Clarke SA40 56104487 (20D) Service Manual
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Clarke SA40 56104487 (20D) Service Manual

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SA40
Service Manual
Clarke SA40 Models: 56104487 (20D)
English
03/2016, Form No. 56043173

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Summary of Contents for Clarke SA40 56104487 (20D)

  • Page 1 SA40 Service Manual Clarke SA40 Models: 56104487 (20D) English 03/2016, Form No. 56043173...

  • Page 2: Table Of Contents

    Service Manual – SA40 Contents General Information Machine Configurations Service Manual Purpose and Application Revision History Other Reference Manuals and Information Sources Diagnostic and Service Tools Conventions Parts and Service Modifications Nameplate Cautions and Warning Symbols General Safety Instructions Prop Rod Moving the Machine Transporting the Machine Specifications...
  • Page 3 Service Manual – SA40 Programming Options Main Menu Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Submenu Functions .
  • Page 4 Service Manual – SA40 Bench-testing the Flyback Diode (bridge rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Removal and Installation Vacuum Motor .
  • Page 5 Service Manual – SA40 Steering System Functional Description Component Locations Troubleshooting Wheel System - Traction Functional Description Wheel Drive Motor Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Power to the E1 Curtis 1210 Speed Controller .

  • Page 6: General Information

    56104487 (20D) 56042653 56091196 - English, Español, Français These manuals can be found on the following Nilfisk-Advance’s electronic supported databases: • Nilfisk-Advance Dealer Customer Zone • Advance website: www.advance-us.com • Nilfisk website: www.nilfisk.com • Clarke website: www.clarkeus.com • EzParts service/parts CD-ROM...

  • Page 7: Diagnostic And Service Tools

    Service Manual – SA40 General Information Diagnostic and Service Tools In addition to a full set of metric and standard tools, the following items are required in order to successfully and quickly perform troubleshooting and repair of Advance commercial floor cleaning equipment. •...

  • Page 8: Cautions And Warning Symbols

    Service Manual – SA40 General Information Cautions and Warning Symbols Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Read this information carefully and take the necessary steps to protect personnel and property. Danger! Is used to warn of immediate hazards that will cause severe personal injury or death. Warning! Is used to call attention to a situation that could cause severe personal injury.
  • Page 9 Service Manual – SA40 General Information Caution! Be sure to follow these safety precautions to avoid situations that could cause personal injury, damage to property or equipment damage. • This machine is not approved for use on public paths or roads. •...

  • Page 10: Prop Rod

    Service Manual – SA40 General Information Prop Rod To prevent the Control Panel Housing / Recovery from dropping unexpectedly and Tank Cover causing injury, always engage the Prop Rod shown before working under the Control Panel Panel Housing Housing/ / Recovery Tank Cover Recovery Tank Cover Prop Rod...

  • Page 11: Transporting The Machine

    Service Manual – SA40 General Information Transporting the Machine Caution! Before transporting the machine on an open truck or trailer, make sure: • All tanks are empty. • The recovery tank cover is latched securely. • The machine is tied down securely. (Refer to the Tie-down Locations below. •...

  • Page 12: Overall Dimensions

    Service Manual – SA40 General Information Overall Dimensions 1.13 [28,7] 52.5 [1332] 48.5 [1232] 24.5 [623] 27.9 [710] Fastener Torque Specifications Size Plated Steel Stainless Steel 42 in.-lb. [4.75 N-m] 28 in.-lb. [3.17 N-m] 1/4“ 100 in.-lb. [11.3 N-m] 67 in.-lb. [7.57 N-m] 5/16”...

  • Page 13: Maintenance

    Service Manual – SA40 General Information Maintenance General Maintenance Information Keep the machine in top condition by closely following the maintenance schedule. Maintenance intervals given are for average operating conditions. Machines used in severe environments may require service more often. Caution! Do not pressure-wash the machine Maintenance Schedule...

  • Page 14: Lubrication Locations

    Service Manual – SA40 General Information Lubrication Locations • Once a month apply Lubriplate® 730-2 or equivalent grease to, or grease the fitting on, the following components. Avoid using too much grease. • Hex Shaft/Steering Tube Assembly • Drive Wheel Chain •...

  • Page 15: Major Machine Components

    Service Manual – SA40 General Information Major Machine Components Control System Electrical System Recovery System Solution System Chassis System Squeegee Assembly Scrub System - REV Scrub System - 20D...

  • Page 16: Machine Controls

    Service Manual – SA40 General Information Machine Controls Key Switch, Emergency Stop and Horn Switch • – controls the battery power to the machine. Key Switch Note that you must turn the to the on ( Key Switch position before stepping onto the machine platform. Switch •...

  • Page 17: Circuit Breakers

    Service Manual – SA40 General Information Circuit Breakers are mounted on the top of the control panel. To reset a , press the Circuit Breakers Circuit Breaker corresponding reset button • – labeled in the 50-amp Circuit Breaker Ladder Diagram; controls the positive voltage to the E1 Curtis 1210 Speed Controller.

  • Page 18: Speed And Direction Controls And Indicators

    Service Manual – SA40 General Information Speed and Direction Controls and Indicators • The – labeled in the Ladder Diagram; Speed Adjustment Knob 100K potentiometer that controls the machine speed in both forward and reverse. Speed Adjustment Knob R1 • The select the direction the machine will move when the Go Pedal is Forward Reverse Drive Switches...

