switch ON, wait 10 seconds, release One Step Button Upper Brush Pressure LED blinks Tens of days of month, Upper Solution Flow LED blinks Single day of month Middle Brush Pressure LED blinks Tens of month, Middle Solution Flow LED blinks Single month Lower Brush Pressure LED blinks Tens of year, Lower Solution Flow LED blinks out Single year Blinking Brush Pressure and Solution Flow LED s indicate reision date Self Test Mode Input Display Mode Press and hold FaST and Vacuum Fan/Squeegee Buttons, turn key switch ON, wait 10 seconds, release buttons Press and hold Decrease Solution Flow (-) Button, turn key switch ON, release button after forth battery LED starts to blink Start of test - Left Scrub Brush turns ON End of test - Horn sounds Fourth battery LED blinks Solid lit One Step LED indicates OK, A Flashing LED indicates an OPEN Fault, A Solid lit LED (other than One Step) indicates a SHORT Fault Shows state of control board inputs from arious switches and sensors Manual Mode Press and hold Decrease Brush Pressure (-) Button, turn key switch ON, release after Lowest Brush Pressure LED starts to blink. Lowest down pressure LED will blink Allows operation of indiidual functions without the safety interlocks affecting or controlling them Propel/Brake Diagnostic Mode Press and hold FaST and Increase Brush Pressure (+) Buttons, turn key switch ON, release after battery LED's are OFF FaST LED ON if in Forward OR Vacuum Fan/Squeegee LED ON if in Reerse - Solution Flow LED's display position of Propel Pedal, Brush Pressure LED's display position of Brake Pedal, Battery LED's display Propel Motor current leel Proides information regarding brake pedal signal, propel pedal signal, and propel motor current Battery Select Mode Press and hold the Increase Solution Flow (+) Button, turn key switch ON, release after one Battery LED starts to blink Any one of lower battery LED s blinks Allows selection of battery type. See Battery Select Mode Settings table. Reerse Alarm Select Mode Put directional switch in Reerse, press & hold Horn Button, turn key switch ON Horn sounds or is silent Allows enable/disable of Backup alarm (Hospital Mode) Propel Speed Selection Mode Press and hold FaST Button, turn key switch ON, release after selecting desired Brush Pressure LED setting Brush Pressure Lower, Middle, and Upper LED s represents LOW, MEDIUM and HIGH maximum Forward Propel Speed selection Allows selection of maximum forward speed during scrubbing LOWER (#1) LED =.0 mph /. kph MIDDLE (#) LED =.7 mph /. kph UPPER (#) LED =. mph /. kph

31 TO ENTER: T7 Display Software Reision Mode Press and hold One Step Button Turn key switch ON, wait 10 seconds Release One Step Button READING THE SOFTWARE REVISION: Upper Brush Pressure LED blinks TENS of DAYS of MONTH, Upper Solution Flow LED blinks SINGLE DAY of MONTH Middle Brush Pressure LED blinks TENS of MONTH, Middle Solution Flow LED blinks SINGLE MONTH Lower Brush Pressure LED blinks TENS of YEAR, Lower Solution Flow LED blinks SINGLE YEAR Brush Pressure LED's # of Blinks Solution Flow LED's # of Blinks Reision Date Day # (Upper) # (Upper) th Month # (Middle) 1 # (Middle) 1 Noember Year # 1 (Lower) 0 (LED OFF) # 1 (Lower) 00 One Step Scrub Button TOUCH PANEL LEFT SIDE DASH PANEL NOTE: An LED that does NOT blink is the digit ZERO (0) Brush Pressure Increase Button LED + + DAY LED Solution Flow Increase Button Brush Pressure Decrease Button LED LED 1 TENS MONTH YEAR ONES - - LED LED 1 Solution Flow Decrease Button = BLINKING (except if zero) 7

