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Tennant T681 Technical & Service Manual
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Tennant T681 Technical & Service Manual

Tennant T681 Technical & Service Manual

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PLDC04893
REVISION DATE
May 28, 2024
DATE
May 28, 2024
TECHNICAL OFFICE
Mercanti
T681
Technical Service Manual

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Summary of Contents for Tennant T681

  • Page 1 PLDC04893 REVISION DATE May 28, 2024 DATE May 28, 2024 TECHNICAL OFFICE Mercanti T681 Technical Service Manual...

  • Page 3: Maintenance Schedule

    PLDC04893 REVISION 00 May 28, 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 Check Disk - Cylindrical...

  • Page 4: Table Of Contents

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Stavale Contents A1.1 Checking brush motor current draw from electrical panel ..........8 A1.2 Checking current draw directly on the motors ............... 9 A1.3 Checking the operation of brush motor thermal overload cutouts ........ 11 ................
  • Page 5 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Stavale...
  • Page 6 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A - BRUSH HEAD CAUTION Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses. necessary, place chocks under the wheels. anticlockwise and/or pressing the emergency switch.
  • Page 7 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A1 BRUSH MOTORS - 600 and 700 mm (23.622 and 27.560 ins) with 2 x 24 Vdc 380 W gearmotor, - 850 mm (33.465 ins) with 2 x 24 Vdc 500 W gearmotor, All motors are equipped with thermal sensor to ensure protection against overheating.

  • Page 8: A1.1 Checking Brush Motor Current Draw From Electrical Panel

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A1.1 Checking brush motor current draw from electrical panel Make sure that the batteries on the machine are charged and that there is detergent solution in the tank. Use a clamp-on ammeter with a full scale reading of at least 200 A (amperes). Go to the designated draining area and empty the dirty water tank.

  • Page 9: A1.2 Checking Current Draw Directly On The Motors

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A1.2 Checking current draw directly on the motors Make sure that the batteries on the machine are charged and that there is detergent solution in the tank. Use a clamp-on ammeter with a full scale reading of at least 200 A (amperes). Go to the designated tank draining area and empty the dirty water tank.
  • Page 10 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Right Left DOUBLE-BRUSH Current draw A (amperes) 2.5 A 5.0 A No load (without brushes) 10.0 A 12.0 A Minimum load (brushes in operation) Pressure 1 25.0 A 27.0 A Maximum load (brushes in operation) Pressure 4 May 28, 2024...

  • Page 11: A1.3 Checking The Operation Of Brush Motor Thermal Overload Cutouts

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A1.3 Checking the operation of brush motor thermal overload cutouts Checks Use a digital multimeter capable of reading continuity. Go to the designated draining area and empty the dirty water tank. Make sure that there is enough room around the machine to carry out disassembly operations in safety.
  • Page 12 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti or when one of the brushes has been replaced. Adjustment Unscrew the top knobs A on both sides, Select the program with the highest load, P4 (four LEDs alight). Screw or unscrew the bottom knobs B Remove the Lx and Rx covers and transfer them to a workbench (recommended).
  • Page 13 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A2 DISASSEMBLING THE BRUSH HEAD May 28, 2024...

  • Page 14: A2.1 Disassembling The Double-Brush Head

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A2.1 Disassembling the double-brush head Disassembly Go to the designated draining area and empty out both tanks. Make sure that there is enough room around the machine to carry out disassembly operations in safety. Disconnect the vacuum hose from the squeegee.

  • Page 15: A2.2 Disassembling And Replacing The Brush Motors

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A2.2 Disassembling and replacing the brush motors Disassembly Go to the designated tank draining area and empty out both tanks. Make sure that there is enough room around the machine to carry out disassembly operations in safety. Proceed to remove the brush head as described in the previous heading A2.1.
  • Page 16 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Flange spring directions one from the other. When tightening the screw that secures the spring, apply threadlocker. forward direction of movement of the machine. Left Right May 28, 2024...

