Tennant T981 Technical & Service Manual

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PLDC04897

REVISION DATE

May 20, 2024

DATE

May 20, 2024

TECHNICAL OFFICE

Allegrini

T981

Technical Service Manual

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Summary of Contents for Tennant T981

Page 1 PLDC04897 REVISION DATE May 20, 2024 DATE May 20, 2024 TECHNICAL OFFICE Allegrini T981 Technical Service Manual...
Page 3 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Stavale MAINTENANCE SCHEDULE PART DESCRIPTION FREQUENCY IN HOURS PARA- GRAPH WEAR PARTS CHECK REPLACE Disk - Cylindrical Squeegee blade, front B2.3 Disk - Cylindrical Squeegee blade, rear B2.3 Disk - Cylindrical PU rear blade , oil resistant B2.3 Disk - Cylindrical Brush PPL...
Page 4 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Stavale Contents A1.1 Checking brush motor current draw ................7 A1.2 Checking brush motor current draw with clamp-on ammeter........12 A1.3 Checking the current draw of brush motors individually..........15 A1.4 Checking and replacing the brush motor carbon brushes ..........17 A1.5 Replacing the carbon brushes on the bench ..............
Page 5 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Stavale C1.1 Checking electrical connections and voltage circuit board ........... 147 C1.2 Checking drive motor current draw ................149 C2.1 Checking and replacing the drive wheel motor carbon brushes ........152 C2.2 Checking and replacing the drive wheel thermal overload cutout ........ 158 C2.3 Replacing the rubber tyred rim of the drive wheel ............
Page 6 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini BRUSH HEAD CAUTION All maintenance operations described and illustrated in this manual must be carried out by an IPC-approved technician. Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses.
Page 7 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A1 BRUSH MOTORS A1.1 Checking brush motor current draw Make sure that the batteries on the machine are charged and that there is detergent solution in the tank. or as described further on in the manual. brush head actuator response.
Page 8 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 9 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini not be completely empty. May 20, 2024...
Page 10 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini returns to the at-rest position. No error message will appear in the display. May 20, 2024...
Page 11 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Current draw A (amperes) May 20, 2024...
Page 12 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A1.2 Checking brush motor current draw with clamp-on ammeter Make sure the machine batteries are charged. May 20, 2024...
Page 13 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Remove the brushes from the head. May 20, 2024...
Page 14 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Current draw A (amperes) May 20, 2024...
Page 15 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A1.3 Checking the current draw of brush motors individually Make sure the machine batteries are charged. May 20, 2024...
Page 16 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini If the levels of current drawn by the two brush motors are identical to one another and the sum is roughly May 20, 2024...
Page 17 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A1.4 Checking and replacing the brush motor carbon brushes Disassembly May 20, 2024...
Page 18 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Always replace all four carbon brushes of the motor at one time. If the two brush motors mounted together. May 20, 2024...
Page 19 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 20 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 21 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly May 20, 2024...
Page 22 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A1.5 Replacing the carbon brushes on the bench If the carbon brushes of the brush motors cannot be inspected and/or replaced without detaching the brush head from the machine, as described in heading A1.4, the head must be removed as described in heading A3.1, and the carbon brushes then replaced on the workbench.
Page 23 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Always make sure that the carbon brushes slide freely in their seats. Reassembly May 20, 2024...
Page 24 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A2 BRUSH HEAD ACTUATOR A2.1 Checking brush head actuator current draw May 20, 2024...
Page 25 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 26 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Current draw A (amperes) May 20, 2024...
Page 27 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A2.2 Replacing the brush head actuator Disassembly Go to the designated draining area and empty the dirty water tank completely. Apply the pedal-operated parking brake. May 20, 2024...
Page 28 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 29 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Testing May 20, 2024...
Page 30 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 31 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Checking and Adjustment of Microswitch Cams May 20, 2024...
Page 32 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini 5 way of the 5 way connector wire May 20, 2024...
Page 33 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini bottom bottom bottom May 20, 2024...
Page 34 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly Checks May 20, 2024...
Page 35 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A3 BRUSH HEAD (DISC) A3.1 Disassembling the brush head Disassembly May 20, 2024...
Page 36 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 37 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly May 20, 2024...
Page 38 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A3.2 Replacing the brush motor end cap and bearing Disassembly May 20, 2024...
Page 39 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 40 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly May 20, 2024...
Page 41 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 42 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A3.3 Replacing the brush motors Disassembly reliably. Right Left May 20, 2024...
Page 43 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 44 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly necessary. May 20, 2024...