  • Page 19: Scrub Controls And Indicators

    Service Manual – SA40 General Information Scrub Controls and Indicators Note: The scrub pressure, recovery vacuum power, solution flow rate and detergent strength settings that will be in effect when the One-touch Scrub On/Off Switch is pressed is determined by the Save Scrub ™ Settings submenu in the Programming Options. is selected, the machine will use the scrub settings that • If SAVE SCRUB SETTINGS/YES were in use when the key switch was switched off.

  • Page 20: Solution Controls And Indicators

    Service Manual – SA40 General Information Solution Controls and Indicators • – functions as follows: Solution Flow Adjustment Switch • When the scrub system is enabled, pressing the Solution Solution Flow Rate will cycle the solution flow rates Flow Adjustment Switch Bar Graph from low (bottom box filled as shown), to medium (bottom two boxes filled), to high (all three boxes filled), then to off...

  • Page 21: Information Switch

    Service Manual – SA40 General Information Note: If the One-touch Scrub On/Off Switch is pressed while wet vacuuming, the wet vacuuming mode ™ will be disabled. The scrub deck and vacuum motor control will revert to the standard scrub mode operation. • –...

  • Page 22: Battery Status Screens

    Service Manual – SA40 General Information Battery Status Screens • – displayed when the battery Battery Low Voltage Screen voltage drops to approximately 21.75 volts. The graphic display will alternate between the Battery Status Screen and the “normal” display at five-second intervals to alert the Operator that the batteries need charging and the remaining Battery Low Voltage Screen battery time is very short.

  • Page 23: Chassis System

    Service Manual – SA40 Chassis System Major Chassis Components The Chassis System provides the framework on which the machine components are mounted. Battery Tray contains the batteries Platform and connectors and is Assembly mounted to the top of Chassis Weldment Battery Tray Platform Assembly...

  • Page 24: Platform Switches

    Service Manual – SA40 Chassis System Platform Switches are mounted on the top of the Operator Presence Pedal Go Pedal Platform • When the Operator stands on the he/she presses the which actuates the Platform, Operator Presence Pedal (called the “Deadman Switch S2” in the Diagram).

  • Page 25: Control System

    Service Manual – SA40 Control System Control System Functional Description The Control System consists of the A1 Control Board (Main Machine Controller) and the E1 Curtis 1210 Speed Controller. The A1 Control Board controls the scrubbing and wastewater recovery functions based on Operator requests, and motion and direction inputs from the E1 Curtis 1210 Speed Controller.

  • Page 26: Component Locations

    Service Manual – SA40 Control System Component Locations The following components are included in this section: Interface E1 Curtis Panel • A1 Control Board A1 Control 1210 Speed Assembly Board Controller • E1 Curtis 1210 Speed Controller is mounted to the A1 Control Board rear of the Interface Panel Assembly...

  • Page 27: Fault Code Table

    Service Manual – SA40 Control System Fault Code Table Display Fault Description Conditions Needed to Set the Fault Code Code The E1 Curtis Speed Controller is communicating a problem to Speed Control fault the A1 Control Board. Scrub Deck Actuator overload The Scrub Deck Actuator has drawn more than 4.5 amps.

  • Page 28: System Disabled By Fault Codes

    Service Manual – SA40 Control System System Disabled by Fault Codes Disable System Flash Indicator Fault Description Speed Control fault Scrub Deck Actuator overload Solution Solenoid overload Vacuum Contactor (SSR1) coil overload Brush Contactor (K2) coil overload Detergent Pump overload Detergent Pump driver fault Deck Actuator driver fault Solution Solenoid open...

  • Page 29: Service Test Mode

    Service Manual – SA40 Control System Service Test Mode The Service Test Mode allows you to switch the individual electrical system components on and off independent of the normal Operator inputs. This serves as a “shortcut” when troubleshooting the machine systems. Service Test Mode is accessed through the hidden menu system which is described in “Programming Options”...
  • Page 30 Service Manual – SA40 Control System Control Panel Switch Service Test Mode Function Graphic Display Descriptions Information Pressing the Information Switch toggles the SPD: R 26.5 BRU: OFF Switch REV: ON VAC: OFF Inhibit output ( ) from the A1 Control Board to INH: ON SOL: OFF the E1 Curtis Speed Controller...

  • Page 31: Programming Options

    Service Manual – SA40 Control System Programming Options The SA40 graphic display has two “layers” of hidden menus that allow you to view and change the various programmable machine configurations, system settings and parameters. The top “layer” is the main menu from which you can navigate to the 20 submenus.

  • Page 32: Submenu Functions

    Service Manual – SA40 Control System Submenu Functions Deck Type The SA40 supports only 1 deck type. So this function should not be PROGRAM OPTIONS changed. This submenus allow you to specify the type of deck installed in 1. DECK TYPE your machine.

  • Page 33: Battery Charger

    Service Manual – SA40 Control System Battery Charger The current series of battery chargers don’t communicate with the A1 PROGRAM OPTIONS control board. So this menu entry has no current function. If there was 3. BATTERY CHARGER communication, this menu entry would permit the A1 control board to notify the charger which type of battery was being charged so the on- board charger would use the charging algorithm that is compatible with the battery type.