  • Page 17: A2.3 Checking And Replacing The Brush Motor Carbon Brushes

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A2.3 Checking and replacing the brush motor carbon brushes Disassembly Go to the designated tank draining area and empty out both tanks. Make sure that there is enough room around the machine to carry out disassembly operations in safety. Set the water delivery control to zero.
  • Page 18 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti 18.9±0.1 mm 7.44±0.03 ins 6.9±0.1 mm 13.9±0.1 mm 2.7±0.03 ins 5.47±0.03 ins Always replace all four brush motor carbon brushes at the same time. If the two brush motors mounted on the head have been in operation for the same number of hours, replace all eight carbon brushes (four on each motor).

  • Page 19: A2.4 Disassembling The Brush Motor Thermal Overload Cutout

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A2.4 Disassembling the brush motor thermal overload cutout Replacement of the thermal cutout on its own is not possible, as the component is incorporated into the carbon brush holder of the end cap. Consequently, the thermal overload cutout can be replaced only by replacing the entire end cap.
  • Page 20 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Reassembly Before assembling the new end cap, check for correct operation of the thermal overload cutout. In addition, make sure that all the carbon brushes slide freely in their slots. Fit the new end cap, repeating the steps of the disassembly operation in reverse order. Check whether or not there is a wave thrust washer installed in the bearing socket of the end cap.
  • Page 21 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A3 BRUSH HEAD ACTUATOR Actuators are electromechanical devices serving to lower and raise the brush head or the squeegee model and part number. May 28, 2024...

  • Page 22: A3.1 Checking Brush Head Actuator Current Draw

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A3.1 Checking brush head actuator current draw Make sure the batteries on the machine are charged. Use a clamp-on ammeter with a full scale reading of at least 200 A (amperes). Go to the designated draining area and empty the dirty water tank.

  • Page 23: A3.2 Replacing The Brush Head Actuator

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti A3.2 Replacing the brush head actuator Disassembly Go to the designated draining area and empty out both tanks. Make sure that there is enough room around the machine to carry out disassembly operations in safety. the head.
  • Page 24 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti The new actuator, supplied as a spare part, requires no adjustment of any kind For maximum ease of assembly, extend the rod from the actuator almost to its full stroke Reassembly The bolt that anchors the actuator to the head acts as a pivot, and therefore must not be overtightened.
  • Page 25 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B - VACUUM UNIT – TANKS CAUTION Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses. necessary, place chocks under the wheels. anticlockwise and/or pressing the emergency switch.
  • Page 26 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B1 THREE-STAGE VACUUM MOTOR The vacuum motor on the T 681 is a THREE-STAGE radial type, which means that the air drawn in is expelled at the end of the third stage and around the outer circumference of the turbine body, through suitably designed vents.

  • Page 27: B1.1 Checking Vacuum Motor Current Draw

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B1.1 Checking vacuum motor current draw Test Make sure the machine batteries are charged. Use a clamp-on ammeter with a full scale reading of at least 200 A (amperes). Go to the designated draining area and empty the dirty water tank. May 28, 2024...
  • Page 28 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Make sure that the brush motor carbon brushes are not worn out or showing signs of abnormal wear. Make sure that the rotor bearings are not seized, which would be recognizable by abnormal noise coming from the rotor.

  • Page 29: B1.2 Disassembling And Replacing The Vacuum Motor

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B1.2 Disassembling and replacing the vacuum motor Disassembly Go to the designated draining area and empty the dirty water tank. workbench. Replace the motor with a new one of the same type. Reassembly May 28, 2024...

  • Page 30: B1.3 Replacing The Vacuum Motor Carbon Brushes On The Bench

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B1.3 Replacing the vacuum motor carbon brushes on the bench Disassembly - Checks Go to the designated draining area and empty the dirty water tank. When inspecting for wear, refer to the indications given below. Both carbon brushes should always be replaced at the same time.
  • Page 31 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B2 SQUEEGEE HEAD ACTUATOR Actuators are electromechanical devices serving to lower and raise the brush head or the squeegee head, which the operator activates by pressing dedicated buttons on the instrument panel. They are powered directly by the instrument panel circuit board.

  • Page 32: B2.1 Checking Squeegee Actuator Current Draw

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B2.1 Checking squeegee actuator current draw Make sure the machine batteries are charged. Use a clamp-on ammeter with a full scale reading of at least 20 A (amperes). Go to the designated draining area and empty the dirty water tank. below.

