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PLDC04452

REVISION 00

December 23, 2020

TECHNICAL OFFICE

Stavale

D1 MACHINE’S MAIN WIRING, “PAD ASSIST” version

The machine’s main wiring has been modified, moving the brush contactor to the
electronics mounting plate, and eliminating the general one. The board is made
using an automated process, with the components or sockets soldered on top,
eliminating the interconnection wires. The board includes the 2 A fuse for the
functions, the board and the solenoid valve. The 40A suction motor fuse and 50A
brush motor fuse. There are some variants to the wiring, such as the cable to power
the current reading board used for the rollers, the wiring to power the Chem-dose
pump, if featured, and the connector to assemble the on-board battery charger. The
connector with safety catch has been added to the drive motor power supply cable.

i

Fig. 111

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Summary of Contents for T290

Page 1: ...Stavale T290 TECHNICAL SERVICE MANUAL TECHNICAL OFFICE PLDC04452 REVISION DATE December 23 2020 DATE December 23 2020 ...

Page 2: ......

Page 3: ...ed in this manual are guaranteed Stavale PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE WARNINGS DANGER Indicates the need for attention in order to avoid a series of consequences which could cause death or damage to the health of the operator Indicates particularly important instructions WARNING Indicates the need for attention in order to avoid a series of consequences which could cause...

Page 4: ...eplacing the brush motor Checking brush motor current imput Replacing the carbon brushes A1 Measuring current draw and replacing the carbon brushes Replacing the suction motor B1 Error codes Troubleshooting E2 Troubleshooting Drive assembly B2 Adjusting and replacing the squeegee Checking and replacing the float Tanks Suction Assembly Drive motor Idle wheels B3 C1 Instrument panel board C2 C3 ...

Page 5: ...BOARD 31 C1 1 Instrument panel board setting the type batteries 33 C1 2 Dismantling the instrument panel board 38 C2 DRIVE MOTOR WHEELS 41 C2 1 Checking the drive motor current input 42 C2 2 Checking and replacing the carbon brushes traction motor 43 C2 3 Replacing the drive wheels BT version 45 C2 4 Replacing the idle wheels 46 C2 5 Replacing the drive motor 47 C3 RELAY AND DRIVE MOTOR ELECTRICAL...

Page 6: ...ecember 23 2020 TECHNICAL OFFICE Subject Page E ERROR CODES TROUBLESHOOTING E1 ERROR CODES 64 E1 1 Alarm messages on the instrument panel board display 64 E2 TROUBLESHOOTING 66 E2 1 Troubleshooting 66 Information on the revision numbers 68 ...

Page 7: ...y for the battery versions or unplugging from the mains power supply for the cable versions In this Service Manual the terms RIGHT and LEFT are used to indicate the sides of the machine These always refer to the direction of travel of the machine In this Service Manual the machine version may be written in brackets Traction Pad Assist or quotation marks Traction Pad Assist This note indicates that...

Page 8: ...PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE Stavale A1 BRUSH MOTOR Fig 1 2 of 68 ...

Page 9: ...switches into position 0 Pad Assist 4 Make sure that the batteries on the machine are charged 5 Use a clamp on ammeter with an end scale reading of at least 200 amperes as shown in Figure 2 6 Remove the power board 7 Move the speed knob on the instrument panel to zero turning it anticlockwise 8 Remove the brush 9 Switch the ammeter to amperes and DC A1 1 Cheking brush motor current input Checks Fi...

Page 10: ...current in operation i e with the brushes 17 Replace the brushes on the reduction drive and lower the brush head to the floor 18 Repeat the readings as described above 19 Compare the values measured against the chart below 20 If the values are OK replace the brush motor cover 21 If the values do not correspond to those specified higher 21a Check that the brush drive and thus the motor is free to r...

Page 11: ...ush head using the pedal control 5 Disconnect the batteries from the machine s main wiring and from each other 6 Remove the batteries from the battery compartment 7 Remove the brush head cover unscrewing the four screw 8 Lay the machine on its side 9 Unscrew the two front screw A that fasten the solution tank to the machine s chassis 10 Loosen the two rear screw B that fasten the solution tank to ...