  • Page 34: Detergent (Ecoflex ™ ) Option

    Service Manual – SA40 Control System Detergent (EcoFlex ) Option ™ The SA40 does not utilize a separate detergent system. So this menu item PROGRAM OPTIONS is not applicable at this time. The menu choice must be set to “No”. 5.

  • Page 35: Lock Out Brush Pressure

    Service Manual – SA40 Control System Lock Out Brush Pressure submenus allow you to lock out the low or high 9. LOCKOUT BRUSH PROGRAM OPTIONS scrub pressure settings. The Operator will not be able to select a scrub 9. LOCKOUT BRUSH pressure setting that is locked out.

  • Page 36: Backup Alarm Volume

    Service Manual – SA40 Control System Backup Alarm Volume (volume) submenus allow you to set the 11. BACKUP ALARM VOL PROGRAM OPTIONS backup alarm volume. 11. BACKUP ALARM VOL The default setting is MEDIUM PROGRAM OPTIONS BACKUP ALARM VOL PROGRAM OPTIONS BACKUP ALARM VOL PROGRAM OPTIONS BACKUP ALARM VOL...

  • Page 37: 14. Restore Defaults

    Service Manual – SA40 Control System Restore Defaults submenus allow you to reset the programmed 14. RESTORE DEFAULTS PROGRAM OPTIONS options/parameters stored in the A1 Control Board EEPROM to their 14. RESTORE DEFAULTS factory default values. Note that selecting will RESTORE DEFAULTS / YES not reset the hour meter.

  • Page 38: Extra Information On The Graphic Display

    Service Manual – SA40 Control System Extra Information on the Graphic Display submenus allow you to display additional 17. EXTRA INFO ON LCD PROGRAM OPTIONS information on the graphic display. This additional information is 17. EXTRA INFO ON LCD displayed in real time on both the Scrubbing and Information screens and can aid in troubleshooting the machine in normal operation.

  • Page 39: Frozen Parameters

    Service Manual – SA40 Control System Frozen Parameters first and second-level submenus allow you 18. FROZEN PARAMETER PROGRAM OPTIONS to view the machine parameters that were saved prior to when an error 18. FROZEN PARAMETER code was detected. This can be helpful when troubleshooting intermittent problems that are causing a code to set.
  • Page 40 Service Manual – SA40 Control System To display the parameter data points in a second-level submenu: PROGRAM OPTIONS 1. Press the Forward (up) or Reverse (down) Drive Switch to scroll through FROZEN PARAMETER the available first-level submenus. (The first-level submenu 3.

  • Page 41: 19. Panel Test

    Service Manual – SA40 Control System Panel Test PROGRAM OPTIONS submenus allow you to verify the function of the control 19. PANEL TEST 19. PANEL TEST panel membrane switches and LEDs, This will help identify any intermittent or non-functioning switches or LEDs. When the submenu is first entered, all LED will turn off PROGRAM OPTIONS PANEL TEST...

  • Page 42: Removal And Installation

    Service Manual – SA40 Control System Removal and Installation A1 Control Board Caution! Electronic devices like the A1 Control Board are sensitive to Electrostatic Discharge (ESD). Before handling the Control Board, touch a metal bench or shelf to discharge any electrical charge that may have built up in your body.

  • Page 43: E1 Curtis 1210 Speed Controller

    Service Manual – SA40 Control System 4. Carefully disconnect the Electrical from the Connectors A1 Control Board 5. Remove the and grounding Phillips Screws strap, then remove the A1 Control Board from the Interface Panel Assembly 6. Reinstall the by following A1 Control Board Electrical the above steps in reverse order.
  • Page 44 Service Manual – SA40 Control System 3. Carefully lift the Interface out of the Panel Assembly Control Panel Control Interface Panel Panel Assembly 4. Carefully disconnect the from Electrical Connectors E1 Curtis 1210 Speed Controller Electrical 5. Remove the two Socket Connector and remove...

  • Page 45: A1 Control Board Shop Measurements

    Service Manual – SA40 Control System A1 Control Board Shop Measurements The following table lists measurements taken from one SA40 machine. While these are not “specifications”, they can help you recognize abnormal vs. normal conditions. Note that the black voltmeter lead is on B- unless otherwise indicated. Color Description Ref.
  • Page 46 Service Manual – SA40 Control System Color Description Ref. Measurements J3-7 ORN/BLU Status 1.77v when no code Unstable when code – max 23.5v J3-8 24.4v key off or on J3-9 GRN/BLK Horn - 14.9v horn off 0.004v horn on J3-10 ORN/RED Horn + 14.9v horn off or on...

  • Page 47: Electrical System

    Service Manual – SA40 Electrical System Functional Description Overview The electrical system consists of the switches, circuit breakers and contactors mounted on and underneath the control panel assembly, the 150-amp main fuse, on-board battery charger (if so equipped) and the batteries.

  • Page 48: On-Board Battery Charger

    Service Manual – SA40 Electrical System On-board Battery Charger An optional on-board battery charger is mounted on the bottom of the machine. Interlock Circuit The battery charger has an “interlock circuit” which consists of an internal relay that interrupts the “Deadman” signal to the main control board, and the Delta-Q Charger Keyswitch Input (KSI) signal to the drive speed controller when the charger is plugged into an AC power outlet.
  • Page 49 Service Manual – SA40 Electrical System Charter Interlock Circuit, Plugged In Battery 24 VDC Fuse, 150 A. Internal Relay in Battery Charger 1 2 3 Not Used YEL/ORN Emergency Stop Dead Man Switch Not Used SPST Key Circuit Breaker, 5 Amp Switch Dead Man Switch J3-4...