  • Page 33: B2.2 Replacing The Squeegee Actuator

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B2.2 Replacing the squeegee actuator Disassembly Go to the designated draining area and empty the dirty water tank. Reassembly The actuator does not require any adjustment. May 28, 2024...

  • Page 34: B2.3 Adjusting The Squeegee

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B2.3 Adjusting the squeegee Adjustment to set the ends higher. wheels, left and right. carrying the wheels. May 28, 2024...
  • Page 35 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B3 SOLENOID VALVE - CLEANING THE FILTERS The solenoid valve is an electromechanical device incorporating a rubber membrane, opened and closed by the action of a solenoid. Its function is to control the amount of water or detergent solution delivered to the brushes, as selected on the instrument panel.

  • Page 36: B3.1 Testing Operation Of Solenoid Valve

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B3.1 Testing operation of solenoid valve Test Use a digital multimeter. Go to the designated draining area and empty the dirty water tank. Elevate the dirty water tank. May 28, 2024...

  • Page 37: B3.2 Replacing The Complete Solenoid Valve

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B3.2 Replacing the complete solenoid valve Disassembly Go to the designated draining area and empty the dirty water tank. If the solenoid valve is not working, replace it with a new one. Reassembly Make the electrical connection to the solenoid valve.
  • Page 38 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti May 28, 2024...
  • Page 39 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti ening. May 28, 2024...
  • Page 40 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B4 TESTING AND REPLACING FLOAT SWITCHES operating principle is similar to that of a pushbutton. When activated, they communicate with the instrument panel pcb, tripping a visual signal (Led indicator and message on the display) and an Go to the designated draining area and empty the dirty water tank.

  • Page 41: B4.1 Checking Operation Of The Dirty Water Tank Sensor

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B4.1 Checking operation of the dirty water tank sensor pushbutton, remaining engaged until such time as a required change in conditions has occurred. When tripped, it informs the pcb by closing the circuit. Test Go to the designated draining area and empty the dirty water tank.

  • Page 42: B4.2 Checking Operation Of The Detergent Solution Tank Sensor

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti B4.2 Checking operation of the detergent solution tank sensor pushbutton, remaining engaged until such time as a required change in conditions has occurred. When tripped, it informs the pcb by closing the circuit. Test Thereafter, empty the tank and check the operation of the sensor with the tank empty.
  • Page 43 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti switch Disconnect the switch from the main wiring harness of the machine. tion on the workbench. May 28, 2024...
  • Page 44 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Disassembly - Dirty water tank Go to the designated draining area and empty the dirty water tank. tion on the workbench. Reassembly May 28, 2024...
  • Page 45 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C - DRIVE UNIT CAUTION Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses. necessary, place chocks under the wheels. anticlockwise and/or pressing the emergency switch Disconnect the machine electronics from the batteries.
  • Page 46 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C1 DRIVE MOTOR CIRCUIT BOARD ITALSEA The function of this circuit board is to supply power to the drive motor, according to the required speed. It is interfaced with the accelerator pedal, with the drive brake motor, and with the instrument panel circuit board, by way of which the maximum required speed can be set (irrespective of the accelerator pedal position) and error or fault messages can be displayed.

  • Page 47: C1.1 Italsea Drive Motor Circuit Board Connections

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C1.1 Italsea drive motor circuit board connections Connections Logic connector linking the drive motor pcb to the services pcb and the instrument panel pcb. Italsea programmer keypad connector, used to for editing standard parameters. Screw contact for drive motor power supply, ±24 V.

  • Page 48: C1.2 Programmer Italsea

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C1.2 Programmer ITALSEA Instructions for using the programmer Plug the programmer into the 4-pin connector available in each Italsea board. Switch on the machine, to supply power to the programmer, the programmer will switch-on in a few seconds.. Seat on the seat of the machine, or bridge the seat sensor to simulate the operator, otherwise the programmer may not switch-on correctly After switch-on, the display shows the active alarm(s), if there is any...
  • Page 49 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Some examples of “Inputs monitor” combinations: After switch-on, press MODE button to enter in the “PARAMETERS menu”. acceleration, …). See factory default parameters in the next paragraph. To exit the “PARAMETERS menu” and go back to the “MONITOR menu”: Press UP button and keep it pressed, then press MODE button.