Page 12: ...SION 00 December 23 2020 TECHNICAL OFFICE Stavale 11 Lift the solution tank from the front keeping the dirty water tank open 12 Identify the screw C that secures the metal band on the brush motor Fig 5 B C C 6 of 68 ...

Page 13: ...e figure below The brush must have a minimum length of 8 0 mm 0 315 in 17 Check the sliding contact surface F1 of the carbon brushes I for wear or damage The surface must not be badly worn or burned 18 When fitting new carbon brushes compare the new ones with the old ones or check them against the dimensions given in the figure below Only the length must be different The carbon brushes must all be...

Page 14: ...over the carbon brushes F align the notch H in the strap with the corresponding reference on the motor body 22 Arrange the clamp H1 of the metal strap H as shown in the figure below when reassembling 1 Repeat the dismantling operations in reverse 2 To reassemble the carbon brushes perform the dismantling operations in reverse 3 Reposition the protection clamp making sure it is positioned on the ca...

Page 15: ...PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE Stavale A2 REPLACING THE BRUSH MOTOR Fig 11 9 of 68 ...

Page 16: ...e the metal clamp C from the solution hose and remove the hose D from the fitting on the motor 5 Lay the machine on its side 6 Unscrew the seven M6 x 12 mm stainless steel bolts E that fasten the reduction drive to the plate 7 Remove the brush motor from the gearmotor support plate 8 Take the reduction drive to the bench and then remove the drive D unscrewing it clockwise 9 Replace the reduction d...

Page 17: ... Warning tighten the seven screws E to a maximum torque of 7 5 Nm 66 4 lbf in and always place the Grover washers between the plate and the screws 3 Apply grease to the brush motor pin before screwing the driver counterclockwise Make sure that the brush rotate in an anticlockwise direction Reassembly E CHEMͲDOSE CONNECTOR D D Fig 14 Fig 13 11 of 68 ...

Page 18: ... s electronics by simply disconnecting the negative pole only for the battery versions or unplugging from the mains power supply for the cable versions In this Service Manual the terms RIGHT and LEFT are used to indicate the sides of the machine These always refer to the direction of travel of the machine In this Service Manual the machine version may be written in brackets Traction Pad Assist or ...

Page 19: ...PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE Stavale SUCTION MOTOR B1 Fig 15 13 of 68 ...

Page 20: ...DC 10 Turn the ignition key on the mushroom shaped switch clockwise to connect power 11 Start the suction motor by pressing the corresponding button on the instrument panel 12 Read the CURRENT A drawn by the suction motor 13 Compare the values measured against the chart below 14 If all the values are normal close the top dirty water tank again 15 If the measurements do not correspond to those spec...

Page 21: ...Lift and turn the top dirty water tank 4 Isolate and disconnect the power connector A to the suction motor see Figure 19 5 Remove the top cap B on the suction motor this operation can be performed without removing the air exhaust pipe 6 To remove the cap B pull the metal catch C outwards and open the two tabs D B1 2 Replacing the suction motor carbon brushes B C D Fig 20 Fig 19 A 15 of 68 ...

Page 22: ...bon brush support F and remove the motor carbon brush G 10 Measure the carbon brush if the length is between 23 7 mm 0 93 in maximum and 5 0 1 mm 0 2 0 04 in minimal the carbon brush is still working otherwise it must be replaced 11 Repeat the operation for the second carbon brush 1 Replace the suction motor performing the dismantling operations in reverse 2 Test the correct operation of the sucti...

Page 23: ...move the white plastic clamp B that fastens the cable to the suction motor plate 6 Unscrew the two M6 screw C that fasten the suction unit motor to the dirty water tank 7 Remove the suction motor from its compartment 8 Check that the area inside the circle and the suction motor gasket D are not moist or wet a sign of liquid being drawn in that may damage the bearings inside the suction motor causi...

Page 24: ...sorbing sponge G suction motor air exhaust pipe When replacing the motor also replace the suction motor gasket D purchased separately 10 Replace the motor and assemble it as shown in Figures 25 26 1 For assembly perform the dismantling operations in reverse 2 Test the correct operation of the suction motor see paragraph B 1 1 Reassembly D E F G Fig 25 Fig 26 G G G F F F G 18 of 68 ...