  • Page 50: Delta-Q Charging Profiles And Charging Progress

    Service Manual – SA40 Electrical System Delta-Q Charging Profiles and Charging Progress The Delta-Q battery charger does not communicate with the main machine controller. It is a “stand-alone” unit. Models that have the Delta-Q charger have a separate LED to communicate charging progress. By pressing a button on the charger you can see what charging profile is in use.
  • Page 51 Service Manual – SA40 Electrical System Battery Manufacturer Volts Battery Model # 20 Hour N-A P/N Use Profile Rating US BATTERY US-125 56206079 P-0-1-1 US BATTERY US-125 40136A P-0-1-1 US BATTERY US-125 40136B P-0-1-1 US BATTERY US-14 5XC 56317154 P-0-7-2 US BATTERY US1800 56206117...

  • Page 52: Component Locations

    Service Manual – SA40 Electrical System Component Locations The following electrical components are included in this section: • Batteries • Optional On-board battery charger • Switches • Circuit Breakers • Contactors/Relays • 150-amp Fuse sit in the Batteries . To access Battery Tray Recovery , lift up the...
  • Page 53 Service Manual – SA40 Electrical System 25-amp Circuit Breaker (CB4), 20-amp Circuit 25-amp 20-amp 5-amp 50-amp (CB3), Circuit Circuit Circuit Circuit Breaker 5-amp Circuit Breaker Breaker Breaker Breaker (CB2) and Breaker 50-amp (CB1), Circuit Breaker 100k Speed Control Potentiometer (R1), Emergency Disconnect (S1) are all Key Switch...

  • Page 54: Troubleshooting

    Service Manual – SA40 Electrical System Troubleshooting Note: Refer to the individual machine system sections for electrical troubleshooting procedures. Problem Cause Correction No power to the Discharged batteries. Check the battery voltage and charge as necessary. machine. Poor battery connection(s). Check the battery cables, terminals and connections and tighten/repair/replace as necessary.

  • Page 55: Wiring Diagrams

    Service Manual – SA40 Electrical System Wiring Diagrams Wiring (Ladder) Diagram Drawing 56104446, Rev. C FUSE, 150A. BATTERY, 24 Vdc X002 BRN/BLK CIRCUIT BREAKER, 50A. X001 1 2 3 CHARGER OPTIONAL WHEN CHARGER IS NOT INSTALLED SEE PAGE 2 THERE NEEDS TO BE A JUMPER BETWEEN PINS 1 AND 2 ON CONNECTOR X126 ON MAIN HARNESS 1 2 3...
  • Page 56 Service Manual – SA40 Electrical System Wiring (Ladder) Diagram, continued MOTOR, BRUSH LIFT ACTUACTOR YEL/ORN J2-3 BAT CHARGER ON BOARD COMMUNICATION BRUSH ACT (-) J1-9 TOP LIMIT A1(CONTROL BOARD) MAIN MACHINE CONTROLLER YEL/BLK B- J1-8 POS 1 RED/VIO ACT POSITION1 J2-12 POS 2 BLK/WHT ACT POSITION2 J2-11...

  • Page 57: Wiring Harness Diagram

    Service Manual – SA40 Electrical System Wiring Harness Diagram Drawing 56104447, Rev. B...

  • Page 58: Electrical Connector Pin-Out Assignments

    Service Manual – SA40 Electrical System Electrical Connector Pin-out Assignments The following tables list the individual connector pin-out assignments. The tables include connector illustrations to help you identify the various connectors on the machine. The connector pin-out information is organized by connector ID in alphabetical order. To Locate and Identify a Connector For example, if you need to find out which connector is on the (solution)

  • Page 59: Connector Pin-Out Assignment Tables

    Service Manual – SA40 Electrical System Connector Pin-out Assignment Tables J1 (Molex Mini Fit Jr. 39012105) Pin# Conductor Wire Color W279 RED/YEL – – W280 BLU/GRA – – – – W302 RED/YEL YEL/BLK W165 W054 W055 ORN/BLK J2 (Molex Mini Fit Jr. 39012125) Pin# Conductor Wire Color...
  • Page 60 Service Manual – SA40 Electrical System J3 (Molex Mini Fit Jr. 39012145) Pin# Conductor Wire Color W181 BRN/VIO – – W166 RED/BRN W294 W066 BLU/BLK W277 RED/WHT W067 ORN/BLU W182 BRN/VIO W281 GRN/BLK W282 ORN/RED W283 VIO/BLK W003 GRA/BLK W010 WHT/RED W183...
  • Page 61 Service Manual – SA40 Electrical System J4 (39012185) Pin# Conductor Wire Color – – – – W060 W272 W293 W276 RED/WHT – – – – W067 ORN/BLU – – – – W302 RED/YEL W064 W278 – – W066 BLU/BLK W166 RED/BRN W217 GRN/ORN...
  • Page 62 Service Manual – SA40 Electrical System X6 (Delphi 12052613) Pin# Conductor Wire Color W191 W194 X7 (Delphi 12015792) Pin# Conductor Wire Color W284 W283 VIO/BLK X126 (AMP 282087-1) Pin# Conductor Wire Color W172 W173 RED-VIO W174 YEL-ORN...
  • Page 63 Service Manual – SA40 Electrical System X127 (Delphi 15363990) Pin# Conductor Wire Color W170 W171 X139 (Delphi 12020786) Pin# Conductor Wire Color W055 ORN/BLK W054 W204 RED/VIO W165 YEL/BLK – – W218 BLK/WHT X143 (Ducon 12147067) Pin# Conductor Wire Color W273 RED/GRN W274...
  • Page 64 Service Manual – SA40 Electrical System X144 (Delphi 12015792) Pin# Conductor Wire Color W278 W275 RED/WHT X161 (Delphi 12020926) Pin# Conductor Wire Color W272 W271 W289 WHT/BRN W293 W294...