  • Page 50: C1.3 Italsea Traction Board Parameters

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C1.3 Italsea traction board parameters PARAMETER DESCRIPTION DEFAULT RESET TO DEFAULT Reset to default parameters I.P.C. CT110 ACCELERATION RAMP Selection of acceleration ramp value 3.0 seconds REVERSE RAMP Selection of acceleration ramp value in reverse 1.5 seconds NEUTRAL RAMP Selection of deceleration ramp value...
  • Page 51 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C2 MOTOR DRIVE WHEEL ASSEMBLY circuit board. The motor is protected against excessive overheating by a thermal overload cutout, dust and liquids. The rubber ring of the drive wheel is easily replaced. May 28, 2024...

  • Page 52: C2.1 Checking Drive Motor Current Draw

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C2.1 Checking drive 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). Go to the designated draining area and empty the dirty water tank. Make sure that there is enough room around the machine to carry out the test in safety.

  • Page 53: C2.2 Checking And Replacing The Drive Motor Electromagnetic Brake

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C2.2 Checking and replacing the drive motor electromagnetic brake The electronic circuit board of the drive system runs an automatic test on the operation of the electromagnetic brake control, activating an audible signal (instrument panel buzzer, for around one minute) and a visual signal (display pcb) if a problem is detected.
  • Page 54 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Disassembly Undo the three screws securing the electromagnetic brake to the motor. Remove the brake unit by pulling outwards horizontally, and replace it with a new one. Reassembly It is best that the brake remains disengaged during assembly, so that the inner disc remains free to move. May 28, 2024...

  • Page 55: C2.3 Checking And Replacing The Drive Motor Carbon Brushes

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C2.3 Checking and replacing the drive motor carbon brushes Disassembly Go to the designated draining area and empty the dirty water tank. Make sure that there is enough room around the machine to carry out disassembly operations in safety. If available, use a lift table.
  • Page 56 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Reassembly If the carbon brushes need to be replaced, use others of the same type and size, referring to the details illustrated. Make sure that the carbon brushes slide freely in their seats. Align the studs and the rotor shaft with the corresponding holes in the motor end cap.

  • Page 57: C2.4 Checking And Replacing The Drive Motor Thermal Overload Cutout

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C2.4 Checking and replacing the drive motor thermal overload cutout Test Use a digital multimeter capable of reading continuity. Make sure that there is enough room around the machine to carry out disassembly operations in safety. Disconnect the thermal overload cutout from the main wiring harness, and check its continuity with the multimeter.

  • Page 58: C2.5 Replacing The Rubber Ring Of The Drive Motor

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C2.5 Replacing the rubber ring of the drive motor Disassembly Go to the designated draining area and empty out both tanks. Make sure that there is enough room around the machine to carry out disassembly operations in safety. If available, use a lift table.
  • Page 59 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Reassembly To assemble the rubber ring, procure screws similar to the ones removed, but longer, or alternatively use much longer hex head bolts, together with nuts and washers. coupling. Tighten the three screws to a maximum torque of 20 Nm ( ~ 2.0 kgm). maximum torque 8 Nm (~ 0.8 kgm).

  • Page 60: C2.6 Replacing The Drive Motor

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C2.6 Replacing the drive motor Disassembly Go to the designated draining area and empty out both tanks. Make sure that there is enough room around the machine to carry out disassembly operations in safety. Block the rear wheels with chocks to prevent the machine from moving during disassembly operations.
  • Page 61 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Stavale C3 STEERING SENSOR A component of particular importance for the safety of the machine in motion is the steering sensor in short-radius curves to avoid stability problems. The intervention of the sensor is felt through Attention: if the steering sensor is not working or the signal to the traction board is interrupted, the machine will not give any alarm indication.