Page 45 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A4 BRUSH HEAD FLAPS (DISC) May 20, 2024...
Page 46 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly Reassembly May 20, 2024...
Page 47 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A4.2 Replacing the brush alignment roller and bearing Disassembly Reassembly May 20, 2024...
Page 48 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly Reassembly The function of the Disassembly Reassembly May 20, 2024...
Page 49 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly Reassembly chine. May 20, 2024...
Page 50 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A5 SOLENOID VALVE Inspection May 20, 2024...
Page 51 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 52 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Replacement Reassembly May 20, 2024...
Page 53 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A6 ROLLER HEAD A6.1 Checking brush motor current draw from the instrument panel Checking current draw with drive belt disassembled. from step 4 to step 21. Current draw A (amperes) Important: for test purposes, set maximum brush pressure May 20, 2024...
Page 54 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A6.2 Checking brush motor current draw with clamp-on ammeter Checking current draw with drive belt disassembled Current draw A (amperes) 3.0 A 6.0 A Scrubbing, without brushes “P1” Scrubbing, with brushes “P1” 10.0 A 45.0 A Motor only, without belt “P1”...
Page 55 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A6.3 Checking and replacing the brush motor carbon brushes The carbon brushes should be inspected and if necessary replaced after around 600 - 700 hours operation. It is advisable to replace all four (4) carbon brushes at the same time. Disassembly May 20, 2024...
Page 56 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Inspection of carbon brushes Replacing the Carbon Brushes May 20, 2024...
Page 57 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly May 20, 2024...
Page 58 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A6.4 Replacing the brush motor Disassembly May 20, 2024...
Page 59 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 60 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 61 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 62 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly Do not tighten the grubscrews. May 20, 2024...
Page 63 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A6.5 Inspection and replacement of belt Disassembly May 20, 2024...
Page 64 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 65 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini two pulley bearings mounted to the driving and driven centres of the train. Reassembly May 20, 2024...
Page 66 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Checking the belt tension May 20, 2024...
Page 67 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A6.6 Checking and replacing the brush spindle bearings Disassembly It is strongly recommended that all four bearings be renewed at the same time. May 20, 2024...
Page 68 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 69 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 70 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly May 20, 2024...
Page 71 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A6.7 Checking current draw of the brush head actuator Current draw A (amperes) 0.8 A 5.0 A downstroke upstroke 1.8 A 5.0 A May 20, 2024...
Page 72 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A6.8 Replacing the brush head actuator Disassembly Go to the designated draining area and empty the dirty water tank completely. Remove the brushes from the head. May 20, 2024...
Page 73 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini avoid screwing or unscrewing May 20, 2024...
Page 74 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Adjustment top and bottom cams. May 20, 2024...
Page 75 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly Checks The distance between the detergent solution tank and the debris bin is of relative importance; in transport purposes will an adjustment close to the minimum distance be advisable. At all events, it is important that when the brushes are lifted, or when fully raised, there should be no interference with other parts of the head or with the solution tank.
Page 76 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Carry out the steps described in heading A5.1. May 20, 2024...
Page 77 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly Reassembly May 20, 2024...
Page 78 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A7 SIDE BRUSH MOTORS (SWEEPER) May 20, 2024...
Page 79 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini that the brushes be replaced. Adjustment May 20, 2024...
Page 80 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Replacement, Disassembly Replacement, Assembly May 20, 2024...
Page 81 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A7.2 Checking the current draw of the side brush gearmotors When checking the current drawn by the side brush gearmotors, measure the current draw of one motor at a time. May 20, 2024...
Page 82 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Current draw A (amperes) 1.1 A 3.0 A with brush without brush 0.5 A 1.5 A May 20, 2024...
Page 83 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini The carbon brushes should be inspected and replaced if necessary at intervals of approx 600 - 700 hours operation, or whenever the carbon brushes of the roller brush motor are serviced. It is advisable to replace all four (4) carbon brushes at the same time: two on the gearmotor of the right hand side brush and two on that of the left hand side brush.
Page 84 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 85 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Inspection of carbon brushes 17 mm 16 mm Reassembly May 20, 2024...
Page 86 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly Use a digital multimeter. May 20, 2024...
Page 87 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 88 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Checking operation of the microswitches Checking operation of the resettable fuses May 20, 2024...
Page 89 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A7.5 Replacing the side brush gearmotor Disassembly Reassembly May 20, 2024...
Page 90 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini VACUUM UNIT - TANKS CAUTION All maintenance operations described and illustrated in this manual must be carried out by an IPC-approved technician. Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses.