Page 25: ...PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE Stavale SQUEEGEE UNIT B2 Fig 27 19 of 68 ...

Page 26: ...even contact with the floor with suitable deflection across the width Figure 28 6 If this is not the case adjust the blade 7 First adjust the angle of the squeegee using the bolt A until the blade touches the flooring uniformly 8 Adjust the deflection of the squeegee blade using the two wheels B tightening decreases the deflection loosening increases the deflection Adjust until one edge of the bla...

Page 27: ... the squeegee taking deflection off the centre 10 Unscrewing the bolt A the squeegee support rais the edges of the squeegee decreasing the deflection on the blade at the sides of the squeegee and it increasing deflection on the centre 11 Once having found the right angle when the squeegee is perfectly parallel to the flooring hold screw A in place lock the position with the nut C C C Fig 29 Fig 30...

Page 28: ...g the screw D the squeegee rises decreasing the deflection on the blade 14 By unscrewing screw D the squeegee is lowered increasing the deflection on the blade 15 Once having found the right deflection when the blades are slanted correctly with respect to the floor hold screw D in place lock the position with the nut E Fig 31 D E 22 of 68 ...

Page 29: ... symmetrically so that they can be rotated on all four edges before being replaced see Fig 33 The rear squeegee blade should be turned around every 50 operating hours 1 Clean the squeegee blades before reassembling them 2 Clean the body of the squeegee where the old or new blades will be fitted 3 Arrange the blades on the squeegee lining up the holes with the reference pins E do not exchange the f...

Page 30: ...e blade pressing devices front and rear 6 Reposition the squeegee on the support and reassemble the suction hose 7 Adjust the squeegee as described in paragraph B 2 1 1 For the complete replacement of the squeegee proceed as described in points B 2 1 2 For the replacement of the squeegee body only proceed as described in points B 2 1 and B 2 2 B2 3 Replacing the squeegee Fig 36 H Fig 37 24 of 68 ...

Page 31: ...PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE Stavale B3 CHECKING AND REPLACING THE FLOATS Fig 38 OFF CLIC ON 25 of 68 ...

Page 32: ...6 Lift the dirty water tank to access the connector A on the float 7 Unplug the connector A so as to be able to perform the check 8 Connect the two tester probes to the pins on the float connector the position is not important 9 If the float is working correctly the tester will emit a BEEP if featured or will display a value with just zeroes 10 Plug the connector back in 11 If the tester display d...

Page 33: ... unscrewing the bolt C 8 Remove the float from the solution tank 9 Replace the float with a new one D 1 Fit the new float performing the dismantling operations in reverse 2 Pay special attention to the position of the float in the tank see Figure 45 3 Pay special attention to the seal gasket E on the new float 4 Tighten the float to the tank holding the body B and tightening the bolt C making sure...

Page 34: ...tion tank 7 Identify the float connector B 8 Unplug the connector B so as to be able to perform the check 9 Connect the two tester probes to the pins on the float connector the position is not important 10 Keep the float raised by hand or hold it position with an elastic band see Figure 49 11 If the float is working correctly the tester will emit a BEEP if featured or will display a value with jus...

Page 35: ...side the tank 8 Remove the float from the tank holding the body of the float E and unscrewing the bolt F 8 Remove the float from the dirty water tank 9 Replace the float with a new one E 1 Fit the new float performing the dismantling operations in reverse 2 Position the float as shown in Figure 57 with the part G tilted towards the bottom of the tank 3 Pay special attention to the seal gasket H on...

Page 36: ...hine s electronics by simply disconnecting the negative pole only for the battery versions or unplugging from the mains power supply for the cable versions In this Service Manual the terms RIGHT and LEFT are used to indicate the sides of the machine These always refer to the direction of travel of the machine In this Service Manual the machine version may be written in brackets Traction Pad Assist...

Page 37: ...er 23 2020 TECHNICAL OFFICE Stavale On the Traction version the board also comprises the circuits that deliver power the drive motor C1 INSTRUMENT PANEL ELECTRONIC BOARD i Fig 60 Fig 61 PAD ASSIST VERSION TRACTION VERSION 31 of 68 ...