32 T7 Self Test Mode TO ENTER: Press and hold FaST & Vacuum Fan/Squeegee Buttons Turn key switch ON, wait 10 seconds Release Buttons The entire Self Test takes approximately 0 seconds AFTER THE SELF TEST IS COMPLETE: If the One Step LED is lit solid, NO FAULTS were found If any LED is blinking, an OPEN FAULT was found refer to table below If any LED (other than One Step) is lit solid, a SHORT FAULT was found refer to table below Self Test Results LED (Flashing = OPEN, Solid = SHORT) System at Fault One Step LED No Faults Found FaST LED Fast Pump Vacuum Fan/Squeegee LED Vacuum-Fan # (Upper) Brush Pressure LED Right Brush # (Middle) Brush Pressure LED Left Brush # 1 (Lower) Brush Pressure LED Head Actuator # (Upper) Solution Flow LED Water Vale # (Middle) Solution Flow LED Squeegee Actuator # 1 (Lower) Solution Flow LED Brake Recoery Tank Full LED Horn/Back-up Alarm 8

33 T7 Input Display Mode The purpose of the Input Display Mode is to show the condition of arious control board inputs TO ENTER: Press and hold the Decrease Solution Flow (-) Button Turn key switch ON Release Button after the # Battery LED blinks INPUT ASSOCIATED LED LED IS ON WHEN: LED IS OFF WHEN: NOTES Charger Interlock Switch FaST LED Seat Switch # (Green) Battery LED Recoery Tank Float Switch Solution Tank Float Switch Recoery Tank Full LED Solution Tank Empty LED Emergency Stop Switch Fault Indicator LED (Blinking) Battery charger IS NOT plugged in (switch is CLOSED) Operator IS NOT sitting on seat (switch is OPEN) Recoery tank IS FULL (switch must be CLOSED for to 7 seconds after One Step Button is actiated) Solution tank IS EMPTY (switch must be OPEN for to 7 seconds after One Step Button is actiated) Emergency Stop Switch IS ACTIVATED (switch is OPEN) Battery charger IS plugged in (switch is OPEN) Operator IS sitting on Seat (switch is CLOSED) Recoery tank IS NOT FULL (switch is OPEN) Solution tank IS NOT EMPTY (switch is CLOSED) Emergency Stop Switch IS NOT ACTIVATED (switch is CLOSED) FaST system will still operate, but without indicator Opening switch and pushing the the One Step Button turns LED off again Closing switch and pushing the the One Step Button turns LED off again Horn will repeat 8 beep cycle when Emergency Stop Switch is actiated One Step Button One Step LED Scrub system IS ACTIVATED Scrub system IS NOT ACTIVATED Vacuum Fan/Squeegee Button Vacuum Fan/Squeegee LED Battery Voltage # 1 (Red) Battery LED Vacuum Fan & Squeegee ARE ACTIVATED Battery needs charging (LED is BLINKING) Vacuum Fan & Squeegee ARE NOT ACTIVATED Battery has sufficient charge leel Left Scrub Brush Low Pressure # 1 (Lower) Brush Pressure LED LOW scrub brush current sensed Medium Pressure # (Middle) Brush Pressure LED MEDIUM scrub brush current sensed High Pressure # (Upper) Brush Pressure LED HIGH scrub brush current sensed Scrub system IS NOT ACTIVATED Right Scrub Brush Low Pressure # 1 (Lower) Solution Flow LED LOW scrub brush current sensed Medium Pressure # (Middle) Solution Flow LED MEDIUM scrub brush current sensed High Press ure # (Upper) Solution Flow LED HIGH scrub brush current sensed Scrub system IS NOT ACTIVATED NOTE: For Propel & Brake signal troubleshooting, refer to the Propel Diagnostics Mode page 9