Page 91 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B1 VACUUM MOTOR: MEASURING CURRENT DRAW B1.1 Checking vacuum motor current draw Make sure the machine batteries are charged. Use a clamp-on ammeter with a full scale reading of at least 200 A (amperes); see photo below. Turn the ignition key to position “0 Detach the vacuum hose A First tilt the driver seat B forward, then tilt the dirty water tank C...
Page 92 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Change AUTO POWER OFF to OFF from the instrument panel, as indicated in the USER PROGRAMMING gui- Continue scrolling the menu with the display button E until the parameter shown in the window is: “Program 1 AutoPowerOFF ON”...
Page 93 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B1.2 Checking and/or replacing the vacuum motor carbon brushes Disassembly Inspection Apply the pedal-operated parking brake A Turn the ignition key B to position “0 Tilt the driver seat C forward and isolate the batteries from the machine electronics by unplugging the Anderson connector D, then tilt the dirty water tank E back to gain access to the vacuum motor F Remove the fan cowl G from the vacuum motor F, by pulling the metal clips H outwards and at the same time May 20, 2024...
Page 94 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Undo the two screws L (two on each mount) securing the carbon brush M Remove the carbon brush M from its mount N If resistance is encountered during this operation, apply pressure to the dark part M1 If all the requirements of the previous step are met, continue by measuring the dark part M1 May 20, 2024...
Page 95 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini It is always advisable to replace both carbon brushes at the same time. Replacement With the two new carbon brushes connected to the two wires O Reassembly May 20, 2024...
Page 96 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B1.3 Replacing the vacuum motor Disassembly Apply the pedal-operated parking brake A Turn the ignition key B to position “0 Tilt the driver seat C forward and isolate the batteries from the machine electronics by unplugging the Anderson connector D Tilt the dirty water tank E back to access the vacuum motor F together with the protective mesh I...
Page 97 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Undo the three screws P with the relative hollow studs Q 10-11 Use a utility knife to cut through the part of the heat shrink Pull the hose U away from the motor, twisting clockwise at 12-13 Before installing the vacuum motor on the dirty water tank, preassemble the Anderson connector and the air May 20, 2024...
Page 98 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Preassembly Complete the preassembly of the motor by adding the air exhaust hose U, using pre-glued heat shrink sheath Z. Insert the air hose U into the hole on the turbine housing, pushing in and twisting clockwise at the same time. Fit the heat shrink sheath over the hole of the impeller casing, taking it as far as the rib, and secure in place with Reassembly With preassembly complete, install the vacuum motor on the machine, repeating the steps of the disassembly...
Page 99 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B2 SQUEEGEE UNIT AND ACTUATOR B2.1 Inspecting and/or replacing the electromechanical actuator The electromechanical actuator is a component that raises and lowers the squeegee, piloted by a electronic circuit board installed in the instrument panel. While the device is intrinsically simple, familiarity with its operation is nonetheless important.
Page 100 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly With the squeegee raised: Unplug the connector B, unseat the left hand spring D, then undo the bolt E securing the rod C1 to the mounting of the actuator C, and the bolt F securing the body of the actuator to the chassis of the May 20, 2024...
Page 101 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini With the squeegee lowered: Unplug the connector B, detach the squeegee, push the machine back so as to bring the wheels of the squeegee frame forward, unseat the springs D and G, so that there is no load on the electromechanical actuator C, lift the squeegee frame H, and undo the bolt E securing the rod C1 to the mounting of the actuator, also the bolt F May 20, 2024...
Page 102 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Checking the motor Inspect the motor C2 of the actuator C Check that the rod C1 A that the actuator functions as it should, attaching the leads to the pins of the connectorC3: the red lead A1 to the pin of the red wire, position 1, and the black lead A2 Connect the two leads A1 and A2 to the batteries of the machine: the black A2 A1 to the positive pole, then operate the control.
Page 103 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Checking operation of the microswitch There are two microswitches installed inside the body of the actuator, one (corresponding to the rod fully retracted position) mounted at the bottom, the motor end C2, and the other (corresponding to the rod fully extended position) mounted at the top, the rod end C1.
Page 104 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Unscrew the rod slowly until the “click” of the microswitch is heard, indicating the rod is fully retracted, then screw Screwing the rod in to its stroke limit, a single “click” should be heard, corresponding to the fully retracted position of the rod.
Page 105 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Unscrewing the rod completely, a single “click” should be heard, corresponding to the fully extended position of the rod. Moving the rod from bottom stroke limit to top stroke limit, and viceversa, two (2) “clicks” of the microswitches should be heard (rod fully retracted - rod fully extended) one when the contact opens, the other when the contact closes.