Page 38: ... TECHNICAL OFFICE Stavale The alphanumeric display is only fitted on battery version machines Pad Assist Traction INSTRUMENT PANEL BOARD IDENTIFICATION BOARDS FOR MACHINES WITHOUT DRIVE BOARDS FOR MACHINES WITH DRIVE Fig 63 Fig 62 32 of 68 ...

Page 39: ... affect battery life and operating autonomy The type of battery is marked on the battery casing The batteries can be divided into three categories Pb Acd lead acid AGM locked acid and GEL with the plates coated by gel 1 Turn the ignition key A1 on the emergency button A to the right 2 Press and hold the brush button B and the suction motor button C together for around 5 seconds and in any case unt...

Page 40: ...the type of batteries or the water solution metering mode Water solution is indicated as the clean water tank can be filled with either a solution of water and detergent or water only using the special Chem dose kit that distributes the detergent to be mixed with water directly onto the brushes thus avoiding waste i Setting EcoMode on Traction versions with drive C C Fig 66 B B Fig 67 34 of 68 ...

Page 41: ...red 6 To save the settings simply switch the machine off using the emergency button A for machines with drive For all other machines press and hold the brush button B until the display switches off i A Fig 69 EcoMode on models with electric drive delivers a flow of solution that is proportional to machine travel speed as is already currently available on our large rideͲon machines 6 20 12Ͳ40 18 60...

Page 42: ... Press and hold the brush button B and the suction motor button C together for around 5 seconds and in any case until the display shows the type of batteries set 9 Use the button C to select the type of battery between GEL and ACID Setting on Pad Assist versions without drive B Fig 70 C B Fig 71 C C Fig 72 36 of 68 ...

Page 43: ...press the brush button B and the suction motor button C together for 5 seconds or wait around 10 seconds until the display shows the machine operating hours 11 Switch the machine off by pressing the brush on off button for more than 3 seconds 10 sec Fig 74 C C B B B C Fig 73 Fig 75 B 37 of 68 ...

Page 44: ...chine to avoid dangerous short circuits 3 Unscrew the three screws B that fasten the instrument panel to the dirty water tank 4 Lift the board and turn it over with care 5 Disconnect the multi wire orientation sensitive connectorsC D from the electronic board with care C1 2 Dismantling the instrument panel board Disassembly Versions with drive Fig 76 B B A Fig 77 C D 38 of 68 ...

Page 45: ...OFF switch when reassembling its orientation is not important 7 Detach the two wires orange and purple connected to the forwards reverse switch F when reassembling being an ON OFF contact the position of the wires is not important 8 Disconnect the four pin connector G dedicated to traction motor taking special care Assembly is orientation sensitive by the locking connector fitted on the instrument...

Page 46: ...he three screws I that fasten the instrument panel to the dirty water tank 12 Lift the board and turn it over with care 13 Disconnect the multi wire orientation sensitive connectors L M and the red fast on terminal N on the black wire from the electronic board with care 1 To assemble the new instrument panel board repeat the disassembly operations in reverse Disassembly Reassembly Versions without...

Page 47: ...errite complyed with the new European standards on electromagnetic compatibility The tecnichal specification the power motor is 145 W at 24 VDC wheel axle speed of 120 rpm gear ratio between the electric motor shaft speed and wheel axle speed is of 18 1 and the ingress protection against solids and liquids of IP20 i Fig 81 41 of 68 ...

Page 48: ...ergency switch clockwise 11 Turn the speed controller on the instrument panel completely clockwise 12 Press the enable brush lever 13 Read the CURRENT with the motor at no load without the machine operating 14 Lower the wheels back to the ground and read the CURRENT with the machine in drive with the tanks empty the brush lifted and all the functions off 15 Compare the values measured against the ...

Page 49: ...ng soft between the floor and the side to avoid damaging the side 9 Identify the L bracket that prevents the motor from rotating on the wheel axle 10 Unscrew the bolt A that fastens the L bracket to the motor 11 Turn the motor so as to easily access the plastic guards on the motor carbon brushes 12 Remove the guards checking their position 13 Use a hook to lift the spring B remove the carbon brush...