34 T7 Manual Mode The purpose of the Manual Mode is to allow functioning of the indiidual systems on the machine without regard of most safety interlocks TO ENTER: Press and hold the Decrease Brush Pressure (-) Button Turn key switch ON Release Button after # 1 (Lower) Brush Pressure LED blinks FUNCTION BUTTON ACTION INDICATOR NOTES Lower Scrub Head One Step Press & Hold One Step LED ON Scrub head will continue to lower as long as button is held! CAUTION : Do not hold One Step Button down too long - actuator stall will occur, possibly damaging actuator or control board Operate Scrub Brushes One Step Release button after lowering scrub head One Step LED ON Scrub head stops lowering after One Step Button is released Turn OFF Scrub Brushes and Raise Scrub Head One Step Press & Release One Step LED OFF Scrub head raises to to top of stroke and stops Turn ON Vacuum Fan and Lower Squeegee Vacuum Fan/ Squeegee Press & Release Vacuum Fan/ Squeegee LED ON! CAUTION : In this mode, automatic raising of the squeegee when in REVERSE is disabled In this mode, pressing the One Step Button during lowering of the squeegee will stop squeegee trael Turn OFF Vacuum Fan and Raise Squeegee Vacuum Fan/ Squeegee Press & Release Vacuum Fan/ Squeegee LED OFF In this mode, pressing the One Step Button during raising of the squeegee will stop squeegee trael Turn ON FaST pump FaST Press & Release FaST LED ON Turn OFF FaST pump FaST Press & Release FaST LED OFF Increase Solution Flow Rate Decrease Solution Flow Rate Increase Solution Flow (+) Decrease Solution Flow (-) Press & Release Solution Flow LED's Press & Release Solution Flow LED's ADDITIONAL NOTES When the Recoery Full switch is grounded for a short time, the Recoery Full LED will light In this mode, the Solution Flow automatic ON/OFF interlock is disabled In this mode, the Solution Flow automatic ON/OFF interlock is disabled When the Solution Empty switch is un-grounded for a short time, the Solution Empty LED will light If the Recoery Full LED or the Solution Empty LED is ON, and the Scrub System or Vacuum Fan/Squeegee system is actiated, the Recoery Full LED and Solution Empty LED will turn OFF and the sensing of both switches will be disabled for about a minute With the Directional Switch in REVERSE, the Back-up Alarm will sound but automatic raising of the squeegee is disabled For safety considerations, the "High Pedal Disable" and "Seat Switch Disable" interlocks & alarms are still actie in Manual Mode 0

35 T7 Propel/Brake Diagnostics TO ENTER: Press and hold FaST & Increase Brush Pressure (+) Buttons Turn key switch ON Release Buttons after FaST LED (if in Forward) or Vacuum Fan/Squeegee LED (if in Reerse) is lit TEST ACTION INDICATOR NOTES Directional Switch - Forward Place Directional Switch in Forward Propel position FaST LED ON LED will be illuminated if the controller senses the Directional Switch in Forward Position - Machine will not propel if any of the Brake LED s are illuminated Directional Switch - Reerse Place Directional Switch in Reerse Propel position Vacuum Fan/ Squeegee LED ON LED will be illuminated if the controller senses the Directional Switch in Reerse Position - Machine will not propel if any of the Brake LED s are illuminated Brake Pedal Depress Brake Pedal Brush Pressure LED's LED s will display the sensed position of the brake pedal - No LED s indicate pedal is released, LED s indicate that the pedal is fully depressed Accelerator Pedal Depress Accelerator Pedal Solution Flow LED's LED s will display the sensed position of the accelerator pedal - No LED s indicate the pedal is released, LED s indicate that the pedal is fully depressed Propel Motor Current Depress Accelerator Pedal Battery LED's Battery gauge LED s display the current leel being drawn by the Propel Motor - Each LED represents 7 Amps of current (ex: LED's = 1 Amps) Direction Wire # Color Polarity Forward Reerse Green Yellow "+" Green "+" Yellow Propelling System Data Voltage during FORWARD trael will ary between 0 to VDC Voltage during REVERSE trael will ary between approximately 0 to 17 VDC Notes Releasing the Propel Pedal will initiate Dynamic Braking; As machine slows to a halt, the Brake solenoid is De-energized, applying the Parking Brake Propel & Brake Pedal Data Pedal LED group Lit LED's Pedal Position Input Voltage Leel Notes 0 Released below 1. VDC Machine must be in Propel 1 Slightly Depressed 1. to 1.89 VDC Propel Solution Flow Diagnostic Mode when testing; Halfway Depressed 1.89 to.7 VDC LED's will display the sensed Fully Depressed.7 to.0 VDC position of the pedal; No LED's 0 Released below 1. VDC indicate pedal is released; 1 Slightly Depressed 1. to 1.89 VDC Brake Brush Pressure LED's indicate pedal is fully Halfway Depressed 1.89 to.7 VDC depressed Fully Depressed.7 to.0 VDC 1

