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PLDC01938 REVISION DATE 01/06/2011 DATE 05/09/2011 TECHNICAL DEPT. Stavale CT 230 ECHNICAL ERVICE ANUAL IPC GANSOW - via Cartesio 39 42040 Villa Bagno RE Tel. 0039 0522 266000 - Fax 0039 0522 342045 - info@ipcleaning.com...
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CT230 Technical Specifications CT230 Technical Specifications Version BT 85 BT 105 36 V Electrical system Voltage 320 Ah 6V (C5 - 5h) x 6 Battery capacity Running time Voltage level on the LCD dispay Battery level indicator brush stop Low battery protection Scrubbing head Scrubbing width 850 mm...
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CT230 Technical Specifications Version BT 85 BT 105 front traction motor wheel + Traction Traction system electronic card Operated accelerator pedal Forward speed Reverse gear speed accelerator pedal Speed adjustment Maximum speed 6,5 km/h Maximum climbing angle 1100 W Motor power Wheels Front Type...
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CT230 Quick Guide This Guide is intended for quick consultation only and does not replace the Use and Maintenance Manual. Before using the machine, read the Use and Maintenance Manual contained in the machine packaging thoroughly and rigorously respect all the instructions.
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Check the detergent output filter Make sure the dirty water tank DAILY MAINTENANCE is undamaged and clean. filter is clean. Empty the dirty water drum through the drain hose. Clean the brushes. Check the squeegee is clean and the blades are not damaged. Clean the dirty water tank with water or water and detergent.
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PLDC01971 Operative instruction Istruzioni operative n° 00/0023 23/05/2011 Model / Modello CT 230 Release SoftWare 2.00.9 SUBJECT / OGGETTO ELECTRONIC PCB PROGRAMMING / PROGRAMMAZIONE SCHEDA ELETTRONICA PARAMETER MODIFICATION OUT OF THE DEFAULT VALUE, COULD CAUSE AN INCORRECT WORKING OF THE MACHINE: CONTACT IPC TECHNICAL DPT, BEFORE ANY MODIFICATION. To enter in the technical programming, keep pushed the button P1 and P3 ( ref.
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PLDC01972 Operative instruction Istruzioni operative n° 00/0024 23/05/2011 Model / Modello CT 230 Release SoftWare 2.00.9 SUBJECT / SOGGETTO USER PROGRAMMING / PROGRAMMAZIONE UTENTE default values PARAMETER MODIFICATION OUT OF THE DEFAULT VALUE, COULD CAUSE AN version version INCORRECT WORKING OF THE MACHINE: DISC BRUSH ROLLER BRUSH CONTACT IPC TECHNICAL DPT, BEFORE ANY...
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Checking the current draw of the brush motors Checking and replacing the brush motor carbon brushes Checking head actuator current draw Checking actuator operation manually Replacing the head actuator Checking operation of the internal actuator micro switches Brush head Disassembling the brush head Replacing the brush motors and carbon brushes Replacing the head flaps Cleaning and replacing the solenoid valve...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale ! 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. IMPORTANT Indicates the need for attention in order to avoid a series of consequences which could cause damage to the machine or work environment or financial loss.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale INDEX Subject Page BRUSH HEAD CHECKING THE CURRENT DRAW OF THE BRUSH MOTORS Checking brush motor draw from the control panel A1.1 A1.2 Checking brush motor draw with a clamp meter Checking and replacing the brush motor carbon brushes A1.3 HEAD ACTUATOR CURRENT DRAW - REPLACEMENT Checking brush head actuator draw...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale INDEX Subject Page DRIVE ASSEMBLY BRAKE PEDAL Replacing the brake pedal/Adjusting the brakes C4.1 C4.2 Checking, adjusting and/or replacing the micro switch SLOW STEERING SENSOR Replacing and/or regulating the steering sensor C5.1 CONTROL PANEL BOARD - ELECTRICAL CIRCUIT CONTROL PANEL BOARD Connecting the chem-dose switch on the control panel (optional) D1.1...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale BRUSH HEAD IMPORTANT Go to the designated draining area and empty the detergent and dirty water tanks via the hoses provided. Move the machine onto flat ground and apply the brake. If necessary, place chocks under the wheels. Switch the machine off by turning the ignition key to position "0".
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A1 CHECKING THE CURRENT DRAW OF THE BRUSH MOTORS The CT 230 is available in two sizes with disk heads of different widths, the BT 85 with a cleaning strip of 850 mm and the BT 105 with a cleaning strip of 1050 mm. Apart from the size, the two heads also differ in the type of motor used.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A1.1 Checking the current draw of the brushes from the control panel Make sure the batteries are charged and the tank contains detergent. Move the machine to a relatively smooth floor to obtain a mean current reading. Enter the machine's technical programming function, following the procedure given in the "Programming the circuit board"...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale To save the new settings, keep button C pressed until the battery voltage is displayed. Press the display button C again for at least 10 seconds until the first selectable parameter, the language, is displayed.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Make sure the detergent tank is not completely empty and that it contains sufficient detergent for the tests. Carry out the tests on an inconspicuous part of the floor, or where it is not important if you leave marks (caused by the brushes rubbing).
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Press the manual brush button E to operate the brushes. PHOTO 14 Read the draw value. The board provides two values, both very important. The first row (Isp) gives the draw of the brush motors during the washing phase, in this case without the brushes. The second row (Tara) gives the draw value of the brush motors without load (with or without the brushes).
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale PHOTO 17 The first row of the display (lsp) gives the draw of the brush motors. To obtain the correct draw value, wait a few minutes with the motors turning until the value stabilises. After a few minutes, the display shows the stabilised brush motor current draw value without load, without the brushes (in this case lsp = 5.3 A) .
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A1.2 Checking the current draw of the brush motors Make sure the batteries on the machine are charged. Obtain a clamp meter able to read up to 200 A (amps), see photograph 19. PHOTO 19 Move the machine to the tank draining area and completely empty the dirty water tank.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Unscrew the knob D by turning it anticlockwise to release the tanks from the machine chassis. Press the pedal E to put the parking brake on. Lift the dirty water and detergent tanks to access the brush motors. PHOTO 21 Identify the left F1 and right F2 brush motor power connectors and, without disconnecting them, connect the clamp meter to first one, then (after performing the test) the other to read the current draw of both brush...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Test by connecting the clamp meter to the red wire of the connector F1 (or F2, the order in which the two motors are tested is irrelevant) on the left motor F. PHOTO 24 Press the brush button G to lower the head and start the motors rotating.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Compare the values for the two brush motors F. The two brush motors must draw more or less the same current. The sum of the draw values for the two motors must be the same as, or only slightly different from, the value read on the control panel display, see paragraph A1.1.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale With the brushes mounted, proceed as for a normal washing phase with "Program 1". Wash for a few minutes, read and note the values of the two motors separately, check that the draw of the two brush motors is more or less the same and that the sum of the values for the two motors is approximately equal to the value read on the control panel display, see paragraph A1.1.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A1.3 Checking and replacing the brush motor carbon brushes The procedure to replace the brush motor carbon brushes is similar for the two motors (BT 85 - BT 105), except that in the BT 105 version the air conveyor must be removed. The procedure for accessing the carbon brushes on the BT 105 version is described below.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Unscrew the four screws D2 until the heads of the screws emerge from the corresponding recess on the air conveyor D1. To facilitate remounting the air conveyor, do not remove the screws D2 completely. PHOTO 31 Switch the machine on by turning the key to position "1".