Page 50: ...ve it from the shaft use a special puller 1 Check where the carbon brushes slide on the rotor that there is not excessive wear 2 Check that the bearing G is in intact check the colour of the outside ring if the steel tends to be purple it has heated up excessively Turning it by hand make sure that there is no wear it rotates smoothly and is not particularly noisy 3 Check that the motor protector H...

Page 51: ...p the end of the spanner lightly yet firmly with a hammer 9 Make sure not to lose the Grover washer B located behind the flat wide washer 10 Remove the old wheel if necessary use a rubber mallet 11 Position the tab E in place on the shaft if necessary to fit the new wheel 12 Fit the new wheel and push it in fully using a rubber mallet 1 Check that the Seeger ring C is intact and check the position...

Page 52: ...axle using the groove C to keep the axle locked 8 Push the side of the machine to tilt it on one side 9 Place a block of wood between 90 mm 3 54 in and 150 mm 5 9 in high under the machine s axle 10 Completely unscrew the bolt A making sure not to lose the Grover washer B 11 Remove the wheel and replace it with a new one 1 Check that the Seeger ring C is intact and check the position 2 Check that ...

Page 53: ... side of the machine to tilt it over until it rests on the left side 8 It is recommended to lay something soft between the floor and the side to avoid damaging the side 9 Start by removing the wheel at the top then continue with the one at the bottom see paragraph C 2 4 10 Remove the keyways the washers and the Seeger tings fitted on the shaft see paragraph C 2 4 11 Identify the L bracket that pre...

Page 54: ...mble the bearings D and E on the shaft ensuring they are inserted in the right direction 4 Respect the assembly positions of the bearings D with the L brackets 5 Position and tighten max torque 25 5 Nm 226 lbf in the two bearings with flanges E on the chassis 6 Adjust the distance of the end of the half axles from the edge of the bearings with flange E to 53 mm 2 1 in 7 Tighten the dowel pins G to...

Page 55: ...rear on the right near the solenoid valve 5 Disconnect the brown wire A and the black wire B and join them together using a piece of wire 6 Check if the relay is working correctly 6a If the machine moves check if there is voltage 24V at the wires C and D 6b If the machine moves and there is voltage at the wires C and D replace the relay 6c If the machine does not move check if there is power suppl...

Page 56: ... wiring and each other and remove them from the battery compartment 5 Remove the bettery plate 6 Identify the crosshead screw closest to the relay 7 Unscrew the screw and proceed to replace the relay 8 Proceed with the electrical connection shown below 1 To assemble the new relay complete the dismantling operations in reverse 2 Pay attention to the connection to the relay the other connections are...

Page 57: ...hine s electronics by simply disconnecting the negative pole only for the battery versions or unplugging from the mains power supply for the cable versions In this Service Manual the terms RIGHT and LEFT are used to indicate the sides of the machine These always refer to the direction of travel of the machine In this Service Manual the machine version may be written in brackets Traction Pad Assist...

Page 58: ...ets soldered on top eliminating the interconnection wires The board includes the 2 A fuse for the functions the board and the solenoid valve The 40A suction motor fuse and 50A brush motor fuse There are some variants to the wiring such as the cable to power the current reading board used for the rollers the wiring to power the Chem dose pump if featured and the connector to assemble the on board b...

Page 59: ...board and solenoid valve fuse B Main wiring board connector C Suction motor relay D Contactor brush motor E Brush motor fuse F Suction motor fuse G Positive isolator switch H Negative isolator switch D1 1 Main wiring board components Pad Assist version C H G F E D B A Fig 112 53 of 68 ...

Page 60: ...ed on top eliminating the interconnection wires The board includes the 2 A fuse for the functions the board and the solenoid valve The 30A drive fuse The 40A suction motor fuse and 50A brush motor fuse There are some variants to the wiring such as the cable to power the current reading board used for the rollers the wiring to power the Chem dose pump if featured and the connector to assemble the o...

Page 61: ...solenoid valve fuse B Main wiring board connector C Suction motor relay D Contactor brush motor E Brush motor fuse F Suction motor fuse G Drive motor fuse H Positive isolator switch I Negative isolator switch D2 1 Main wiring board components Traction version C I H G F E D B A Fig 114 55 of 68 ...