  • Page 65: Recovery System

    Service Manual – SA40 Recovery System Functional Description The Recovery System pulls the wastewater from the squeegee and directs it into the recovery tank. The 24-volt, three-stage electric vacuum motor creates a vacuum in the recovery tank with sufficient airflow to lift the used cleaning solution from the squeegee and into the vacuum hose assembly, which then directs the water into the recovery tank.

  • Page 66: Circuit Descriptions

    Service Manual – SA40 Recovery System • The ) controls the Solid State Relay voltage to the Vacuum Motor. Note that the Solid State Relay has an LED that Solid State Relay (K1) lights when the is on. Relay • The reduces the high- Flyback Diode (D2) voltage spike through the Solid State...

  • Page 67: Vacuum Motor On

    Service Manual – SA40 Recovery System Vacuum Motor On Bat + Bat - Control Board SPST Key Switch Vacuum Contactor Curtis 1210 BRN/VIO GRA/BLK J3-12 Speed Bat - Controller RED/WHT J3-6 Pin 6 Brake - Bat - Motion Input (0.1v) BLU/ORN Circuit Breaker, 20 Amp Solid State...

  • Page 68: Component Locations

    Service Manual – SA40 Recovery System Component Locations The following components are included in this section: • Recovery Tank • Vacuum Motor • Debris Cage • Float Cage Assembly • Vacuum Hose Assembly • Drain Hose • Solid State Relay (K1) •...
  • Page 69 Service Manual – SA40 Recovery System allows you to drain the wastewater Drain Hose from the Recovery Tank. Drain Hose Solid State Relay (K1) Fly-back Diode (rectifier bridge) are (D2) located inside the control panel assembly Solid State Relay (K1) Fly-back Diode (D2) Control...

  • Page 70: Troubleshooting

    Service Manual – SA40 Recovery System Troubleshooting General Troubleshooting Problem Cause Correction Vacuum motor not No voltage from the Key Check the wiring from the Key Switch S1 to terminal running - the LED on Switch S1 to terminal 3+ on 3+ on relay SSR1 and repair as necessary.

  • Page 71: Bench-Testing The Flyback Diode (Bridge Rectifier)

    Service Manual – SA40 Recovery System Bench-testing the Flyback Diode (bridge rectifier) Negative When functioning properly, the flyback diode should conduct only when the voltage gets reversed by the vacuum motor. To test the bridge rectifier, use a DC continuity tester or an ohm meter (on the R x 100 scale) as follows.
  • Page 72 Service Manual – SA40 Recovery System 8. If you replace the Fly-back , make sure the White Diode Positive Wire is in the upper left position as shown, then fasten the to the electrical Fly-back Diode panel with the Black Screw Wire Positive Tab...

  • Page 73: Removal And Installation

    Service Manual – SA40 Recovery System Removal and Installation Vacuum Motor Vacuum Cover 1. Drain the recovery tank. M6 Screw, Flat Washer and Cover Plate (3) 2. Lift the recovery tank to access the Vacuum Cover 3. Remove the three M6 Screws Flat Washers and remove the...

  • Page 74: Specifications

    Service Manual – SA40 Recovery System Specifications Component Specifications Low Speed: 11 - 12 Amps Vacuum Motor Current Draw High Speed: 16 - 17 Amps Sealed 40 - 44 Inches of Water Vacuum Water Lift 1” open hole 9.5 Inches of Water Vacuum Motor Mounting Screws 3 NM (26 in lb) Special Tools...

  • Page 75: Scrub System

    Service Manual – SA40 Scrub System Functional Description The Scrub System includes the Scrub Deck, Brush or Pad Motor, Brush Motor Contactor (K2 relay) and Deck Actuator Assembly. A 24-volt electric motor powers the brush/pad. The scrub deck has four vertical positions: •...

  • Page 76: Scrub Deck And Motor

    Service Manual – SA40 Scrub System Scrub Deck and Motor 20D Scrub Deck Brush The 20D Scrub Decks use a Motor horizontally-mounted Brush Motor with an integral gearbox to drive the and attached Brush Plate Assembly . The is fastened to Brush Brush Motor , which is bolted to the...

  • Page 77: Brush Motor Contactor

    Service Manual – SA40 Scrub System Brush Motor Contactor controls the Brush Motor Contactor (K2) power to the Brush/Pad Motor. Brush Motor Contactor (K2) Deck Actuator Assembly uses an electric to run a lead screw Deck Actuator Assembly Motor that extends and retracts the and attached .
  • Page 78 Service Manual – SA40 Scrub System Two internal , actuated by rotating , provide Position Switches Cams actuator position feedback to the A1 Control Board. Two internal (top and bottom), also actuated by Limit Switches rotating , switch off the actuator at the fully-retracted Cams Motor...