Page 106 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B2.2 Checking current draw of the electromechanical actuator and if possible with every change of the squeegee blades. This will help to minimize the need for early replacement of the actuator, or of the instrument panel circuit board. Make sure the machine batteries are charged.
Page 107 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B2.3 Replacing the squeegee blades Disassembly Turn the ignition key to position “0 Detach the vacuum hose A Unscrew the two knobs B Rear blade Undo the four wing nuts C Release the lever clamp D Remove the right hand retainer F, the left hand retainer G, and the rear squeegee blade H 6-7-8...
Page 108 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B2.4 Adjusting the squeegee Turning the knob A clockwise, the squeegee is raised toward the swivel plate of the caster, reducing pressure on the blade (– May 20, 2024...
Page 109 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Loosen the lock nut D C and tightening the knob denoted of lowering the ends of the squeegee and elevating the middle section. Conversely, loosening the knob denoted B and tightening the knob denoted C middle section of the squeegee and elevating the ends.
Page 110 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B2.5 Squeegee frame Squeegee stabilizer Disassembly The function of the squeegee stabilizer is to reposition the squeegee swiftly after it has struck an obstacle during operation. It also serves to prevent the squeegee from snaking, which would adversely Release the clevis retaining clip A to detach the stabilizer B Undo the bolt C Check (by pulling and pushing) that there is no backlash between the rod B1 and the body B2...
Page 111 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Squeegee caster Disassembly Hold the head of the bolt A fast with a size 19 ring wrench, and using another wrench, loosen the lock nut B If possible, change both casters C Reassembly Continue with adjustment (wiping pressure) of the squeegee, as described in heading B2.4 Squeegee joint...
Page 112 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Undo the two screws F by which the pivot G bushes. Clean the surface of the pivot G Reposition the stainless steel 14 mm plain washer M on the linkage pivot D Reassembly May 20, 2024...
Page 113 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Positioning the squeegee joint The position in which the squeegee joint is secured to the rear axle assembly will vary according to the size of the squeegee blade and the model of the machine. Consequently, the position in which the squeegee stabilizer and the return springs are secured will also change.
Page 114 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Referring to the illustration below, position the various components according to the length of the existing Position the springs A in one of the holes denoted H and I, according to the length of the B in one of the holes denoted L Position the bracket G of the squeegee stabilizer in one of the holes denoted M, according to the length of the In the case of the BT 75 R Sweeper version, refer to positions BT 85 –...
Page 115 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini CLEANING THE FILTERS - HOSES - DETERGENT SOLUTION PUMP Remove the cap B A under running water, wor- king from the outside inwards, then blow through with compressed air, likewise from the outside inwards. A and the cap B to the deter- gent solution tank.
Page 116 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini emptied out completely; accordingly, it is advisable to clean at regular intervals, preferably Unscrew the bowl A1 May 20, 2024...
Page 117 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini A3 under running water, working from the outside inwards, then blow through with compressed air, likewise from the outside inwards. Make sure that the rubber seal A4 is in place at the top of the bowl A1 A3, aligning it with the bowl A1 and with the body A2 Screw the bowl A1 onto the body A2 Reassembly...
Page 118 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly Go to the designated draining area and empty the detergent solution tank completely. Undo the two screws A Remove the metal hose clips C Detach the two hoses D E and F, taking care with the O-rings G May 20, 2024...
Page 119 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Preassembly depth in order to ensure that the drive wheel will not rub against the component when in rotation. The left hand stud A5 B with its various parts E, F, C, May 20, 2024...
Page 120 B3.2 Checking operation of the detergent solution pump On the T981, dosage of the required quantity of water is controlled by the ECU at the instrument panel: according to the amount of water selected (on the panel), a given level of voltage will be supplied to the water pump, which consequently is caused to turn faster or slower.
Page 121 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini On the male connector D, locate pin D4 Insert the negative prod E Locate the red wire F Insert the positive prod G Switch the machine on, turning the ignition key to position “1 Select the downward movement of the brushes using the relative button H Use the controls I 13-14...
Page 122 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Depress the accelerator pedal lightly and momentarily: the brushes will begin to turn, but the click of the solenoid valve being energized will not Keep pressing the accelerator lightly and momentarily to make certain that voltage signals continue to be supplied correctly by the instrument panel to the water pump and to the solenoid valve.
Page 123 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Checking operation of the detergent solution pump Prepare two leads A for use as a by-pass circuit, as described in heading B2.1 Undo the two screws B Elevate the footplate and remove the two screws C, then remove the screws D low down on the pillar and the 4 screws E on the panel.