  • Page 62: C3.1 Replacing The Steering Sensor

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Stavale C3.1 Replacing the steering sensor The quickest way to check the correct functioning of the steering sensor is to check that the LED at the top of the steering sensor itself turns on, and/or check that the WHITE-YELLOW wire on the traction board receives a voltage close to voltage on the batteries.
  • Page 63 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Stavale Disassembly Move the machine to the tank discharge area and empty the dirty water tank and, if necessary, also the solution tank. Make sure that there is enough room around the machine to perform the disassembly operations safely. Remove the caps on the footboard and unscrew the two screws that secure it to the frame.
  • Page 64 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Stavale Adjustment Measure the distance between the sensor head and the dedicated bracket, the measurement is approximately 18.6 mm / 0.73 in, the precision is not important, as the working range of the sensor is between 4 mm / 0.16 in and the 8 mm / 0.31 in.
  • Page 65 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C4 ACCELERATOR PEDAL The accelerator pedal, together with the relative control on the instrument panel, are used to determine the ground speed of the machine both in transit and when scrubbing. The electrical connection is 3-pin component for the accelerator potentiometer.

  • Page 66: C4.1 Disassembly And/Or Replacement Of The Accelerator Pedal

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C4.1 Disassembly and/or replacement of the accelerator pedal Disassembly Make sure that there is enough room around the machine to carry out disassembly operations in safety. To ensure safety, disconnect the batteries from the main wiring harness by pressing the emergency stop button. Unscrew the four bolts securing the accelerator pedal to the footplate.

  • Page 67: C4.2 Checking The Pedal Potentiometer And Microswitch

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C4.2 Checking the pedal potentiometer and microswitch. microswitch. Use a digital multimeter for this purpose, checking one component at a time. Disassembly Use a digital multimeter capable of reading electrical resistance and continuity. Make sure that there is enough room around the machine to carry out disassembly operations in safety.
  • Page 68 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Testing the accelerator microswitch Set the digital multimeter to detect continuity. Apply the prods of the digital multimeter to the central pin (C) and the right hand pin (NO). With the accelerator pedal in the at -rest position — circuit open — there should be no continuity reading. Depressing the pedal in the forward or reverse direction —...

  • Page 69: C4.3 Replacing The Pedal Potentiometer

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C4.3 Replacing the pedal potentiometer Disassembly Use a digital multimeter capable of reading electrical resistance and continuity. Disassemble the accelerator pedal as described in the previous heading, and transfer it to the workbench. Loosen the nut securing the potentiometer to the bracket, and remove the potentiometer.

  • Page 70: C4.4 Replacing The Pedal Microswitch

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C4.4 Replacing the pedal microswitch Disassembly Use a digital multimeter capable of reading electrical resistance and continuity. Disassemble the accelerator pedal as described in the previous heading, and transfer it to the workbench. Undo the screws securing the microswitch to the bracket and remove it.

  • Page 71: C4.5 Adjusting The Pedal Potentiometer And Microswitch

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti C4.5 Adjusting the pedal potentiometer and microswitch. Adjusting the microswitch With the pedal raised and in the neutral position (centred), move the roller near to the hollow of the pedal cam. Depress the pedal slightly to test the operation of the microswitch;...
  • Page 72 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti Adjusting the potentiometer Turn the potentiometer spindle to zero. Connect the digital multimeter to the potentiometer (see heading C3.2), depress the pedal to full travel in the forward direction and turn the spindle of the potentiometer so as to give a reading of 0 Ohms. Fit the gear of the potentiometer but without fully tightening the screw, so that the interference with the spindle is Proceed with testing of the pedal as described in heading C3.2.
  • Page 73 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti ELECTRONIC BOARDS - ELECTRICAL DIAGRAM CAUTION Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses. necessary, place chocks under the wheels. anticlockwise and/or pressing the emergency switch Disconnect the batteries from the wiring harness i INFORMATION...
  • Page 74 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti D1 INSTRUMENT PANEL CIRCUIT BOARD The circuit board of the instrument panel uses touch controls integrated into the pcb for the control of all functions May 28, 2024...

  • Page 75: D1.1 Setting The Type Of Batteries

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti D1.1 Setting the type of batteries Programming Turn the ignition key to “0”, and press the emergency stop button. Press and hold the water delivery buttons “+” and “-” simultaneously, then reset the emergency stop button by 4 seconds the type of battery will appear: “tIP A/G/t”...