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Disconnect the power to the brush motor or motors by means of the Anderson connectors G and remove the terminals G1 from the connectors G. PHOTO 35 Remove the sheath H from the motor power wires. Gently lift up the air conveyor D1 running the motor power wires D3 through the cable glands D4 on the air conveyor D1.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Lift the air conveyor D1 to completely expose the metal band D5 protecting the four carbon brushes D6. Mark the position of the metal band D5 on the motor D with a felt pen to facilitate positioning during remounting.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale VERSION BT 105 Check the state of wear of the carbon brush D7. Check that the carbon brush is between 19 ± 0.5 mm and 11.5 ± 0.5 mm long as shown in the photograph below.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Checks As well as checking the length of the carbon brush D7, also check that it is in good condition, with particular attention to the surface in contact with the rotor. Check that the brush motor rotors D9 are not excessively or unevenly worn. PHOTO 41 Clean around the carbon brush mounts and rotor by blowing with a jet of compressed air.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale PHOTO 44 VERSION BT 85 As explained above, the brush motors mounted in the disk versions (BT 105, BT 85) are very similar. Externally, they differ in the presence of the air conveyor, internally they differ for the different carbon brushes.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Carbon brush measurements All four carbon brushes must be replaced at the same time and if the operating hours of the two brush motors mounted on the head are the same, all eight carbon brushes must be replaced together. Measure the carbon brush I2 to check the wear.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A2 HEAD ACTUATOR CURRENT DRAW - REPLACEMENT The head is raised and lowered by means of an electromechanical actuator. Controlled from the control panel board, as well as positioning the head (washing or standby), the actuator also regulates the head to the pressure set by the operator on the control board.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A2.1 Checking brush head actuator current draw When checking the draw of the electric motors, it is important for the batteries to be charged. If the battery voltage (V) is not 36 V (in the case of the CT 230) the draw in amps (A) will be misleading.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Disconnect the "operator present" sensor connector A and bridge it with a special connector. Lift the tanks to facilitate access to the fuse holder. Place the ignition key in position "1". Press the button B to set water flow to zero, no LED on. PHOTO 48 The fuse holder C is located alongside the Anderson plug D for recharging the batteries.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Press the button F to lower the brush head. Read the draw in amps and compare with the table below. PHOTO 51 Press the button F to raise the brush head. Read the draw in amps and compare with the table below. PHOTO If the values are within the range shown in the table below, everything is within the norm.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Checking absorption on the control panel board wires Make sure the batteries on the machine are charged (36 V ± 1 V). Obtain a clamp meter able to read up to 200 A (amps), see photograph below. PHOTO 54 Move the machine onto a flat dry area of floor.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale On connector D identify the pink wire D5 and the yellow wire D6 and connect the clamp meter to both. D5 D6 PHOTO Turn the machine on and test with the brushes mounted (preferably new). Press the button E to lower the head.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale If the measurements do not correspond to those specified but are higher: Check that the head parallelogram is free to move up and down without interference and that there are no squeaks or rubbing sounds. Check the draw of the actuator without load or replace the actuator with a new one.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A2.2 Checking head actuator operation manually Checks Obtain two wires A1 - A2 with different colours (see photograph below) with plugs compatible with the terminals of the connector B. Move the machine to the tank draining area and completely empty both tanks. Move the machine onto a flat dry area of floor.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Test with the brushes mounted. Connect the two wires A1 - A2 to the connector B, connecting the terminal of the red wire A1 to the plug of the yellow wire B5 in position 5 of the connector B, and the terminal of the black wire A2 to the plug of the blue wire B1.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Connect the two wires A1 - A2 to the connector B, connecting the terminal of the red wire A1 to the plug of the white wire B3 in position 3 of the connector B and the terminal of the black wire A2 to the plug of the grey and brown wires B2 in position 2 of the connector B.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A2.3 Replacing the brush head actuator Disassembly Go to the tank draining area and empty both tanks. Move the machine to a flat dry surface. The operation can be simplified by using an autolift if available. Put the brake on by pressing pedal A.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale With the head fully lowered, press the emergency button E to block the position and avoid the head returning to the standby position. Disconnect the batteries by means of the connector F, turn the ignition key to position “0”, restore the emergency button E to the original position.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Use a pair of circlip pliers to remove the circlip I. PHOTO 72 With a wide screwdriver or lever, push the actuator arm L downwards and at the same time use a screwdriver to push the pin M completely out of its housing. PHOTO 73 33/195 - date 05/09/2011...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Rest the head on the surface and proceed to remove the nut M fastening the actuator G to the top bracket. PHOTO 74 For convenience, given the tight space available, use a no. 17 ratchet spanner. If the solenoid valve wires and pump wire make it difficult to remove the actuator, disconnect them.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A2.4 Checking head actuator operation manually on the bench Description There are two micro switches in the body of the actuator, one, X, is positioned at the bottom on the side of the motor Z, the other, Y, is positioned at the top on the rod side W. They signal the limits (bottom and top respectively) of rod travel to the circuit board controlling raising and lowering.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Checks Before replacing the actuator A, check visually that there are no burnt areas on the motor and that the wires are tightly crimped to the terminals of the connectors B and C and are not damaged. Then check operation manually.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Connect the red wire E1 to the yellow wire B5 and the black wire E2 to the blue wire B1 of the actuator motor. Hold the rod A1 of the actuator A with one hand to prevent it from turning. PHOTO Connect the wire E1 to the positive pole of the battery and the wire E2 to the negative pole (a 6 V - 24 V battery is sufficient, providing it is charged and of a good capacity).
