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Tennant T290 Service Manual
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Tennant T290 Service Manual

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PLDC04452
REVISION DATE
December 23, 2020
DATE
December 23, 2020
TECHNICAL OFFICE
Stavale
T290
T
S
M
ECHNICAL
ERVICE
ANUAL

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Summary of Contents for Tennant T290

  • Page 1 PLDC04452 REVISION DATE December 23, 2020 DATE December 23, 2020 TECHNICAL OFFICE Stavale T290 ECHNICAL ERVICE ANUAL...
  • Page 3 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale 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. WARNING! 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.
  • Page 4 Checking brush motor current imput, Replacing the carbon brushes Brush head Replacing the brush motor Measuring current draw and replacing the carbon brushes Replacing the suction motor Tanks / Suction Assembly Adjusting and replacing the squeegee Checking and replacing the float Instrument panel board Drive assembly...
  • Page 5 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale INDEX Page Subject BRUSH HEAD BRUSH MOTOR A1.1 Cheking brush motor current input A1.2 Replacing the brush motor carbon brushes REPLACING THE BRUSH MOTOR A2.1 Replacing the brush motor SUCTION UNIT - TANKS SUCTION MOTOR B1.1 Checking the suction motor current input B1.2 Replacing the suction motor carbon brushes...
  • Page 6 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale INDEX Page Subject ERROR CODES - TROUBLESHOOTING ERROR CODES E1.1 Alarm messages on the instrument panel board display TROUBLESHOOTING E2.1 Troubleshooting Information on the revision numbers...
  • Page 7 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale BRUSH HEAD WARNING Go to the designated draining area and empty the solution and dirty water tanks using the drain plugs and the hose provided. Move the machine onto flat ground. If necessary, place chocks under the wheels.
  • Page 8 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale A1 BRUSH MOTOR Fig. 1 2 of 68...
  • Page 9 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale A1.1 Cheking brush motor current input Checks Empty the solution tank and the dirty water tank. Move the machine onto flat dry and smooth flooring. Press the emergency switch (Traction) or switches into position "0" (Pad Assist). Make sure that the batteries on the machine are charged.
  • Page 10 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Isolate the red wire A. Connect the clamp to the red wire A as shown in Figure 3. Fig. 3 Checking the current with no load, i.e. without brushes. Turn the emergency button clockwise, Traction version only. Press the button in instrument panel per the actuator of the brushes.
  • Page 11 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale A1.2 Replacing the brush motor carbon brushes Dismantling Move the machine to the tank draining area, and empty the solution tank and the dirty water tank. Move the machine onto flat and dry flooring. Press the emergency switch (Traction) or switches into position "0"...
  • Page 12 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Lift the solution tank from the front, keeping the dirty water tank open. Identify the screw C that secures the metal band on the brush motor. Fig. 5 6 of 68...
  • Page 13 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Identify the four carbon brushes (for each individual motor), arranged 90° degrees apart. Remove and check or replace the brush carbon brushes. Using long-nosed pliers remove the fast-on D from its socket. Use a hook to lift the spring E, and pull the carbon brush F outwards.
  • Page 14 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Blow the inside of the motor clean with a jet of compressed air, paying particular attention to the area around the carbon brushes and to the part of the rotor G with which the carbon brushes come into sliding contact. Check the rotor M for wear, paying particular attention to the area of contact with the carbon brushes.
  • Page 15 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale A2 REPLACING THE BRUSH MOTOR Fig. 11 9 of 68...
  • Page 16 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale A2.1 Replacing the brush motor Dismantling Move the machine to the tank draining area, and empty the solution tank and the dirty water tank. Dismantle the solution tank as described in paragraph A1.2 Disconnect the power A and thermal B of the brush motor.
  • Page 17 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale CHEM DOSE CONNECTOR Fig. 13 Fig. 14 Reassembly To assemble the new reduction drive, perform the dismantling operations in reverse. 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.
  • Page 18 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale SUCTION UNIT - TANKS WARNING Go to the designated draining area and empty the solution and dirty water tanks using the drain plugs and the hose provided. Move the machine onto flat ground. If necessary, place chocks under the wheels.
  • Page 19 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale SUCTION MOTOR Fig. 15 13 of 68...
  • Page 20 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B1.1 Checking the suction motor current input Move the machine onto flat and dry flooring. Press the emergency switch (Traction) or switches into position "0" (Pad Assist). Make sure that the batteries on the machine are charged. Use a clamp-on ammeter with an end scale reading of at least 200 amperes, as shown in Figure 16.