Page 124 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini In the case of the roller head version, be careful to ensure that the reduction L mounted on the solenoid valve does not remain caught in the May 20, 2024...
Page 125 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini switch A4. Place the hose H in the graduated recipient, detergent solution for half a minute (30 secon- B3.3 Cleaning the water delivery hose It is advisable to check for correct operation and possible clogging of the solenoid valve, also for correct operation of the water pump, as described in heading B3.2, before checking the remainder of the water delivery circuit.
Page 126 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B3.4 Checking and/or replacing the detergent solution pump The detergent solution pump has undergone a design change from serial n° 8000127901 onwards, consisting in the addition of a ferrite (A4), to protect the electronics of the machine from possible electromagnetic interference.
Page 127 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly Disconnect the detergent solution pump A electrically by unplugging the watertight connector C Cut through the plastic ties D Loosen the clip E retaining the solution inlet hose, and the clip B Undo the two screws F securing the pump A Replace the pump A Reassembly...
Page 128 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini CHECKING OPERATION AND/OR REPLACEMENT OF FLOAT SWITCH warning (buzzer) and a visual alert (Led indicator and display message on instrument panel) when the dirty water tank B, the body, incorporating two metal strips, When the magnet of the moving part A part B metal strip, thereby closing the electrical circuit of the switch.
Page 129 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini also pilots the ECB installed in the instrument panel (only if programs P1, P2, P3 are in use) to raise the brush head, and consequently stop the rotation of the brushes. turning the key to position “0”...
Page 130 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly Cut through the tie A C fast and loosening the clamp nut D Reassembly Once in position, secure the component to the tank by holding the body C fast and tightening the clamp nut D, taking care not to damage the thread on the body C E Do not overtighten May 20, 2024...
Page 131 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini switch mounted to the dirty water tank also pilots the ECB installed in the instrumental position “0” in order to restore operation of the squeegee (reset) and cancel the alarms. which case after 20 seconds the squeegee frame will be raised to avoid the circuit switching May 20, 2024...
Page 132 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 133 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disassembly B fast and loosening the clamp nut C Reassembly Once in position, secure the component to the tank by holding the body B fast and tightening the clamp nut C, taking care not to damage the thread on the body B Do not overtighten May 20, 2024...
Page 134 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B5 TANKS: REPLACEMENT dirty water tank A and a detergent solution tank B, both of which are ma- nufactured by a method known as Rotational Moulding, or Rotomoulding. The advantages of this method are that tanks can be designed with complex geometries, and incorporating metal inserts that facilitate the steps of mounting them to the structure of the machine and attaching components such May 20, 2024...
Page 135 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B5.1 Replacing the dirty water tank Disassembly Detach the dirty water drain hose A and the relative supports B Remove the metal mesh C E allowing inspection of the vacuum pump, undoing the stainless M6 x 12 mm retaining screw F The gasket seal G drying action will remain unimpaired subsequently.
Page 136 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Remove the vacuum motor I, as described in heading B1.3. Cut through the plastic tie and remove the retaining Remove the retaining straps N to free the squeegee vacuum hose O and the electrical wiring P Detach the squeegee vacuum hose O by pulling it from Q of the dirty water tank by unscrewing the hose union R, being careful not to...
Page 137 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Undo the screw T that secures the travel limiting stay rod U Detach the stay rod U Return the tank to the closed position and continue by removing the pivot V On the left hand side of the machine, locate the screw Z by which the hinge pivot V Be careful to retain the spacer Y May 20, 2024...
Page 138 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Preassembly position the part on the inside of the tank, substantially as illustrated. On the outside, insert the hose union R into the tank from beneath, with the seal S screw it into the Reassembly Fit the clip M Insert the squeegee vacuum hose O into the socket of the hose union R...
Page 139 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Insert the pivot V Tighten the screw Z May 20, 2024...
Page 140 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini B5.2 Replacing the detergent solution tank Disassembly Isolate the batteries from the machine electronics by unplugging the Anderson connector A Remove the battery tray B Undo the screws C1to allow the removal of the Anderson socket C Undo the screw D that secures the travel limiting stay rod E May 20, 2024...
Page 141 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Detach the vacuum hose F and position it under the squeegee bumper G Undo the four screws H1 securing the battery box to the chassis, and remove the box H Remove the solution drain hose M May 20, 2024...
Page 142 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Undo the three screws O Disconnect the operator-on-board sensor Q May 20, 2024...
Page 143 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini T2, then taking out the plastic guard T1 Detach the accelerator pedal T Undo the electrical connection T3 Remove the black plastic footplate, undoing the four screws U Undo the six screws V1, V2 and V3 to remove the pillar panel V Undo the screw T4 24-25 23-24...