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Connect the red wire E1 to the positive pole of the battery and the black wire E2 to the negative pole (a 6 V - 24 V battery is sufficient, providing it is charged and of a good capacity). If the actuator A is also operating correctly during retraction, the rod A1 will start moving, retracting inside the body of the actuator.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale If the motor Z of the actuator A begins to move, causing the rod A1 to protrude outside the body, this means that the motor is operating correctly. Proceed to check operation of the micro switches X and Y. Checking operation of the internal micro switches You do not need to remove the protective cover to check operation of the micro switches in the body of the actuator as they produce an audible sound when...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Check correct operation of the micro switches X and Y by means of the connector B and the two wires E1 - PHOTO 88 Before starting testing, pay attention to the symbols (not conventional) given below, indicating where there must and must not be continuity.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Move the black wire E2 from position 4 to position 1 of the connector B and connect to the terminal of the brown wire B1. PHOTO 91 Connect the opposite ends of the wires E1 and E2 to the digital multimeter again and check electrical continuity.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale As the actuator button Y1 (of the micro switch Y) is in the inactive position, thus normally closed (NC), there must be continuity and there will be movement on the digital multimeter display. PHOTO 93 By manually unscrewing the rod A1 completely, move the position of cam K until the actuator button Y1 of the micro switch Y is pressed.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Keep the cam K of the rod A1 in the same position and with the actuator button Y1 of micro switch Y pressed, check operation of the micro switch X Connect the plug on the red wire E1 to the terminal of the white wire B3, position 3 of the connector B. Connect the plug on the black wire E2 to the terminal of the green-pink wires B4, position 4 of the connector Connect the opposite ends of the wires E1 and E2 to the digital multimeter and check electrical continuity.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A3 DISASSEMBLING THE BRUSH HEAD - BRUSH MOTORS - CARBON BRUSHES The CT 230 mounts two different sizes of disk head, a small head with a cleaning strip of 850 mm in the BT 85 version and a larger head with a cleaning strip of 1050 mm in the BT 105 version.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A3.1 Disassembling the brush head Disassembly Go to the tank draining area and empty both tanks. Move the machine onto a flat dry area of floor. Follow the procedure to remove the electromechanical actuator as described in paragraph A2.3 up to point Turn the lever of the water tap A anticlockwise to prevent the outflow of water.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Disassemble the front bumper E, removing the two self locking nuts at the front E1 and four bolts E2 fixing the bumper E to the shock absorber F. PHOTO 102 PHOTO 103 Unscrew the four screws F1 fastening the shock absorber F to the machine chassis. PHOTO 104 46/195 - date 05/09/2011...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale First unscrew one of the two screws F1 per side. Then unscrew the other two screws F1, taking care not to damage the thread on the chassis. To avoid this, you should keep the head raised until the last screw F1 has been removed. PHOTO 105 Rest the head on the surface and push it forwards to release the actuator rod and free it from the detergent pump G.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A3.2 Disassembling and replacing the brush motors Disassembly If you are replacing the motor due to wear of the top and above all bottom bearings (noisy), or oil leaks from the reduction unit (visible under the head on the shaft where the drive disk flange is mounted) and the two motors have the same number of working hours, you are recommended to replace both brush motors.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale M 6 x 20 mm PHOTO 109 Remove the drive flange B from the brush motor reduction unit shaft. If the drive flange B is difficult to remove, you are recommended to use an appropriate extractor. PHOTO 110 Extract the tab E (h 6.9 X 8 X L 30) to avoid losing it.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Remove the vibration dampers G from the brush motor flange H. Unscrew the four screws I fixing the motor flange H to the brush motor L. Replace the motor L with a new one with the same characteristics.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Remounting the 850 head Position the new brush motor L using the power wires L1 as a reference. Place the brush motor flange H on the motor L (850). To mount the left motor (photo 115), position the hole H1 on the same axis as the outlet of the brush motor power wires L1, keeping the hole H2 on the right of the wires L1.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Remounting the 1050 head Position the new brush motor L using the power wires L1 as a reference. Place the brush motor flange H on the motor L (1050). To mount the right motor, position the hole H1 on the same axis as the outlet of the brush motor power wires L1, keeping the hole H2 on the opposite side of the wires L1.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Reassembly Insert the screws of the nuts F into the bushing G1 respecting the insertion position and screw up with a maximum torque of ~ 20 Nm (~ 2.0 Kgm). PHOTO 121 Wire the new Anderson connector A on the motor (or motors) replaced, respecting the polarity of the power wires on the motor dismounted previously.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale RIGHT LEFT PHOTO 124 Remount the head as described in paragraph A3.1. After mounting, check brush motor rotation, referring to the photograph below. PHOTO 125 54/195 - date 05/09/2011...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A3.3 Checking and replacing the brush motor carbon brushes on the bench If the brush motor carbon brushes cannot be checked and/or replaced without removing the head from the machine (see paragraph A1.3), remove the head as described in paragraph A3.1 to replace the carbon brushes on the bench.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Measure the carbon brush C to verify wear. The minimum acceptable length is 11.5 mm. When replacing, compare the new carbon brush with the one being replaced and/or the measurements below. Only the length may differ. All four carbon brushes must be replaced at the same time and if the operating hours of the two brush motors mounted on the head are the same, all eight carbon brushes must be replaced together.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Disassembly Version BT 85 Remove the head from the machine as described in paragraph A3.1. If the metal bands A allowing inspection and replacement of the carbon brushes have not already been removed, remove by pulling the plastic spring clips B outwards. Identify the crosshead screw I and unscrew it to disconnect power to the carbon brush L With a hook (as for the previous motor) lift spring M and extract the carbon brush.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A4 REPLACING THE BRUSH HEAD FLAPS The brush head has a series of flaps, some of which are critical for the results in the washing phase, such as the right flap A and left flap B mounted on the side flap plates, others less so such as the front flap C the back flap D and the two brush centring flaps on the right E and left F.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A4.1 Replacing the brush centring flaps The importance of the brush centring flaps to washing is only relative as their function is to facilitate centring of the brush under the head. They are not liable to wear but should nevertheless be replaced when they begin to deteriorate.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A4.2 Replacing the brush centring bearing and roller The brush centring roller and bearing ensure the brush rotates without coming into contact with the brush centring frame between the start of rotation and when it touches the floor. You do not have to remove the head to replace them.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A4.3 Replacing the front and back flaps The front flap prevents splashes of water and detergent from reaching the front motor wheel, reducing its drive power and dirtying the entire drive group with detergent. You do not have to remove the head to replace the flap.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A4.4 Replacing the side flaps The flaps on the side flap plates are extremely important during the washing phase. They prevent splashes of detergent from dirtying the part of the floor already washed and dried and, particularly in the case of the right flap, convey the used detergent from the brushes to the squeegee.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A5 CLEANING, CHECKING AND REPLACING THE SOLENOID VALVE A solenoid valve is a mechanical opening and closing device actuated by means of a solenoid. It regulates or stops the flow of water to the head brushes. It is powered at 36 V DC directly from the control panel, which also controls it simultaneously with operation of the brushes, either manually or through three programs, P1, P2 and P3.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A5.1 Cleaning the solenoid valve Disassembly Check there is water or detergent in the detergent tank. If it is empty, add a little water. Move the machine onto a flat area of floor. Brake the machine by pressing pedal A to put the parking brake on.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Identify the position where the solenoid valve F is mounted on the head. Unscrew the solenoid valve cap G to free any dirt present. PHOTO 145 Connect the batteries and turn the key to the “1” position to turn the machine on.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A5.2 Checking and/or replacing the solenoid valve Checks Obtain a digital multimeter able to read a direct current (DC) of at least 50V. Move the machine to the tank draining area and completely empty both tanks. Move the machine onto a flat dry area of floor.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Identify the position where the solenoid valve F is mounted on the head. The position of the solenoid valve is different in version BT85 and BT105. Unscrew the screw G fixing the cap connector H and disconnect it from the solenoid valve F. PHOTO 152 Pay attention to the gasket I under the cap connector H of the solenoid valve F.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Press button M to lower the head as though for washing. PHOTO 154 With the head in the washing position, press the accelerator pedal N lightly and briefly to start brush rotation, operate the solenoid valve F and detergent pump. Read the voltage on the digital multimeter.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Replacing To replace the solenoid valve, access it as described above and, if not already connected, disconnect the cap connector H. Detach the detergent intake hose O and outlet hose P by removing the two hose clips O1 and P1. Unscrew the two bolts Q to release the solenoid valve from its bracket.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale A5.3 Controlling and/or replacing the compensator The compensator hose was introduced for the first time on the CT 230 heads to improve distribution of the water flow to the two brushes. Checks If for any reason head operation must be checked (brush motors, solenoid valve, etc.), also check the state of the hydraulic compensator hose on the head, with particular attention to verifying that the holes in the compensator hose are free and not obstructed.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Obtain two pieces of hose C and D with a length of ~ 11 cm and the same diameter as the previous pieces of hose (A - B). To complete the hydraulic compensator, assemble the two hoses C and D to the tube B coming from the solenoid valve and to the compensator hose A.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Reassemble all components following the above instructions. Position the compensator hose behind the solenoid valve and electromechanical actuator, see photograph below. PHOTO 161 72/195 - date 05/09/2011...