36 T7 Battery Select Mode & Voltage Leels Battery Select Mode TO ENTER: Press and hold Increase Solution Flow (+) Button Turn key switch ON Release Button after one of the Battery LED s begins blinking Location / Type Worldwide / Wet Europe** / Wet TNV** / Wet BDI Indicator LED's R x x x x Y x x x x G x x x x Worldwide / Gel x x x G x LED's: R=RED Y=YELLOW G=GREEN x =OFF =BLINKING **Used only under instruction of battery manufacturer Voltage Leels* Battery Leel Worldwide Voltage (Wet) European** Voltage (Wet) TNV** Voltage (Wet) Worldwide Voltage (Gel) Full Battery Voltage.... Leel Leel.1... Leel Leel Full discharge BDI Indicator LED's R Y G G G R Y G G x R Y G x x R Y x x x R x x x x R x x x x LED's: R=RED Y=YELLOW G=GREEN x =OFF =BLINKING *Voltage measured at circuit board - Assume 0. Volts higher at batteries (under load) **Used only under instruction of battery manufacturer

37 T7 Reerse Alarm & Propel Speed Select Modes Reerse Alarm Select Mode Reerse Alarm Select Mode allows enabling or disabling of the Backup Alarm TO ENTER: Put directional switch in Reerse Press & Hold Horn Button Turn key switch ON If Back-up Alarm is silent, Hospital (Quiet) Mode has been selected If Back-up Alarm is sounding, Normal mode has been selected Cycle key switch OFF, then ON again Verify correct mode has been chosen Propel Speed Select Mode Propel Speed Select Mode allows selection of maximum forward speed during scrubbing TO ENTER: Press and hold FaST Button Turn key switch ON Release Buttons after selecting desired Brush Pressure LED Refer to table below for speed selection BRUSH PRESSURE LED MAXIMUM SCRUB SPEED # 1 (Lower) LED.0 mph /. kph # (Middle) LED.7 mph /. kph # (Upper) LED. mph /. kph

38 T7 Inputs & Outputs Table Inputs and the Outputs they Control Key Switch (ON) Seat Switch (Operator on seat) Charger Switch (Charger plugged in to machine) Emergency Stop Switch (Pressed) One Step Switch (ON) FaST Switch (ON) Vacuum Fan/ Squeegee Switch (ON) Inputs Recoery Tank Full Switch (Tank Full) Solution Tank Empty Switch (Tank Empty) Directional Switch Forward Directional Switch Reerse Throttle Input (Pedal pressed) Brake Input (Pedal pressed) Main Contactor E D D Propel Forward E E D D E D E D Propel Reerse E E D D D E** E D Dynamic Braking Force - Increase E E D E Parking Brake E E D E*** Scrub Motors E D D E D D E D Scrub Head Pressure Control E D D E D D E D Vacuum Motor E D D E D D Squeegee Down E D D E D D E D FaST System E D D E E D D E D Solution Solenoid E D D E Hour Meter Operation E E* E* Horn E E** Battery Gauge Reset E E = Input that will ENABLE Output D = Input that will DISABLE Output * Actiating Vacuum Fan OR Propelling machine will enable the Hour Meter ** Horn will sound when Directional Switch is selected for Reerse (except in Hospital Mode) *** Parking Brake actiated after timer has expired Horn Button (Pressed) E Outputs

39 Thread Size SAE Grade 1 SAE Grade Carriage Bolts Torque Standard Inch Fasteners Thread Cutting Thread Rolling SAE Grade Socket and Stainless Steel SAE Grade 8 Headless Socket Set Screws (.11) ()--(.) ()--() (.1) ()--(8) (9)--(11) (.18) (7)--(9) (0)--() (9)--(11) 8 (.1) (1)--(1) (0)--(7) (17)--() 10 (.190) (0)--() (0)--(0) (1)--(1) Square Head Set Screws I N C H P O N U D S 1/ (.0) /1 (.1) /8 (.7) /1 (.8) / (.00) /8 (.) F O O T P O U N D S / (.70) (1.000) Torque Foot Pounds (Inch Pounds) Zinc Plated Fasteners and Torque Control ( )