  • Page 76: D1.2 Disassembling The Instrument Panel Circuit Board

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti D1.2 Disassembling the instrument panel circuit board Disassembly Make sure that there is enough room around the machine to carry out disassembly operations in safety. To ensure safety, disconnect the batteries from the main wiring harness. Undo the 5 screws securing the instrument panel to the steering column.

  • Page 77: D1.3 Main Electrical Panel

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti D1.3 Main electrical panel Disassembly Make sure that there is enough room around the machine to carry out disassembly operations in safety. To ensure safety, disconnect the batteries from the wiring harness. Remove the plastic front panel by unscrewing the four screws, two on either side.
  • Page 78 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti FUSES MAIN FUSE MAIN CONTACTOR BRUSH AND VACUUM MOTOR CONTACTORS BATTERY CHARGER ACTUATOR CIRCUIT BOARD May 28, 2024...

  • Page 79: D2.1 Wiring Diagram

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti D2 WIRING DIAGRAM D2.1 Wiring diagram May 28, 2024...
  • Page 80 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti May 28, 2024...
  • Page 81 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti May 28, 2024...
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  • Page 83 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti May 28, 2024...
  • Page 84 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti E - ERROR CODES – TROUBLESHOOTING CAUTION Go to the designated draining area and empty the detergent solution and/or dirty water tanks by way of the relative hoses. necessary, place chocks under the wheels. anticlockwise and/or pressing the emergency switch.

  • Page 85: E1.1 Alarms And Warnings Displayed On Instrument Panel

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti E1 ERROR CODES E1.1 Alarms and warnings displayed on instrument panel The display incorporated into the instrument panel shows safety warnings and error codes relative to events that can occur during use of the machine. The table below lists the various messages that could appear on the display.

  • Page 86: E1.2 Italsea Motor Drive Circuit Board Alarms

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti E1.2 ITALSEA Motor Drive circuit board alarms The STATUS LED provides two types of information: SLOW BLINK, faults are reset automatically; once a fault has been remedied, the machine returns to normal operation. FAST BLINK, shown in table with the symbol "...

  • Page 87: E2.1 Troubleshooting

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti E2 TROUBLESHOOTING E2.1 Troubleshooting E5.1.1 Machine display does not light up If there is no voltage, replace the batteries. Check the battery voltage If there is voltage registering, go to point 2 Check the electrical continuity of the power wire to the instrument Check the state of the tracks on the instrument panel circuit board panel pcb.
  • Page 88 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti E2.1.3 Brushes do not turn Reset the error message as described in table E4.2. Check whether or not there are alarm or warning messages on the If there are no errors, go to point 2. If there is voltage, go to point 3 output of the brush motor contactor and the negative pole insulator If there is no voltage registering, replace the contactor.
  • Page 89 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti 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 If everything is as it should be, go to point 3. Check that the metal clip is properly tightened and that the seal in the cap of the dirty water drain hose A is watertight - see heading if not.
  • Page 90 PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti E2.1.7 Squeegee not moving Reset the error message as described in table E4.2. Check whether or not there are alarm or warning messages on the If there are no errors, go to point 2. If actuator is working correctly, go to point 3 If the actuator is not working, replace it.

  • Page 91: E3.1 Solution To Drive Problem

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Mercanti E3 DRIVE PROBLEM E3.1 Solution to drive problem DRIVE PROBLEM Follow the instructions of heading Drive problem disappears Drive problem persists Apply remedies according to the Check carbon brushes of drive Check output voltage and input alarm generated motor and possible ingress of...

  • Page 92: Technical Service Manual Revision - Updates

    PLDC04893 REVISION 00 May 28, 2024 TECHNICAL OFFICE Stavale TECHNICAL SERVICE MANUAL REVISION - UPDATES EDITION No. DATE Edition 00 April 24, 2024 Added Italsea traction board parameters sheet. May 23, 2024 Paragraph C1.3. Added steering sensor indications. Paragraph C1.3. May 28, 2024 May 28, 2024...
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