  • Page 21 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B1.2 Replacing the suction motor carbon brushes Move the machine onto flat and dry flooring. Press the emergency switch (Traction) or switches into position "0" (Pad Assist). Lift and turn the top dirty water tank. Isolate and disconnect the power connector A to the suction motor, see Figure 19.
  • Page 22 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Unscrew the two screw E that fasten the carbon brush support F. Take care when handling the carbon brush support F, as it contains the spring that presses the carbon brush against the rotor, which may propel out the carbon brush Fig.
  • Page 23 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B1.3 Replacing the suction motor Dismantling Move the machine onto flat and dry flooring. Press the emergency switch (Traction) or switches into position "0" (Pad Assist). Lift and turn the top dirty water tank. Isolate and disconnect the power connector A to the suction motor, see Figure 23.
  • Page 24 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Check that all the parts of the suction unit are in good condition: D suction motor gasket, E nylon flange, F sound absorbing sponge, G suction motor air exhaust pipe. Fig. 25 When replacing the motor, also replace the suction motor gasket D purchased separately.
  • Page 25 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale SQUEEGEE UNIT Fig. 27 19 of 68...
  • Page 26 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B2.1 Adjusting the squeegee Move the machine onto flat and dry flooring. Press the emergency switch (Traction) or switches into position "0" (Pad Assist). Start a washing cycle in normal operation. Travel a few metres (forwards) with the machine. Check that the blade is in even contact with the floor, with suitable deflection across the width, Figure 28.
  • Page 27 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Screwing the screw A, the squeegee support lowers the edges of the squeegee, increasing the deflection (compression) on the blade at the sides of the squeegee, taking deflection off the centre. Fig. 29 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.
  • Page 28 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Adjust the deflection of the blade by means of the screw D. By screwing the screw D, the squeegee rises, decreasing the deflection on the blade. By unscrewing screw D, the squeegee is lowered, increasing the deflection on the blade. 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.
  • Page 29 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B2.2 Replacing the squeegee blades Dismantling Remove the suction hose A from the squeegee. Remove the squeegee from the dedicated support, unscrewing the knobs B Open the levers that lock the blade pressing devices, front C and rear D, once released slide them outwards.
  • Page 30 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Reassemble the front and rear blade by fixing the ends using the white nylon straps H, as shown in the photos below. Fig. 36 Reassemble the blade pressing devices, front and rear. Reposition the squeegee on the support, and reassemble the suction hose.
  • Page 31 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B3 CHECKING AND REPLACING THE FLOATS CLIC Fig. 38 25 of 68...
  • Page 32 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B3.1 Checking operation of the solution tank float Use a tester set to read resistance in or check the diodes, see Figure 41. Move the machine to the tank draining area, and completely empty the solution tank. Move the machine onto flat and dry flooring.
  • Page 33 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B3.2 Replacing the solution tank float Dismantling Move the machine to the tank draining area, and completely empty the solution tank. Move the machine onto flat and dry flooring. Press the emergency switch (Traction) or switches into position "0" (Pad Assist). Identify the point where the float is fitted, see paragraph B 3.1.
  • Page 34 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B3.3 Checking operation of the dirty water tank float Use a tester set to read resistance in or check the diodes, see Figure 50. Move the machine to the tank draining area, and completely empty the dirty water tank. Move the machine onto flat and dry flooring.
  • Page 35 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale B3.4 Replacing the dirty water tank float Dismantling Move the machine to the tank draining area, and completely empty the dirty water tank. Move the machine onto flat and dry flooring. Press the emergency switch (Traction) or switches into position "0" (Pad Assist). Identify where the float is fitted on the dirty water tank, proceed as described in paragraph B3.3.
  • Page 36 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale DRIVE UNIT WARNING Go to the designated draining area and empty the solution and dirty water tanks using the drain plugs and the hose provided. Move the machine onto flat ground. If necessary, place chocks under the wheels.
  • Page 37 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C1 INSTRUMENT PANEL ELECTRONIC BOARD On the “Traction” version, the board also comprises the circuits that deliver power the drive motor. PAD ASSIST VERSION Fig. 60 TRACTION VERSION Fig. 61 31 of 68...
  • Page 38 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale INSTRUMENT PANEL BOARD IDENTIFICATION: The alphanumeric display is only fitted on battery version machines, "Pad Assist - Traction". BOARDS FOR MACHINES WITHOUT DRIVE Fig. 62 BOARDS FOR MACHINES WITH DRIVE Fig. 63 32 of 68...