Page 144 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Cut through the tie W1 and unplug the connector W2 With the tank away from the machine, remove the detergent solution level sensor W Reassembly May 20, 2024...
Page 145 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini DRIVE UNIT CAUTION All maintenance operations described and illustrated in this manual must be carried out by an IPC-approved technician. Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses. Move the machine onto a level surface and apply the parking brake.
Page 146 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C1 DRIVE WHEEL CONTROL CIRCUIT BOARD The ITALSEA DRIVE circuit board supplies “current” to the drive motor. Abnormalities detected by the circuit board are indicated by the blinking of a Led on the instrument panel.
Page 147 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C1.1 Checking electrical connections and voltage circuit board Test Make sure the machine batteries are charged. Use a digital multimeter (tester) of dependable precision. Turn the ignition key to position “0”. Remove the front pillar panel as described in heading A1.2.
Page 148 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Check the voltage between the insulator of the negative wires and the positive wire coming from the fuse, at the contactor. Switch on the machine by turning the ignition key to position “1” Read the voltage at the poles of the drive control circuit board.
Page 149 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C1.2 Checking drive motor current draw Proceed as described in heading C1.1 above. Use a clamp-on ammeter with a full scale reading of at least 200 amperes (A). Locate and disconnect the operator-on-board sensor and wire in a jumper as illustrated. Raise the drive wheel a few centimetres, using a jack.
Page 150 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini In addition, place the clamp-on ammeter around the red wire to the drive wheel. Depress the accelerator pedal to its full travel. Read and note down the value of the current (stabilized) drawn by the drive wheel. Lower the machine back onto the ground and take a reading with the drive motor propelling the machine.
Page 151 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C2 DRIVE WHEEL May 20, 2024...
Page 152 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C2.1 Checking and replacing the drive wheel motor carbon brushes The carbon brushes should be inspected and if necessary replaced after around 600 - 700 hours operation. It is advisable to replace all four (4) carbon brushes at the same time. Disassembly 0”...
Page 153 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disconnect the drive wheel unit electrically, undoing the two nuts that connect the thermal overload cutout of the motor to the machine wiring harness, the nut securing the positive wire (red) and the nut securing the negative wire (black) to the drive wheel.
Page 154 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Take particular care when removing the motor, to avoid damaging the seal positioned on the inside, at the interface with the gear unit. Transfer the motor to the bench and proceed with inspection of the four (4) carbon brushes, which are spaced 90°...
Page 155 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Loosen the nut to release the wires of the thermal overload cutout, the power supply and the carbon brush. Use a tool with a hook end to lift the tension spring of the carbon brush, and remove the brush from its seat. Inspection of carbon brushes Measure the carbon brush: if the length is greater than 8.0 to 9.0 mm the carbon brush can remain in place;...
Page 156 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Testing operation of the thermal overload cutout The purpose of the thermal overload cutout is to prevent the motor from reaching high temperatures that could cause irreparable damage. These devices are usually placed in the hottest part of the motor, near the carbon brushes, or in the end cap that houses the carbon brushes.
Page 157 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly parts must Always make sure that the carbon brushes slide freely in their seats, and that the seats do not show signs of deformation, or simply that they are not dirty. Blow compressed air onto the motor, holding it preferably with the pinionshaft directed downwards, so as to elimi- nate the dust left by the carbon brushes as they are gradually consumed.
Page 158 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C2.2 Checking and replacing the drive wheel thermal overload cutout The purpose of the thermal overload cutout is to prevent the motor from reaching high temperatures that could cause irreparable damage. These devices are usually placed in the hottest part of the motor, near the carbon brushes, or in the end cap that houses the carbon brushes.
Page 159 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini In case of emergency In the event that the “motor overload” alarm should appear when the motor is cold, and there is a need for the machine to be moved, a temporary connection can be created to bypass the ECU of the should be reinstated as soon as possible.
Page 160 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C2.3 Replacing the rubber tyred rim of the drive wheel Disassembly 0”. Apply the pedal-operated parking brake, or place chocks under the rear wheels. Raise the front drive wheel of the machine using a hydraulic jack, or as described in heading A3.1. Remove the plastic guard, using a slotted head screwdriver.
Page 161 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Turn the drive wheel round to the other side and locate the four (4) threaded holes, provided as jacking points for the purpose of removing the tyred rim more easily. Insert two (2) M10 bolts of suitable length, at least 80 mm, and drive them forward simultaneously, so as to force the rubber tyred rim outwards.