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale TANKS - SUCTION ASSEMBLY IMPORTANT Go to the designated draining area and empty the detergent and dirty water tanks via the hoses provided. Move the machine onto flat ground and apply the brake. If necessary, place chocks under the wheels.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B1 CHECKING THE DRAW OF THE SUCTION MOTOR The suction motor A on the CT 230 is a two-stage brushless motor, in other words, without carbon brushes which slide against the rotor. This means that carbon brushes and others parts subject to wear due to sliding do not therefore need controlling and/or replacing.
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PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B1.1 Checking the current draw of the suction motor Make sure the batteries on the machine are charged (36 V ± 1 V). Obtain a clamp meter able to read up to 200 A (amps), see photograph below. PHOTO 163 Move the machine to the tank draining area and completely empty both tanks.
Page 87
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Unlike one might think, a suction motor absorbs much more current (amps) when it takes in air without obstructions, as it can take in the maximum quantity of air possible. As the motor absorbs current in proportion to the quantity of air the turbine must move, the greater the amount of air moved, the greater the current draw of the suction motor.
Page 88
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale On the fuse holder F, identify the maxi fuse F4 protecting the suction motor. Connect the clamp meter between the two wires A4 of the suction motor A. The clamp can be connected to either of the two wires A4 connected to the fuse F4. PHOTO 169 PHOTO 170 Position the clamp meter to A (amps) and DC.
Page 89
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Read the CURRENT (A) drawn by the suction motor, note the value then proceed with the next test. Replace the foam retardant sponge H and cap G in position (closing the intake). Press the button M again to start the suction motor. If the draw value read is the same in both tests (with the cap G raised and with the cap G in position) and is within the values in the following table, proceed to check current draw with the hose E capped.
Page 90
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B1.2 Replacing the suction motor Disassembly Move the machine to the tank draining area and completely empty both tanks. Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key A to "0" and press the pedal B to put the parking brake on. Unscrew knob C and lift both tanks to facilitate access to the air exhaust hose D.
Page 91
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Lift the seat support H and lid I of the dirty water tank to facilitate access to the suction motor support G. Unscrew the seven grub screws fixing the suction motor support to the dirty water tank and remove them. Pay attention to the washers mounted with the screws G1.
Page 92
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Unscrew the metal band G4 and remove the air exhaust hose G5 from the suction motor pipe. Remove the heat protection G6 from the suction motor L. PHOTO Unscrew the three screws L1 fixing the suction motor L to the filter support G, paying attention to the three stand-offs L2 and the three Grover washers L3.
Page 93
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Reassembly Before mounting the new suction motor, remember to mount the gasket L4. Position the new gasket L4 as centrally as possible with respect to the motor intake hole. It is very important to mount the gasket L4. As well as making the intake airtight, it also acoustically insulates the suction motor from the support.
Page 94
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B2 SQUEEGEE AND ACTUATOR ASSEMBLY The squeegee assembly is raised and lowered by means of an electromechanical actuator controlled and powered directly from the control panel board. When the suction motor button on the control panel is pressed, the actuator positions the squeegee and controls operation of the suction motor by means of the micro switch in the actuator itself.
Page 95
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B2.1 Checking the current draw of the electromechanical actuator Make sure the batteries on the machine are charged (36 V ± 1 V). Obtain a clamp meter able to read up to 200 A (amps). Move the machine to the tank draining area and completely empty both tanks.
Page 96
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Carry out the tests with the squeegee mounted and the machine configured for drying. Identify the wires G on the actuator connected to the fuse holder terminal F and corresponding to the fuse F3. Connect the clamp meter between the two wires G.
Page 97
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Compare the values noted with those in the table below. If the values are within the table, the actuator is working correctly and there are no mechanical impediments to its operation. If the measurements do not correspond to those specified, but are higher: Check that the squeegee mount is not distorted in such a way that moving it requires more force than normal and that the squeegee mount joints are not excessively stiff.
Page 98
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B2.2 Checking squeegee actuator operation manually Checks Make sure the batteries on the machine are charged (36 V ± 1 V). Obtain a clamp meter able to read up to 200 A (amps), see photograph below. PHOTO 186 Obtain two wires A1 - A2 with different colours (see photograph below) with plugs compatible with the terminals of the connector B1.
Page 99
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Disconnect the batteries from the machine electronics via the Anderson connector F. Identify the two squeegee actuator connectors G and H. PHOTO 189 To carry out the tests, you need only disconnect the connector G (the larger 5-way connector), if necessary remove the plastic tie E and also disconnect the connector H.
Page 100
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale If the actuator does not move, check the fuse M. If the fuse M is burnt out, disconnect the actuator from the batteries, replace the fuse with a new one and check actuator operation again. PHOTO 192 If the fuse burns out at the beginning of the test, the actuator motor might be in short circuit.