  • Page 79: Circuit Descriptions

    Service Manual – SA40 Scrub System Circuit Descriptions Scrub Brush Motor Scrub Brush Motor Off Control Board Bat + Bat - Brush Contactor WHT/RED Curtis 1210 J3-13 Bat - SPST Key Speed Switch Controller RED/WHT Brake - J3-6 Pin 6 Bat - Motion Input 24v BRN/VIO...

  • Page 80: Scrub Brush Motor On

    Service Manual – SA40 Scrub System Scrub Brush Motor On Control Board Bat + Bat - Brush Contactor WHT/RED Curtis 1210 J3-13 Bat - SPST Key Speed Switch Controller RED/WHT Brake - J3-6 Pin 6 Bat - Motion Input (0.1v) BRN/VIO Brush Brush Motor...

  • Page 81: Deck Actuator Assembly

    Service Manual – SA40 Scrub System Deck Actuator Assembly Scrub Deck Up When the Scrub System is switched from active to not active, Deck Actuator Assembly Control Board in the Gang Switch A1 Control switches on the power to the Board Upper Brush Lift Actuator Motor M3...

  • Page 82: Scrub Deck At Normal Scrub Pressure

    Service Manual – SA40 Scrub System Scrub Deck at Normal Scrub Pressure When the Scrub System is active, the in the Deck Actuator Assembly Gang Switch A1 Control Board Control Board switches on the power to the Brush Lift . The Actuator Motor M3 Deck Actuator lowers the scrub deck to the...

  • Page 83: Component Locations

    Service Manual – SA40 Scrub System Component Locations The following components are included in this section: • Scrub Deck • Scrub Deck Motor • Brush Motor Contactor (K2) • Scrub Deck Actuator Assembly is suspended underneath Scrub Deck the machine and pivots up and down on a mechanical mount.
  • Page 84 Service Manual – SA40 Scrub System controls Brush Motor Contactor (K2) the power to the scrub deck motor and is located inside the control panel assembly. Brush Motor Contactor (K2) Scrub Deck Actuator Assembly is attached to the Scrub Deck machine frame and lowers and Scrub Deck raises the...

  • Page 85: Troubleshooting

    Service Manual – SA40 Scrub System Troubleshooting Problem Cause Correction Brush Motor not No voltage to the K2 Brush 1. Check the voltage on pin J3-13 on the A1 Control running Contactor coil Board. The signal, referenced to ground, should be 24.3v with the Brush Motor off, 0.2v with the Brush Motor on.

  • Page 86: Removal And Installation

    Service Manual – SA40 Scrub System Removal and Installation Scrub Deck 1. Turn the key switch on, then press the Scrub On/ Off Switch to lower the scrub deck to the normal scrub position. This will relieve the tension between the scrub deck actuator and the scrub deck.
  • Page 87 Service Manual – SA40 Scrub System 8. Remove the from the Vacuum Hose Scrub Deck Scrub Deck 9. Press the rear of the Squeegee Mount to disengage it from the pins on Bracket and remove Squeegee Link Weldment Vacuum from the Squeegee Scrub Deck Squeegee...
  • Page 88 Service Manual – SA40 Scrub System Service Tip: Note of the rotational position of the screw hole in the when you remove the Plunger . Be careful not to rotate Shoulder Screw once the Tube Plunger Scrub Deck is disconnected from the scrub Actuator deck.
  • Page 89 Service Manual – SA40 Scrub System 14. Disconnect the Scrub Deck Motor Electrical Connector Scrub Deck Motor Electrical Connector 15. Carefully slide the deck out of the machine. Service Tip: The scrub motors on the 20R REV™ scrub decks are slightly taller than the motors on 20D decks.

  • Page 90: Scrub Deck Actuator Assembly

    Service Manual – SA40 Scrub System Scrub Deck Actuator Assembly 1. Turn the key switch on, then press the Scrub On/Off Switch to lower the scrub deck to the normal scrub position. This will relieve the tension between the scrub deck actuator and the scrub deck. 2.

  • Page 91: Scrub Deck Actuator Adjustment

    Service Manual – SA40 Scrub System Service Tip: If you’re going to reinstall the Scrub Deck without readjusting the position Actuator of the , be careful not to rotate the Tube with the Tube Plunger Scrub Deck out of the machine. This can Actuator cause the to get out of Scrub Deck Actuator adjustment.

  • Page 92: Specifications

    Service Manual – SA40 Scrub System Specifications Component Specifications Voltage – 24 VDC RPM – 140 No Load ≈ 6.2 Amps 20D Scrub Deck Brush Motor Normal Operation ≈ 12-19 Amps Current Draw depending on floor surface, solution flow rate and scrub pressure Output Power –...

  • Page 93: Solution System

    Service Manual – SA40 Solution System Functional Description The Solution System is a gravity-feed system that supplies cleaning solution to the scrub brush/pad on the scrub deck. The Solution Solenoid Valve controls the solution flow to the scrub deck. The A1 Control Board sends a pulsed voltage signal to the Solution Solenoid Valve that opens and closes the Valve to regulate the solution flow according to the flow rate selected with the solution flow adjustment switch.