40 Torque Standard Inch Fasteners Mechanical Properties Fastener Identification Type Material Nominal Size Proof Load (PSI) Yield Strength Min (PSI) Tensile Strength Min (PSI) SAE Grade 1 Machine Screws Low or Medium Carbon Steel # Thru #10 1/ Thru 11/,000,000,000 0,000 SAE Grade Carriage Bolts Low or Medium Carbon Steel 1/ Thru / Oer / Thru 1 1/,000,000 7,000 7,000,000 0,000 Stainless Steel Austenitic Stainless Steel 0,000 90,000 SAE Grade Medium Carbon Steel Quenched Tempered 1/ Thru 1 Oer 1 to 11/ 8,000 7,000 9,000 81,000 10,000 10,000 Socket Screws High Carbon Alloy Steel Quenched Tempered 1,000 10,000 SAE Grade 8 Medium Carbon Alloy Quenched Tempered 1/ Thru 11/ 10,000 10,000 10,000 Fasteners and Torque Control ( )

41 Torque Standard METRIC Fasteners Thread Size.8/. 8.8 Stainless Steel Set Screws M -- Ncm Ncm Ncm 1--1 Ncm Ncm M Ncm --90 Ncm Ncm Ncm Ncm M Ncm --7 Ncm Ncm Ncm 7-- Ncm C E N N T E I W M T E O T N E R S M.--. Nm Nm Nm Nm Nm M Nm Nm.-- Nm 1--0 Nm M Nm 7--8 Nm --7 Nm --81 Nm M1 8-- Nm --8 Nm Nm Nm M1 --8 Nm Nm Nm Nm M Nm Nm Nm --0 Nm Nm N E W T O N M E T E R S M Nm Nm --0 Nm Nm M Nm Nm 7--7 Nm Nm M 7--9 Nm 0--7 Nm Nm Nm Zinc Plated Conersion Tables Ncm to Inch Pound x Inch Pound to Ncm x Nm to Foot Pound x 0.77 Foot Pound to Nm x 1.8 Fasteners and Torque Control ( ) 7

42 Torque Standard METRIC Fasteners Mechanical Properties Fastener Identification Type Class Material Nominal Size Yield Stress (Min) MPa Yield Point.% Elongati (Min) MPa Tensile Strength (Min) MPa./. Carriage Bolts Low or Medium Carbon Steel 190 (7,0 PSI) 0 (,800 PSI) 0 (7,80 PSI) 00 (8,000 PSI).8 Pan Head Machine Screws Low or Medium Carbon Steel 0 (9,00 PSI) 0 (0,900 PSI) A A--70 Stainless Steel Austenitic Stainless Steel 0 (,00 PSI) 700 (101,000 PSI) 8.8 A 8.8 Hex Head (Grade ) Medium Carbon Steel Quenched Tempered < M1 >M1 0 (9,800 PSI) 0 (9,700 PSI) 800 (11,000 PSI) 80 (10,0 PSI) Hex Head Flat Head (Grade 8) Medium Carbon Steel Quenched Tempered 90 (1,00 PSI) 100 (10,800 PSI) Socket Head Alloy Steel 1100 (19,00 PSI) 10 (17,900 PSI) Conersion Table Mega Pascals to Pounds per Square Inch x 1.18 Fasteners and Torque Control (1---01) 8

43 Torque Standard Nylon Insert Lock Nuts Nut-Hex Light THIN (Cad or Zinc Plated) Size Grade Bolt Grade Bolt 1/ / / / / / / / / / Torque in Foot Pounds Fasteners and Torque Control ( ) 9

44 Torque Standard Wheel Bolt and Nuts Stud or Bolt Size and Thread Recommended Torque in Foot Pounds 7/ / / / Wheel Bearing Adjustment 1. Tighten the spindle nut to 1 ft lbs while turning the wheel assembly forward by hand to fully seat the bearings.. Back off the nut to the just loose position.. Hand tighten the spindle nut. Loosen the spindle nut until either hole in the spindle lines up with a slot in the nut. (Not more than 1/ flat.). Install the cotter pin. Bend the ends of the cotter pin against the nut, cut off extra length to ensure ends will not interfere with the dust cap. Fasteners and Torque Control ( ) 0