Page 101
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale If the fuse has not blown, but the actuator does not move, it could be a problem with the micro switches in the actuator. Before removing the actuator, check by powering the actuator motor directly. Connect the two wires A1 - A2 to the connector G, connecting the terminal of the red wire A1 to the plug of the yellow wire G2 in position 2 of the connector G and the terminal of the black wire A2 to the plug of the black and brown wires G1 in position 1 of the connector G.
Page 102
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B2.3 Replacing the squeegee actuator Disassembly Move the machine onto a flat dry area of floor. Turn the ignition key to position "0". Press the pedal to put the parking brake on. Detach the suction hose A from the squeegee. Unscrew the two clamping handles B to remove the squeegee from the squeegee mount.
Page 103
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Unscrew and remove the bolt E1 fixing the rod of the actuator E to the squeegee mount. PHOTO Continue by unscrewing the second bolt E2 fixing the body of the actuator E to the machine chassis. PHOTO 198 92/195 - date 05/09/2011...
Page 104
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Disconnect the connectors E3 and E4 of the actuator E and remove it from its support for testing on the bench. PHOTO 199 Reassembly Before replacing the electromechanical actuator E, test it on the bench as described in the following paragraph.
Page 105
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B2.4 Checking head actuator operation manually on the bench Checks There are two micro switches in the body of the actuator, one, X, is positioned at the bottom on the side of the motor Z, the other, Y, is positioned at the top on the rod side W. They signal the limits (bottom and top respectively) of rod travel to the circuit board controlling squeegee raising and lowering.
Page 106
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Before replacing the actuator A, check visually that there are no burnt areas on the motor Z and that the wires are tightly crimped to the terminals of the connectors B and C and are not damaged. Then check electrical operation of the actuator manually.
Page 107
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Connect the red wire D1 to the terminal of the white wire B5 and the black wire D2 to the terminal of the black and brown wires B1 of the connector B. Hold the rod A1 of the actuator A with one hand to prevent it from turning. PHOTO 203 Connect the other end of the red wire D1 to the positive pole of the battery and the other end of the black wire D2 to the negative pole (a 6 V - 24 V battery is sufficient, providing it is charged and of a good capacity).
Page 108
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Connect the other end of the red wire D1 to the positive pole of the battery and the other end of the black wire D2 to the negative pole (a 6 V - 24 V battery is sufficient, providing it is charged and of a good capacity). If the actuator A is also operating correctly during retraction, the rod A1 will start moving, retracting inside the body of the actuator.
Page 109
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Check that the motor Z of the actuator A is functioning correctly (it is not necessary to check its function in the opposite direction), then proceed to control operation of the internal micro switches X and Y. Checking operation of the internal micro switches You do not need to remove the protective cover to check operation of the micro switches in the body of the actuator as they produce an audible sound when...
Page 110
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Check correct operation of the micro switches X and Y by means of the connector B and the two wires D1 - PHOTO 212 Before starting testing, pay attention to the symbols (not conventional) given below to indicate where there must and must not be continuity.
Page 111
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Move the black wire D2 from position 4 to position 1 of the connector B and connect to the terminal of the brown wire B1. PHOTO 215 Connect the opposite ends of the wires D1 and D2 to the digital multimeter again and check electrical continuity.
Page 112
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale As the actuator button Y1 (of the micro switch Y) is in the inactive position, thus normally closed (NC), there must be continuity and there will be movement on the digital multimeter display. PHOTO 217 By manually unscrewing the rod A1 completely, move the position of cam K until the actuator button Y1 of the micro switch Y is pressed.
Page 113
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Keep the cam K of the rod A1 in the same position and with the actuator button Y1 of micro switch Y pressed, check operation of the micro switch X. Connect the plug on the red wire D1 to the terminal of the yellow wire B3, position 3 of the connector B. Connect the plug on the black wire D2 to the terminal of the green and pink wires B4, position 4 of the connector B.
Page 114
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B2.5 Replacing the squeegee blades (flaps) Disassembly Move the machine onto a flat dry area of floor. Turn the ignition key to position "0". Press the pedal to put the parking brake on. Detach the suction hose A from the squeegee.
Page 115
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Front blade (flap) The standard blades mounted on the front of the squeegee are made from 8 mm thick latex. Their mirror design enables them to be mounted to use either of the two faces. This extends the working life of the blade before it needs replacing definitively.
Page 116
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Pay attention when tightening the two (2) bolts D pressing directly on the two squeegee blades F and I. Tighten with moderation to avoid distorting the blades. PHOTO 226 Reassembly To assemble the new squeegee blades, perform the disassembly operations in reverse. Clean the contact surface of the squeegee thoroughly before mounting the new blades.
Page 117
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B2.6 Regulating the squeegee Move the machine onto a flat dry area of floor. Check that the squeegee blades are in good condition before regulating. Wash a few metres in normal working conditions to position the squeegee blades in the drying phase. Check that the entire length of the blade presses evenly on the floor with a suitable pressure.
Page 118
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale If the blade does not press evenly on the floor, in other words, the centre part of the squeegee is higher or lower than the ends, adjust the angle of the squeegee by means of the metal knobs B and C. Regulate by unscrewing the knurled knob C and screwing up the knob B to lower the ends and raise the centre of the squeegee.
Page 119
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B3 DETERGENT HOSES/PUMP CLEANING - FILTERS The CT 230 is fitted as standard with two water filters. The larger of the two A is located at the entrance to the detergent tank and filters the water entering the tank during the filling phase. The smaller filter B is housed in a filter holder and filters the water flowing from the detergent tank to the water/detergent pump.
Page 120
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B3.1 Cleaning the filters Water fill filter Move the machine onto a flat dry area of floor. Turn the machine off and press the pedal to put the parking brake on. Lift the tank lid A to access the clean water filter B. Remove the clean water filter B by pulling upwards.
Page 121
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Output water filter When cleaning or replacing the output water filter, always remember to shut off the water flow by means of the tap. You are recommended to clean the detergent filter frequently. Move the machine onto a flat dry area of floor.
Page 122
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Unscrew the tank E2 from the filter body E1 and remove the water filter E3. PHOTO 240 Clean the filter E3 with running water, working from the outside inwards, then blow with a jet of compressed air, again working from the outside inwards.
Page 123
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Replacing the output water filter Disassembly For convenience (not indispensable), move the machine to the tank draining area and completely empty both tanks. Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key A to "0"...
Page 124
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Replace the clean water filter assembly E with a new one. Preassemble the coupling L to the new filter assembly E, paying attention to the arrow on the body of the filter E and the O-ring M. PHOTO 245 Reassembly Important: respect the water inflow direction in order to make the internal water filtration system as...
Page 125
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B3.2 Checking operation of the detergent pump + solenoid valve. Water delivery through the detergent pump and operation of the solenoid valve is controlled by the electronic control unit on the control panel. According to the quantity of water selected on the control panel, the control unit commands constant or intermittent functioning of the solenoid valve and power to the water pump which as a result rotates more or less quickly.