Page 62: ...the machine check that the connector is correctly plugged onto the board Board power connector 24 V forwards reverse signal 24 V start suction motor control signal 24 V start brush motor control signal Electric motor and function management connector Drive connector red power wire 24 V protected by fuse Fast on terminal for forwards reverse travel selector Purple wire and orange wire 24 V Fast on ...

Page 63: ... lugs roller version only powers the current reading board Orange wire with spade lugs to connect to the mushroom head button with key carries 24 V signal to the functions Fig 118 Suction motor connector red wire 24 V protected by fuse and blue negative wire Fig 119 Battery terminals and terminal covers Red wire on the positive pole black wire on the negative pole Fig 120 Sealed connector for dirt...

Page 64: ...V Fig 122 Drive motor connection Fast on terminal brown wire and fast in terminal grey wire Relay coil connector fast on terminal black wire connected directly to the negative isolator switch 0 V Drive motor protector connector Male tubular cable lugs for red wire female tubular cable lugs for orange wire 24 V Relay coil connector fast on terminal orange wire 24 V Fig 123 24V 24V 24V 24V 24V 24V 2...

Page 65: ...he negative isolator switch Fig 125 Brush motor protector fast on terminal connector Yellow black wire and brown white wire 0 V Fig 126 Connect the red wire to the motor s positive pole and the black wire to the negative The thermal protector has orientation sensitive connectors Fig 127 Two pin connector for connecting the Chem dose pump Pink wire 24 V yellow black wire 0 V in series with the brus...

Page 66: ...us preventing machine operation The sealed connector provided for the on board battery charger must be detached from the microswitch and connected to the microswitch on the battery charger Fig 129 Connection via Ø 8 mm cable eyelet Only used on machines with roller head not used on the others Red wire 24 V coming directly from the positive isolator switch Connected directly to ground on the brush ...

Page 67: ...PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE Stavale D3 ELECTRICAL WIRING DIAGRAMS D3 1 Wiring diagram Pad Assist version 61 of 68 ...

Page 68: ...PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE Stavale D3 2 Wiring diagram Traction version 62 of 68 ...

Page 69: ...ectronics by simply disconnecting the negative pole only for the battery versions or unplugging from the mains power supply for the cable versions In this Service Manual the terms RIGHT and LEFT are used to indicate the sides of the machine These always refer to the direction of travel of the machine In this Service Manual the machine version may be written in brackets Traction Pad Assist or quota...

Page 70: ... turning the key for around 2 seconds all the LEDs and the display will switch on Immediately after this the display will be show in sequence the firmware loaded on the electronic board F05 Firmware 05 the hardware version of the instrument panel board r01 Release 01 type of electronic board o09 Option 09 and finally total machine operating hours which remain displayed until the machine is shut do...

Page 71: ...mal protector to cool down Check drive motor current draw Replace the instrument panel board Drive shutdown due to low battery voltage Replace the instrument panel board BLT DRIVE LEVER already pressed when starting or after emergency Electronic board MOSFET short circuited Drive motor protector activated HOT Check that the drive motor cable is not interrupted Replace the instrument panel board AC...

Page 72: ...to the wiring diagram 1 2 Replace the brush motor Check the brush motor If the motor is intact go to point 10 If there is continuity go to point 9 3 Replace the squeegee If the squeegee is clean and intact go to point 4 Check that the suction hose is clean and intact B 3 2 B 3 4 4 Otherwise restore continuity Otherwise replace it Check the lid gasket see paragraph B 5 1 4 Check that the squeegee b...

Page 73: ... is a voltage of 24 V at the ends of the solenoid valve wires Check the connections under the instrument panel see paragraph C 4 2 C 4 3 1 Check the error codes on the instrument panel board display see chapter E 1 1 E2 1 6 The machine doesn t move forwards Replace the instrument panel board see paragraph C 4 2 C 4 3 If the output voltage is not 24 V check the wiring replace the instrument panel b...

Page 74: ...PLDC04452 REVISION 00 December 23 2020 TECHNICAL OFFICE Stavale REVISION No DATE REVISION 00 Drafting of the manual and release date REVISION 01 December 23 2020 Xxxxx 00 20XX 68 of 68 ...

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