45 Tightening Nuts on Tapered Shafts Example of recommended torque , /9, UNEF--B SLOTTED KEY WIDTH HEX LOCKNUT PER SAE J--01 (EXCEPT 1.0/8,1 ACROSS FLATS). RECOMMENDED TOQUE TO 17 FT LB PLUS TORQUE REQUIRED TO ALIGN SLOTTED NUT TO SHAFT HOLE.7/7,7 CLEARANCE DIA. P SHAFT DIA..1,9 DIA. THRU TAPER PER FOOT/1 + 0,17 MM TAPER PER METER ,0 + 0, , , Check with the manufacturer to see what the recommended maximum torque is. Tighten the slotted nut to a lower torque, and then tighten the nut to align the cotter pin hole with the slot on the nut. Do not exceed the recommended torque. Do not back off the nut to align the holes. Motor Tapered Shaft Nut Info. Torque Specification Recommendations A&H Series 1.00 dia UNF 10 ft lb dry Hex 1 ft lb lubricated Plus torque to align for pin 000 Series 1. dia UNEF ft lb dry 1. Hex ft lb lubricated PLUS torque to align for pin 000 Series 1. dia UNEF 7 ft lb dry.187 Hex 7 ft lb lubricated PLUS torque to align for pin 000 Series 1.7 dia UNEF 7 ft lb dry.187 Hex 7 ft lb lubricated PLUS torque to align for pin Fasteners and Torque Control ( ) 1

46 Torque Standard Shoulder Bolts Nominal Diameter Thread Size Recommended Seating Torque In Lbs.1 1/--0 9 Ft Lbs.7 / Ft lbs.00 /8--1 Ft Lbs. 1/--1 8 Ft Lbs.70 / Ft Lbs Metric Nominal Diameter Thread Size Recommended Seating Torque 8 Mx0.8 Mx1.0 7Nm 1 Nm 10 M8x1. 9 Nm 1 M10x1. 7 Nm 1 M1x Nm Fasteners and Torque Control ( )

47 Taper Lockr Bushings IMPORTANT: Follow all these instructions carefully. This is necessary to insure satisfactory performance. C C 1008 to 00 To Install 1. Clean shaft, bore and outside of bushing, and hub bore of all oil, lacquer, and dirt.. Insert bushing in hub. Match the hole pattern, not threaded holes (each hole will be threaded on one side only).. Oil setscrews and thread into those half threaded holes indicated by C on aboe diagram.. Alternately torque setscrews to recommended torque setting in chart below.. Using a block, sleee, or drift, hammer large end of bushing (do not hammer bushing directly).. Repeat steps and until torque wrench reading after hammering is the same as before hammering. 7. Fill all unoccupied holes with grease. To Remoe 1. Remoe all setscrews.. Insert setscrews in holes indicated by D on the diagram. Loosen bushing by alternately tightening setscrews.. To reinstall, complete all seen (7) steps installation steps. Recommended Wrench Torque Wrench Torque Bushing No. Screws (Pound-Inch) 1008, , 11, , , 00, 00 1/ Setscrews /8 Setscrews /8 Setscrews 7/1 Setscrews 1/ Setscrews /8 Setscrews Hammer Size lb lb lb lb lb lb If two bushings are used on same component and shaft, fully tighten one bushing before working on the other. Fasteners and Torque Control ( )

48 Sequence Tightening On some assemblies, it is adisable to use a crisscross pattern. Always aoid starting in one spot and tightening one after another in a row. Remember that the object is to tighten the parts in such a manner that een stress is set up throughout, at the same time allowing the parts to be drawn together so that their mating surfaces will contact Torque in Steps 1. Run each fastener, in proper sequence, up to the recommended torque.. Repeat the process of running up each fastener, in proper sequence, up to the recommended torque.. If necessary, repeat step two until all the fasteners are tightened to the recommended torque. Fasteners and Torque Control ( )