Page 126
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Turn the lever E1 of the tap E through 90° (degrees) to shut off the flow of wate r to the brushes. PHOTO Obtain a digital multimeter with probes and position it on volts (V) DC. First, check the output voltage of the solenoid valve.
Page 127
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Identify the red wire to the key with the round red insulated terminal, or remove the key support G. Insert the positive probe H (red) inside the fast-on cover I connected to the key contact. Start the machine by turning the key to position "1".
Page 128
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale To avoid problems caused by the intermittent reading, unreliable for the test, press the button M+ and adjust the quantity of water to position four (four LEDs on) or above. The reading on the digital multimeter display should be approximately the voltage read on the battery poles or on the display 36 ±...
Page 129
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Continue the test, gradually increasing the quantity of detergent delivered. Press the M+ button once to command (intermittent) operation of the pump and solenoid valve and set the quantity of detergent to one LED on. Continue in steps of one, turning one LED on at a time on, until the sixth and last LED comes on, maximum flow rate.
Page 130
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Check the output voltage, pressing the button M+ to select position 6, six LEDs on. Read and write the value. Solenoid ± 1V valve continuous. Detergent flow 9.5 L - 10.5 L. PHOTO 257 If the values noted are similar to those given above, the control panel is functioning correctly and the cause of the pump malfunction lies elsewhere.
Page 131
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Disconnect the connector R1 of the detergent pump R from the main machine wiring. Connect the two wires N to the pump connector R1, paying attention to the polarity. Connect the red wire N1 to the red wire R2 on the pump and the black wire N2 to the blue wire R3 on the pump.
Page 132
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale If possible, obtain a graduated recipient with a capacity of 5 litres to check the flow rate of the water precisely and reliably. Gravity causes detergent to flow out of the hose even when the pump is off. Before placing the hose in the recipient, you should therefore close the end with a finger, removing it the instant you activate the pump.
Page 133
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B4 Checking operation of and/or replacing the float switch The two float switches in the detergent and dirty water tanks indicate (acoustically with a buzzer and visually by an LED on the control panel and information on the display) when the dirty water tank must be emptied or the detergent tank requires filling.
Page 134
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Detergent tank float switch The magnet is distant from the flexible metal strip and the circuit is therefore open. The digital multimeter will not detect electrical continuity. CLIC The magnet is near the flexible metal strip and the circuit is therefore closed.
Page 135
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B4.1 Checking the detergent tank float switch As well as indicating when the tank needs refilling by a message on the control panel display and a buzzer, the detergent tank float switch also commands raising of the head and stopping of the brushes via the control panel board (in programs P1, P2 and P3 only).
Page 136
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Proceed with the first test (with water in the tank) to check operation of the float switch. Connect the ends of the float switch connector to the two probes of the digital multimeter, their position is not important.
Page 137
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale You are recommended to check correct functioning of the “no water”/“no detergent” LED on the control panel regularly. The float switch communicates that the water/detergent has reached the reserve level to the control panel board (“Water Reserve”...
Page 138
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Switch the machine off by turning the ignition key to position "0". Connect the female “bridge” connector C to the male connector B in the main wiring. Switch the machine on by turning the ignition key to position "1". In this configuration, no detergent tank alarm should be displayed on the control panel board, otherwise check: The float switch wiring, there must be continuity between the yellow wire (on the connector) and the...
Page 139
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B4.2 Replacing the detergent tank float switch Disassembly Move the machine to the tank draining area and completely empty both tanks. Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key A to "0" and press the pedal B to put the parking brake on. Unscrew knob C and lift both tanks to facilitate access to the float switch.
Page 140
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B4.3 Checking the dirty water tank float switch As well as indicating when the dirty water tank needs emptying, the dirty water tank float switch also commands raising of the squeegee and shutdown of the suction motor via the control panel board.
Page 141
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Remove the plastic protection B, paying attention to the wing nut B1 and the plastic washer B2. If the float switch C is in good condition and free of excessive dirt and the lever C1 of the float switch moves without interference through its entire travel, proceed to check electrical continuity.
Page 142
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Identify the location of the float switch C on the dirty water tank. Disconnect the connector C2 of the float switch from the main wiring. PHOTO 280 Connect the ends of the float switch connector to the two probes of the digital multimeter, their position is not important.
Page 143
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale You are recommended to check functioning of the dirty water tank full LED on the control panel regularly. Tripping of the float switch is communicated to the control panel board which, after a delay of about five seconds (5”), indicates that the dirty water tank is full by displaying a message on the control panel display ("Dirty Water Level") and by a flashing LED in the dedicated icon.
Page 144
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale B4.4 Replacing the dirty water tank float switch Disassembly Move the machine to the tank draining area and completely empty both tanks. Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key A to "0" and press the pedal B to put the parking brake on. Unscrew knob C and lift both tanks to facilitate access to the connector D1 of the float switch D.
Page 145
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale Identify the location of the float switch D and remove the gasket G closing the hole in the tank to access the back part of the float switch. Remove the guard, complete with the bracket H by unscrewing the two screws H1. PHOTO 288 With a no.
Page 146
PLDC01938 REVISION 00 01/06/2011 TECHNICAL DEPT. Stavale DRIVE ASSEMBLY IMPORTANT Go to the designated draining area and empty the detergent and dirty water tanks via the hoses provided. Move the machine onto flat ground and apply the brake. If necessary, place chocks under the wheels. Switch the machine off by turning the ignition key to position "0".
Page 147
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C1 DRIVE CIRCUIT BOARD The DRIVE control circuit board supplies “current” to the drive motor. As well as to the drive motor, it is also connected to the accelerator pedal, maximum speed control on the control panel and the speed-on-bends limitation sensor.
Page 148
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C1.1 Checking electrical connections and the presence of voltage Checks Make sure the batteries on the machine are charged. Obtain an accurate digital multimeter (tester). Move the machine onto a flat dry area of floor. Turn the ignition key to position "0".
Page 149
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Start the machine by turning the ignition key to position “1”, wait for the drive circuit board check and verify the input voltage on the contact B+ of the drive board C. Then move the probe from the power contact B1 to the board contact B+ (keeping the black probe on the negative insulator) and read the input voltage V3.
Page 150
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C1.2 Checking the input signals on the drive logic board The drive circuit board communicates with the rest of the machine electronics through the 16 pin connector marked “LOGIC”. The wires carrying both passive signals (they receive the signal) and active signals (they activate a command by means of a signal) are connected to this connector.
Page 151
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Place the front wheel in the straight position (to activate the steering sensor), sensor LED on, and proceed to measure the input voltage on the board between the BROWN wire, pin 11, (connected together with the green wire, corresponding to the Curtis interface board, it indicates the reduction in speed to the control panel board) and the negative power contact B-.