  • Page 39 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C1.1 Instrument panel board, setting the type of batteries and EcoMode Set the instrument panel board according to the type of batteries (Acid or Gel) fitted or to be fitted, for best performance. The discharge voltage threshold for ACID batteries is 20.5 V.
  • Page 40 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Use the button C to select the type of battery, between GEL and ACID. Fig. 66 Setting EcoMode on "Traction" versions with drive Using the button B, choose whether to modify the setting of the type of batteries, or the water/solution metering mode.
  • Page 41 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Pressing the button C, select whether to meter the water/solution manually, or automatically (EcoMode). Fig. 68 The EcoMode function delivers water/solution in proportion to machine travel speed and one of the five programs selected on the instrument panel. In this way, when machine speed changes, there is no need to constantly and manually adjust the quantity of water delivered.
  • Page 42 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Setting on "Pad Assist" versions without drive Switch the machine on using the brush button B. Fig. 70 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.
  • Page 43 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale To save the new setting, 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. Fig.
  • Page 44 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C1.2 Dismantling the instrument panel board Versions with drive Disassembly Switch the machine off by pressing the emergency button A fully in. Disconnect the batteries that power the machine, to avoid dangerous short circuits. Unscrew the three screws B that fasten the instrument panel to the dirty water tank.
  • Page 45 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale To remove the contact E from the "mushroom" head or emergency button, use a flat-head screwdriver to slightly lift the tab until it detaches from the support. Being an ON/OFF switch, when reassembling, its orientation is not important.
  • Page 46 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Versions without drive Disassembly Switch the machine off by pressing the brush-on/off button H for more than 3 seconds. Disconnect the batteries that power the machine, to avoid dangerous short. Unscrew the three screws I that fasten the instrument panel to the dirty water tank. Lift the board and turn it over with care.
  • Page 47 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C2 DRIVE MOTOR The drive reduction unit (BT) with the addition of a ferrite 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.
  • Page 48 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C2.1 Checking the drive motor current input. Make sure that the batteries on the machine are charged. Move the machine onto flat and dry flooring. Press the emergency switch fully in. Use a clamp-on ammeter with an end scale reading of at least 200 amperes, as shown in Figure 82. Lift the drive wheels, at least one of them, a few centimetres to check the current input with no load.
  • Page 49 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C2.2 Checking and replacing the carbon brushes traction motor. Dismantling Move the machine to the tank draining area, and empty the solution tank and the dirty water tank. Move the machine onto flat and dry flooring. Press the emergency key switch until it is held in the bottom position.
  • Page 50 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Dismantling With the carbon brushes removed, identify the two nuts D that fasten the cover to the motor body. With a 7 mm / 0,28 in spanner, unscrew the two nuts D, holding the bolts E on the opposite side. With a plastic mallet, tap the side of the cover to detach it from the motor body.
  • Page 51 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C2.3 Replacing the drive wheels, "BT" versions Dismantling Move the machine to the tank draining area, and empty the solution tank and the dirty water tank. Move the machine onto flat and dry flooring. Press the emergency key switch until it is held in the bottom position.
  • Page 52 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C2.4 Replacing the idle wheels Dismantling Move the machine to the tank draining area, and completely empty the dirty water and solution tanks. Move the machine onto flat and dry flooring. Press the switches into position "0" to switch off all the functions. Disconnect and remove the batteries from the battery compartment, if the machine is laid on one side.
  • Page 53 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C2.5 Replacing the drive motor Dismantling Move the machine to the tank draining area, and empty the solution tank and the dirty water tank. Move the machine onto flat and dry flooring. Press the emergency key switch until it is held in the bottom position.
  • Page 54 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Unscrew the four bolts that fasten the two self-aligning bearings D fitted on the "L" support brackets. Unscrew the four nuts that fasten the two bearings with flanges E fitted on the machine's chassis. Take the reduction drive to the bench and unscrew the four dowels F that lock the shaft to the bearings D.
  • Page 55 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale C3 RELAY AND DRIVE MOTOR ELECTRICAL CONNECTIONS C3.1 Checking and replacing the drive relay WARNING ONLY MACHINES WITH TRACTION MOTOR The drive relay is fitted to make the machine lighter to push, when the drive cannot be used (no batteries, flat batteries or off).