  • Page 94: Solution Solenoid Valve

    Service Manual – SA40 Solution System Solution Solenoid Valve controls the solution flow to the L1 Solution Solenoid Valve scrub deck. The solution from the solution tank enters the Electrical Connector through the side port and exits through the Solution Solenoid Valve rear port to the scrub deck as shown.

  • Page 95: Circuit Descriptions

    Service Manual – SA40 Solution System Circuit Descriptions Solution Solenoid Valve Off Bat + BRN/VIO SPST Key Switch Control Board Solution Solution Line from E1 Curtis VIO/BLK Solenoid Solenoid Valve J3-11 1210 Speed Bat - to Scrub Deck Controller RED/WHT Brake - J3-6 Pin 6...

  • Page 96: Solution Solenoid Valve On

    Service Manual – SA40 Solution System Solution Solenoid Valve On Bat + BRN/VIO SPST Key Switch Control Board Solution Solution Line from E1 Curtis VIO/BLK Solenoid Solenoid Valve J3-11 1210 Speed Bat - to Scrub Deck Controller RED/WHT Brake - J3-6 Pin 6 +24v...

  • Page 97: Component Locations

    Service Manual – SA40 Solution System Component Locations The following components are included in this section: • Solution Tank • Solution Solenoid Valve • Solution Ball Valve • Water Filter • 90° Ball Valve and Drain Hose • Detergent Cartridge holds approximately Solution Tank 12 gallons of solution.
  • Page 98 Service Manual – SA40 Solution System The solution controls the solution flow Ball Valve from the solution tank to the Water Filter Ball filters the solution upstream of the Valve Water Filter solution solenoid valve. Water Filter allow you to 90°...

  • Page 99: Maintenance

    Service Manual – SA40 Solution System Maintenance Cleaning the Water Filter Water Filter 1. Close the solution to shut off the Ball Valve Ball solution flow from the solution tank to the Valve Water Filter 1. Unscrew the Filter Cap 1.

  • Page 100: Specifications

    Service Manual – SA40 Solution System Specifications Component Specifications Component Specifications Nominal Voltage – 24 VDC, 11 Watt Solution Solenoid Valve Duty – Continuous Resistance – 55.5 Ohms ±10% @ 25° C Solution Tank Capacity – 12 gal. [45,4 l] Nominal Solution Flow Rates The nominal solution flow are listed in the following table.

  • Page 101: Squeegee System

    Service Manual – SA40 Squeegee System Functional Description Squeegee Assembly is designed to be easily removed from its mounting Squeegee hardware for cleaning and Link Squeegee Weldment Mount maintenance. Bracket Rear Squeegee Strap Knob Assembly (4) holds the Rear Squeegee on the Blade Squeegee...

  • Page 102: Component Locations

    Service Manual – SA40 Squeegee System Component Locations The following components are included in this section: • Vacuum Hose Assembly • Squeegee Link Weldment • Knob Assemblies • Squeegee Blades • Squeegee Casting • Caster Wheel • Squeegee Mount Bracket •...

  • Page 103: Troubleshooting

    Service Manual – SA40 Squeegee System Troubleshooting Problem Cause Correction Poor water pick-up. The squeegee blades are torn Check and replace the blades as necessary. or worn. The squeegee assembly is out Readjust the squeegee as follows: of adjustment. 1. Park the machine on a flat, even surface and lower the squeegee.

  • Page 104: Steering System

    Service Manual – SA40 Steering System Functional Description Steering Wheel attached Steering Shaft connected to and rotate the Steering Upper Universal Joint Wheel Upper Universal Joint drives the which Hex Shaft drives the Steering Tube . Note that the Assembly Steering is designed to Hex Shaft...

  • Page 105: Component Locations

    Service Manual – SA40 Steering System Component Locations The following components are included in this section: • Upper Universal Joint • Hex Shaft • Steering Tube Assembly • Lower Universal Joint • Steering Plate The Upper Universal Joint, Hex Shaft and Steering Tube Assembly are located underneath the Recovery Tank Cover.

  • Page 106: Troubleshooting

    Service Manual – SA40 Steering System is fastened to the top of the Steering Plate Drive Wheel Assembly and rotates the Drive Steering Wheel Assembly to steer the machine left and Plate right. Troubleshooting Problem Cause Correction The steering is The upper and lower universal Realign the upper and lower universal joints.

  • Page 107: Wheel System - Traction

    Service Manual – SA40 Wheel System - Traction Functional Description The machine is propelled by the Drive which consists of a 24- Wheel Assembly volt DC and attached Drive Wheel Motor Steering that drive an Gearbox 11-tooth Sprocket Plate drives the 11-tooth Sprocket Drive that drives a...

  • Page 108: Wheel Drive Motor Circuit Descriptions

    Service Manual – SA40 Wheel System - Traction Wheel Drive Motor Circuit Descriptions Power to the E1 Curtis 1210 Speed Controller B+ B- Internal Relay in Battery Charger 1 2 3 Emergency Stop Dead Man Switch WHT/BRN SPST Key Switch Curtis 1210 Speed Controller...

  • Page 109: Speed Control Drive Functions

    Service Manual – SA40 Wheel System - Traction Speed Control Drive Functions Brake +24V Brake - Pin 6 E1 Curtis 1210 Speed Controller Pin 3 High YEL/BLK Speed GRN/ORG Limit 100K Pot. Pin 18 Wheel Drive Motor Pin 13 Pot. Low Go Switch RED/GRN Pin 4...