Page 152
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale The wires used by the two potentiometers on the control panel and on the accelerator pedal are connected from pin 4 to pin 1. Pin 3 and pin 1 are common to the two potentiometers.
Page 153
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C1.3 Replacing the drive circuit board Disassembly Move the machine onto a flat dry area of floor. Press the pedal to put the parking brake on. Place the ignition key in the “0” position and disconnect power to the machine from the batteries by means of the Anderson connector B.
Page 154
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C2 DRIVE MOTOR WHEEL The CT 230 is fitted with a latest generation motor wheel developed specifically for quicker access and replacement of the carbon brushes and rubber tyred ring. The protection class for dust and liquids has been raised to IP 44.
Page 155
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C2.1 Checking and replacing the motor wheel carbon brushes You are recommended to check the carbon brushes after about 600-700 working hours and replace if necessary. You are recommended to replace all four (4) carbon brushes at the same time.
Page 156
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale 30 mm 35 mm PHOTO 302 Electrically disconnect the motor wheel B by unscrewing the two nuts B1 connecting the thermal cutout of the motor to the machine wiring, the nut B2 connecting the positive wire (red) and the nut B3 connecting the negative wire (black) to the motor wheel B.
Page 157
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Remove the two (2) dust protection sponges E mounted at the sides of the motor B. PHOTO 305 Unscrew the four (4) screws B5 fastening the motor to the reduction unit. Extract the motor holding it as horizontal as possible. PHOTO 306 146/195 - date 05/09/2011...
Page 158
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale When extracting the motor B, take care to avoid damaging the seal ring F1 on the reduction unit F inside the motor. PHOTO 307 Place the motor B on the bench and proceed to check the four (4) carbon brushes G at 90° to each other. The red power wire G5 and thermal cutout G7 are connected to the carbon brush eye terminal G1.
Page 159
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Unscrew the nut G8 to release the thermal cutout wires G7, power wire G5 and carbon brush wire G1. If present, pay attention to the washer G9. With a hook, raise the spring G10, press on the carbon brush G1 and extract it from its seat. PHOTO PHOTO 310 Checking the carbon brushes...
Page 160
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Checking functioning of the thermal cutout Thermal cutouts protect electric motors from reaching high temperatures which could cause irreparable damage. They are usually installed on the hottest parts of the motor near the carbon brushes, or on the casing where the carbon brushes are mounted. The thermal cutouts on IPC scrubber driers are triggered by temperatures of 80°...
Page 161
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Reassembly To mount the new carbon brushes, perform the disassembly operations in reverse. Before remounting the carbon brushes, compare the dimensions with those to be replaced. Only the length should differ. Make sure the carbon brushes slide freely in their housing H and the housing is not distorted or dirty.
Page 162
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C2.2 Checking and replacing the thermal cutout Thermal cutouts protect electric motors from reaching high temperatures which could cause irreparable damage They are usually installed on the hottest parts of the motor near the carbon brushes, or on the casing where the carbon brushes are mounted.The thermal cutouts on IPC scrubber driers are triggered by temperatures of 80°...
Page 163
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Place the two probes of the multimeter on the eye terminals B without disconnecting them and check continuity with a digital multimeter. If the above conditions are respected, the thermal cutout can also be checked without disconnecting the terminals from the main machine wiring.
Page 164
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale In case of emergency If the "Motor Temperature PAUSE" warning is displayed when the motor is cold and you need to move the machine, you can create a temporary by-pass connection (to be restored as soon as possible) to exclude the control panel control unit and enable the machine to be moved.
Page 165
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C2.3 Replacing the rubber tyred motor wheel ring Disassembly Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key to position "0". Brake the machine by putting the parking brake on or wedges under the rear wheels. Raise the front motor wheel A using a hydraulic jack.
Page 166
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale PHOTO 322 Turn the motor wheel to the opposite side and identify the four (4) threaded holes A6 provided specifically as extractors to facilitate removal of the rubber tyred ring. Insert two (2) M10 screws B with at least 80 mm of thread and screw them up almost simultaneously in order to push the rubber tyred ring A4 outwards.
Page 167
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale First remove the centring coupling A5, then continue screwing up the screws B until you can extract the rubber tyred ring A4. PHOTO 324 Replace the rubber tyred ring with a new one. Reassembly To mount the new rubber tyred ring, perform the disassembly operations in reverse.
Page 168
PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Obtain four (4) M8 screws C (C1 or C2) at least 40 mm long to be used as "introducers" for the new rubber tyred ring A4. M8 x 40 mm PHOTO 326 Spread graphite grease on the raised aluminium part inside the rubber tyred ring A4. Place the preassembled rubber tyred ring A4 on the motor wheel reduction unit and fit it on the bearing.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale When screwing up the four screws C, pay attention to the position of the drive hub A8 with respect to the motor wheel reduction unit casing. PHOTO 328 With the drive coupling A5 near the drive hub A8, unscrew the screws C and screw up the new screws A2 (VTVT01352) provided with the new rubber tyred ring.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C2.4 Replacing the complete drive motor (motor wheel) The drive motor should never need replacing. However, if used incorrectly, or if one of the protection systems fails, it may be irreversibly damaged. It will therefore have to be replaced or repaired.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Disconnect the motor wheel B by unscrewing the two nuts B1 connecting the thermal cutout to the machine wiring, the nut B2 connecting the positive wire (red) and the nut B3 connecting the negative wire (black) to the motor wheel B.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Place a piece of wood or a wedge D under the rubber tyred ring B5 to facilitate removal of the screws E. Unscrew the four screws E fixing the complete motor wheel B to the plate F. Unscrew the screws in the back of the motor wheel B first.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C3 ACCELERATOR PEDAL The accelerator pedal regulates the speed of the machine when being moved and while working. Irrespective of use of the machine, it can be limited by means of the potentiometer on the control panel and, while steering round tight bends, by means of the steering sensor.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C3.1 Replacing the accelerator pedal Disassembly Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key to position "0" and put the parking brake on. Unscrew the screw A fixing the pedal B to the footplate.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C3.2 Replacing the accelerator potentiometer and/or micro switch Disassembly Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key to position "0" and put the parking brake on. Remove the accelerator pedal as described in paragraph C3.1.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Replacing If present, eliminate the plate B1 with mechanical anti-rotation lock. PHOTO 342 Insert the wiring of both the micro switch C and the potentiometer B into the opening in the base of the accelerator pedal.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Check that the lever with fork A is 45 mm ± 1 mm long and that the axis of the fork is aligned with the axis of the lever. Proceed to mount the connecting rod D on the shaft of the potentiometer B. PHOTO 345 45 ±...