  • Page 56 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Dismantling Move the machine to the tank draining area, and empty the recovery tank. Move the machine onto flat and dry flooring. Press the emergency key switch until it is held in the bottom position. Disconnect the batteries from the wiring and each other and remove them from the battery compartment.
  • Page 57 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale DRIVE UNIT WARNING Go to the designated draining area and empty the solution and dirty water tanks using the drain plugs and the hose provided. Move the machine onto flat ground. If necessary, place chocks under the wheels.
  • Page 58 PLDC04452 REVISION 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.
  • Page 59 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale D1.1 Main wiring board components, “Pad Assist” version Instrument panel board and solenoid valve fuse Main wiring board connector Suction motor relay Contactor brush motor Brush motor fuse Suction motor fuse Positive isolator switch Negative isolator switch Fig.
  • Page 60 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale D2 MACHINE’S MAIN WIRING, “TRACTION” 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.
  • Page 61 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale D2.1 Main wiring board components, “Traction” version Instrument panel board and solenoid valve fuse Main wiring board connector Suction motor relay Contactor brush motor Brush motor fuse Suction motor fuse Drive motor fuse Positive isolator switch Negative isolator switch Fig.
  • Page 62 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale D2.2 Machine’s main wiring connections, “Traction” version MULTI-PIN CONNECTOR ON PANEL BOARD If replacing the machine’s main wiring, or there are electrical problems on the machine, check that the connector is correctly plugged onto the board. Fig.
  • Page 63 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale FAST-ON TERMINAL CONNECTOR FOR IGNITION KEY / EMERGENCY BUTTON White wire with spade lugs to connect to the mushroom-head button with key, carries +24 V signal from the batteries. Orange wire with spade lugs to connect to the mushroom-head button with key, carries +24 V signal to the functions.
  • Page 64 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale SOLENOID VALVE FAST-ON TERMINAL CONNECTOR Solenoid valve fast-on terminal connector. Purple wire and pink wire +24 V. Fig. 122 DRIVE MOTOR, DRIVE MOTOR PROTECTOR AND RELEASE RELAY CONNECTOR Relay coil connector, fast-on terminal orange wire +24 V.
  • Page 65 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale BRUSH MOTOR AND MOTOR PROTECTOR CONNECTOR Brush motor connector. Ø 6 mm cable eyelet, red wire +24 V from the Fig. 125 contactor, black wire +0 V from the negative isolator switch. Brush motor protector fast-on terminal connector.
  • Page 66 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale EXTERNAL BATTERY CHARGER CONNECTOR Connector for recharging the batteries using an external battery charger. Alongside is a microswitch that detects when the recharging connector is plugged in. When activated, the microswitch cuts off the power supply to the electronic board, thus preventing machine operation.
  • Page 67 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale D3 ELECTRICAL WIRING DIAGRAMS D3.1 Wiring diagram, Pad Assist version 61 of 68...
  • Page 68 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale D3.2 Wiring diagram, Traction version 62 of 68...
  • Page 69 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale ERROR CODES - TROUBLESHOOTING WARNING Go to the designated draining area and empty the solution and dirty water tanks using the drain plugs and the hose provided. Move the machine onto flat ground. If necessary, place chocks under the wheels.
  • Page 70 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale E1 ERROR CODES E1.1 Alarm messages on the instrument panel board display The instrument panel boards with display include verification of LED operation; 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"...
  • Page 71 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale Check the relay, disconnected or power contacts Suction relay control fault stuck in “closed” position. Instrument panel board fault DRIVE LEVER already pressed when starting Release the drive lever and activate it again. or after emergency Check wiring, connection or short-circuit solenoid Anomaly control solenoid valve water...
  • Page 72 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale TROUBLESHOOTING E2.1 Troubleshooting E2.1.1 The machine won’t start If there is voltage, go to point 2 Check battery voltage (B, BT). Recharge the batteries. Check the key contact, “BT” only, see paragraph If OK, go to point 3 If there is no continuity replace the key contact.
  • Page 73 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale E2.1.4 The suction motor isn’t working If shown, check the suction relay C paragraph Check whether the display on the instrument D5.1 and its wiring. panel shows error code "AcA". If not shown go to point 2. Check if the “tank full”...
  • Page 74 PLDC04452 REVISION December 23, 2020 TECHNICAL OFFICE Stavale REVISION No. DATE December 23, 2020 REVISION 00 Drafting of the manual and release date. Xxxxx 00, 20XX REVISION 01 68 of 68...