Page 162 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini First remove the alignment coupling A5, then continue turning the bolts B, until the tyred rim A4 is completely free. Replace the tyred rim with a new part. Reassembly Clean the contact surface of the drive hub and the four (4) threaded holes, and the contact surface of the ali- gnment coupling.
Page 163 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Procure four (4) M8 screws of at least 40 mm length to use as a “replacer” for the new rubber tyred rim. Smear the inner surface of the rim with graphite grease, on the aluminium part in relief. Insert the four screws of whatever type, using washers under the heads if need be, to avoid damaging the countersunk holes on the alignment coupling.
Page 164 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini When driving the four screws, take care over the position of the wheel hub relative to the casing of the gear unit. With the alignment coupling almost up against the hub, unscrew the bolts and insert the new screws provided with the new tyred rim.
Page 165 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C2.4 Replacing the complete drive motor and wheel unit The drive motor has been designed as a part that should never need replacing: nonetheless, in the event of improper use, In this situation, the part must be replaced or repaired permanent damage.
Page 166 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Disconnect the wheel motor electrically, undoing the two nuts that connect the thermal overload cutout of the motor to the machine wiring harness, the nut securing the positive wire (red), and the nut securing the negative wire (black) to the motor.
Page 167 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C3 ACCELERATOR PEDAL The function of the accelerator pedal is to regulate the speed of the machine both in transit and in operation; in operation, moreover, selecting one of the three work programs, the maximum speed can be preset and limited elec- tronically from the instrument panel .
Page 168 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C3.1 Replacing the accelerator pedal Disassembly Remove the plastic guard. Lift the accelerator pedal, pulling at the same time, so as to free it from the footplate. Unplug the watertight connectors so that the accelerator pedal is also isolated from the electrical system. Reassembly May 20, 2024...
Page 169 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C3.2 Replacing the accelerator potentiometer and microswitch The potentiometer and the microswitch are supplied together as replacement parts; accordingly, when renewing either one, it is advisable to renew both. Disassembly Use a digital multimeter able to measure resistance at least up to 5 kOhm. 0”...
Page 170 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Replacement nuts without tightening, to allow adjustment of the microswitch. Position the potentiometer horizontally, with the wires running parallel to the base. Tighten the nut of the potentiometer without excessive force, using a 13 mm wrench to hold the potentiometer in position (parallel to the base of the pedal) and a 12 mm wrench to tighten the nut.
Page 171 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini select the resistance function (Ohms) of the multimeter, and proceed with adjustment of the potentiometer. With the pedal raised, using a screwdriver, set the potentiometer to ZERO by turning the spindle clockwise as far as it will go.
Page 172 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C4 BRAKE PEDAL May 20, 2024...
Page 173 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini C4.1 Brake pedal The brake pedal operates by braking the rear wheels, employing a mechanical control linkage (twin cables). It is therefore important that inspections be carried out, and adjustments when necessary, to can be locked in position, thereby functioning as a parking brake.
Page 174 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reassembly Cut the connectors of the old microswitch to allow reutilization of the protective sheath. Reinstate the screws without tightening, so that the microswitch can be adjusted. Adjustment With the pedal in the at-rest position, not depressed, move the microswitch closer to the pedal until the click is heard, then closer still, another one (1) millimetre max, and tighten the screws.
Page 175 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Replacing the pedal Proceed as described in steps 1 to 6. Set the pedal in the at-rest position (not depressed). On all versions, remove the plastic footplate, as described in heading A3.1. Disconnect the two preinsulated round terminations.
Page 176 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini CIRCUIT BOARDS - ELECTRICAL SYSTEM CAUTION All maintenance operations described and illustrated in this manual must be carried out by an IPC-approved technician. Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses.
Page 177 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini INSTRUMENT PANEL CIRCUIT BOARD - POWER CIRCUIT BOARD May 20, 2024...
Page 178 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini D1.1 Description of instrument circuit board “A” Controls Buttons A button scrubbing pressure, amount of water, speed, operation of brushes, operation of vacuum system. Button B Button C Button D Buttons E alongside.
Page 179 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Connections Connector M main contactor and the buzzer. Connector N Connector O squeegee. Connector P Connector Q connection of the drive selector F H, and the beacon power supply, red wire R Connector Q R: to enable inspection, undo the four screws R1...
Page 180 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Connector Q, denoted CN4 Red wire Q1 by the Violet-Black wire. This must be connected to the preinsulated cylindrical red female termination Q9 of the The preinsulated cylindrical red female termination Q7 Q3 —...
Page 181 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini May 20, 2024...
Page 182 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini circuitry H are normally, the problem is with the logic pcb connected to the Violet wire, which must be tested and/or replaced. button all function normally, but there is no response from the reverse drive and buzzer, and/ or repaired.