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Keeping the pedal fully raised, proceed to regulate the micro switch C, moving it forwards towards the connecting rod until the wheel on the micro switch C goes in, emitting the classic click. Fix the position of the micro switch C by tightening the first two nuts C2 with moderation, screw up the other two nuts C3 as lock nuts to avoid the single nut coming loose, causing the position of the micro switch C to be lost.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C4 BRAKE PEDAL The brake pedal works by braking the rear wheels. The command is mechanical (double cable) and must therefore be checked and if necessary adjusted to ensure efficient operation. A mechanical braking system enables the brake pedal to be blocked, providing a parking function.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C4.1 Replacing the pedal / Adjusting the brakes Disassembly Move the machine to the tank draining area and completely empty the dirty water and detergent tanks. Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key to position "0".
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Unhook the two clips F fastening the brake wires G to the pedal. Remove the micro switch H by unscrewing the two bolts H1. For convenience, disconnect it from the wiring by means of the two round red terminals H2. Replace the pedal with a new one.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C4.2 Checking, adjusting and/or replacing the micro switch Checks Obtain a digital multimeter with a continuity measurement function. Move the machine onto a flat dry area of floor. Switch the machine off by turning the ignition key to position "0".
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Disassembly Unscrew the two bolts C, remove the micro switch A and replace with a new one. PHOTO 358 Reassembly To mount the new micro switch, perform the disassembly operations in reverse. Cut the connectors B of the old micro switch to recover the protective sheath A2.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C5 SLOW STEERING SENSOR The sensor which slows the machine down when steering around bends is an electronic safety device which prevents high speeds during tight curves. Located near the steering rim and activated by a cam, it tells the drive circuit board to reduce speed by 60% with respect to the forwards movement speed to a minimum of 40%.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale C5.1 Replacing and/or regulating the steering sensor Disassembly Move the machine onto a flat dry area of floor. Brake the machine by pressing the pedal to put the parking brake on. Place the ignition key in the “0” position and disconnect the batteries from the main machine wiring. Remove the bumpers, footplate and front panel.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale CIRCUIT BOARDS, WIRING IMPORTANT Go to the designated draining area and empty the detergent and dirty water tanks via the hoses provided. Move the machine onto flat ground and apply the brake. If necessary, place chocks under the wheels. Switch the machine off by turning the ignition key to position "0".
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale D1 CONTROL PANEL BOARD The control panel board is made in two pieces to facilitate disassembly of the steering column. It consists of pressure buttons to select the various functions, emergency button, forwards- backwards direction selector, speed limiter potentiometer, status LED indicating drive board errors, ignition key and switch to activate the optional detergent dosing unit.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale D1.1 Connecting the chem-dose switch on the control panel (optional) Assembly The CT 230 control panel is designed to take the optional chem-dose device. Move the machine onto a flat dry area of floor. Brake the machine by pressing the pedal to put the parking brake on.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale D2 FUNCTIONS CIRCUIT BOARD The functions circuit board controls and powers the suction and brush motors – – PHOTO 367 178/195 - date 05/09/2011...
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale D2.1 Removing the functions circuit board Disassembly Move the machine onto a flat dry area of floor. Brake the machine by pressing the pedal to put the parking brake on. Place the ignition key in the “0” position and disconnect the batteries from the main machine wiring. Remove the bumpers, footplate and front panel.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale D3 IMPORTANT ELECTRICAL COMPONENTS The other internal components in the machine’s electrical circuit include: functions contactor TL1 and drive contactor TL2, fuse holder and main 150 Amp fuse F1 and two isolators, positive A and negative B. F1 150A PHOTO 369 180/195...
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale D3.1 Contactor TL1 (functions) and TL2 (drive) Move the machine onto a flat dry area of floor. Brake the machine by pressing the pedal to put the parking brake on. Place the ignition key in the “0” position and disconnect the batteries from the main machine wiring. Remove the bumpers, and front panel.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale D3.2 Disassembling and/or replacing the chem-dose pump Disassembly Move the machine onto a flat dry area of floor. Brake the machine by pressing the pedal to put the parking brake on. Place the ignition key in the “0” position and disconnect the batteries from the main machine wiring. Remove the bumpers, footplate and front panel.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale Adjustment The chem-dose pump mounted on the machine can be calibrated according to the user’s needs. The percentage can be regulated from a minimum of 0% to a maximum of 3%. The pump can be regulated either before mounting or afterwards, during washing.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale ERROR CODES - TROUBLESHOOTING IMPORTANT Go to the designated draining area and empty the detergent and dirty water tanks via the hoses provided. Move the machine onto flat ground and apply the brake. If necessary, place chocks under the wheels. Switch the machine off by turning the ignition key to position "0".
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale E1 ERROR CODES E1.1 Curtis drive board alarms The drive board status is displayed by means of an LED on the control panel. During normal operation, the LED is on steadily. When there is a malfunction, the LED flashes. The frequency of flashing indicates the severity of the malfunction.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale NOTES: LED OFF The drive board is incorrectly powered or faulty. LED ON When the LED is on steadily, the board is functioning correctly. When the LED flashes, there is a malfunction. The drive board indicates one error only at a time, so when one error is resolved a different error may be displayed.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale E1.2 Functions board alarms and display Alerts and error codes occurring during use of the machine are displayed on the control panel. The table below lists the error codes which might appear on the control panel. SUCTION BATTERY + 36V BATTERY - 36V...
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale E2 TROUBLESHOOTING E2.1 Troubleshooting E2.1.1 The display does not light up If the fuse is burnt out, replace it. Check the 5 amp fuse F1. If the fuse is intact, go to point 2. If the voltage is less than 29 V, replace or recharge the batteries.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale E2.1.3 The machine does not move forwards Consult the message in the table E1.2. Check there are no messages on the control panel display, see paragraph E1.2. If there are no messages, go to point 2. Correct the error as described in table E1.1.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale E2.1.5 The head does not descend Correct the error as described in table E1.2. Check there are no errors on the control panel display, see paragraph E1.2. If there are no errors, go to point 2. If the fuse is burnt out, replace it.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale E2.1.7 The suction motor is not working Correct the error as described in table E1.2. Check there are no errors on the control panel display, see paragraph E1.2. If there are no errors, go to point 2. If the fuse is burnt out, replace it.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale E2.1.9 No water is delivered Correct the error as described in table E1.2. Check there are no errors on the control panel display, see paragraph E1.2. If there are no errors, go to point 2. If the tap is closed, open it Check that the detergent delivery tap on the tank is open, see B3.2.
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PLDC01938 REVISION 01/06/2011 TECHNICAL DEPT Stavale REVISIONS - UPDATES TECHNICAL SERVICE MANUAL REVISION NO. DATE Revision 00 04/10/2010 Start of manual production. Revision 00 01/06/2011 Approval and consignment of manual in Italian, translation in English. Revision 01 00/00/0000 rgwhthwhtr 195/195 - date 05/09/2011...
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Questions and answers
we turn the ct230 on and the display turns on, but has nothing on it and then beeps continuously.