Page 183 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini D1.2 Removing and/or replacing the instrument panel circuit board “A” Disassembly connector B Remove the snap cap C May 20, 2024...
Page 184 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini E with the aid of the puller D, so as to access the instrument panel more easily, or to Undo the dome head screw E1 Remove the washer E? and return the screw E1 Undo the screw E1 May 20, 2024...
Page 185 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini M, N, O and P, the connector H I1 and I2 and the Disassembly May 20, 2024...
Page 186 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini D1.3 Removing the power circuit board “B” Disassembly Isolate the machine from the batteries by unplugging the relative connector Undo the two white plastic screws B2 Reassembly May 20, 2024...
Page 187 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini D1.4 Replacement of components on electronics backboard Disassembly Isolate the machine from the batteries by unplugging the relative connector Parts Drive circuit board Main fuse Main contactor Clamp nut - positive pole Reassembly May 20, 2024...
Page 188 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Stavale D2 WIRING DIAGRAM D2.1 Wiring diagram with ITALSEA drive circuit board May 20, 2024...
Page 189 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Stavale COMPONENTS CHART PROPEL MOTOR CLIXON PROPEL-MOTOR BRUSH MOTOR SOLUTION-TANK LEVEL-SWITCH Switch CLOSED = full BRUSH MOTOR VACUUM MOTOR SEAT SWITCH Switch CLOSED = seat pressed SQUEEGEE MOTOR SOLUTION PUMP RECOVERY-TANK LEVEL-SWITCH Switch CLOSED = full BRUSH ACTUATOR CHEMICAL DOSE PUMP...
Page 190 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini ERROR CODES - TROUBLESHOOTING CAUTION All maintenance operations described and illustrated in this manual must be carried out by an IPC-approved technician. Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses.
Page 191 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini E1 ERROR CODES E1.1 Instrument panel circuit board display — alarms CAUSE ERROR CODE REMEDY Machine being overworked, high brush pressure. Wait 30 minutes for the temperature to come down. BRUSH TEMPERATURE Selected work program too heavy for the type of Drop from 3 to 2 or 1.
Page 192 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini E1.2 ITALSEA drive circuit board alarms - ALARMS - Handheld programmer, SCT utility (“Alarm” on Tester Pages) and Alarm Led (on-board and/or external by counting blinks) display the failures or alarms: the following table shows the list, the meaning of this alarms, and how to solve the problem. ALARM 1: Forward switch closed at power-up.
Page 193 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini ALARM 8: Power fuse or on-board contactor damaged. Led alarm status 8 blinks. Controller had detected a fault at the external power fuse or in power connections. If the controller repeats this alarm and the power connections are good, change the controller. ALARM 9: Undervoltage.
Page 194 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini E2 TROUBLESHOOTING E2.1 Troubleshooting E5.1.1 Machine display does not light up If there is no voltage, replace the batteries. Check battery voltage If there is voltage present, go to point 2 Check electrical continuity of black-violet wire C5 in heading D1.5 and red wire Q1 then Q7 in heading D1.1.
Page 195 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini E2.1.3 Brushes do not turn Reset the error message as described in table E1.1 Check for possible error messages on the instrument panel display - see heading E1.1 If there are no errors, go to point 2. If there is voltage present, go to point 3 Using a digital multimeter, check for voltage (36 V) between position 4 and position 2 on the power circuit...
Page 196 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini E2.1.5 Machine not vacuuming If the hose is dirty or damaged, clean or replace it Check that the vacuum hose is clean and intact. Otherwise go to point 2 Check that the metal clip is properly tightened and that If everything is as it should be, go to point 3.
Page 197 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini Reset the error message as described in table E1.1 Check for possible error messages on the instrument panel display - see heading E1.1 If there are no errors, go to point 2. If actuator is working correctly, go to point 3 Check the operation of the actuator, as described in heading B2.1.
Page 198 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini E3 DRIVE PROBLEM E3.1 Solutions to drive problem DRIVE PROBLEM Disconnect drive wheel motor Drive problem disappears Drive problem persists Inspect drive wheel motor car- Check output voltage and input bon brushes voltage at main contactor Replace drive wheel and motor If output voltage is lower than...
Page 199 PLDC04897 REVISION 00 May 20, 2024 TECHNICAL OFFICE Allegrini TECHNICAL SERVICE MANUAL REVISION - UPDATES EDITION No. DATE Edition 00 March 07, 2024 Updated Electrical Diagram May 20, 2024 May 20, 2024...

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