  • Page 110: Speed Control Communication With The A1 Control Board

    Service Manual – SA40 Wheel System - Traction Speed Control Communication with the A1 Control Board B+ B+ Control Board Brake Main Machine E1 Curtis Controller 1210 Speed Controller Motion Input Pin 6 J3-6 RED/WHT + 24v Brake - (B -) Inhibit Input Pin 12 J1-7...
  • Page 111 Service Manual – SA40 Wheel System - Traction A1 Control Board Speed Controller Function Terminal Terminal Status Signal J3-7 Pin 9 - Status (B -) uses the status signal to tell the Speed Controller when it has set a fault, and which fault is set. Control Board The switch on opens and closes in a pattern...

  • Page 112: Component Locations

    Service Manual – SA40 Wheel System - Traction Component Locations The following components are included in this section: • Drive Wheel Assembly • E1 Curtis 1210 Speed Controller • Speed Control Adjustment Knob/100k Speed Control Potentiometer • Drive Wheel Brake is fastened to Drive Wheel Assembly the machine frame underneath the front...
  • Page 113 Service Manual – SA40 Wheel System - Traction The Speed Adjustment Knob controls the 100K Speed Control Potentiometer, labeled R1 in the Wiring Diagram. The Speed Adjustment Knob is mounted on the control panel and controls the Speed machine speed in both forward and reverse. Adjustment Knob R1 100k Speed...

  • Page 114: Maintenance And Adjustments

    Service Manual – SA40 Wheel System - Traction Maintenance and Adjustments Speed Control Programming Options The following table lists the Speed Control parameters that can be accessed and changed using the 1311 Programmer. Note that these parameters normally do not need to be changed, and should not be changed arbitrarily.

  • Page 115: Troubleshooting

    Service Manual – SA40 Wheel System - Traction Troubleshooting General Troubleshooting Note: use the Service Test Mode to simplify troubleshooting the Drive Wheel System. (Refer to the Controls System/Service Test Mode.) Problem Cause Correction Machine not moving in The Speed Adjustment Knob Rotate the Speed Adjustment Knob to a higher speed forward or reverse.

  • Page 116: Diagnostics Method B - Curtis Programmer

    Service Manual – SA40 Wheel System - Traction Diagnostics Method B - Curtis Programmer Diagnostics Method B uses the optional hand-held Curtis programmer model 1311. With a programmer, diagnostics and troubleshooting are more direct than with the Direction Indicator LED alone. The programmer presents complete diagnostic information Display in plain language with no codes to decipher.

  • Page 117: Status Led Fault Code Table

    Service Manual – SA40 Wheel System - Traction Status LED Fault Code Table Status Light Explanation Possible Cause Code Display Over-/under-temperature cutback 1. Temperature >92°C or < -25°C 2. Excessive load on vehicle 3. Operation in extreme environments 4. Electromagnetic brake not releasing. 0 00 Throttle fault 1.

  • Page 118: Removal And Installation

    Service Manual – SA40 Wheel System - Traction Removal and Installation Drive Wheel Assembly 1. Loosen the Setscrew holding the Steering Assembly Tube in Steering Assembly the lower Universal Joint. Tube Universal Joint Setscrew 2. Disconnect the upper Drive Motor and Brake Drive Motor Electrical Connectors.
  • Page 119 Service Manual – SA40 Wheel System - Traction 7. Remove the four M8 x 45 Screws and flat washers, then remove the Drive Wheel Assembly and attached Spindle Spindle Mount Weldment from the machine. Mount Weldment Spindle Mount Weldment Drive Wheel Assembly M8 x 45...

  • Page 120: Drive Wheel Motor

    Service Manual – SA40 Wheel System - Traction Drive Wheel Motor 1. Remove the Drive Wheel Assembly M8 x 55 Screw described on page 118 2. Loosen the M6 Locknut, then back the M6 Sprocket x 35 Idler Adjuster Screw out of the Idler Assembly Adjust Weldment.
  • Page 121 Service Manual – SA40 Wheel System - Traction 7. Remove the four M6 x 25 Screws and flat washers, M6 x 25 Screw (4) then remove the Drive Motor from the Drive Drive Wheel Wheel Frame Weldment. Frame Weldment 8. To reinstall the Drive Motor into the Drive Wheel Frame Weldment, follow the above steps in reverse order.

  • Page 122: Steering Spindle Bearings

    Service Manual – SA40 Wheel System - Traction Steering Spindle Bearings 1. Remove the Drive Wheel Assembly described on page 118. 2. Remove the Drive Wheel Motor described on page 120. Steering Shaft 3. Remove the three M6 x 14 Screws and flat Weldment washers holding the Steering Shaft Weldment to the Spindle Mount Weldment.
  • Page 123 Service Manual – SA40 Wheel System - Traction 6. Carefully remove the Shaft Seal, Bearing Cup and Bearing Cone from the Bearing Block. 7. Replace the Shaft Seal, Bearing Cup or Bearing Cone as necessary. Make sure the Bearing Cone is greased adequately with a high-quality lithium-base grease before reassembly.

  • Page 124: Drive Wheel Motor Maintenance

    Service Manual – SA40 Wheel System - Traction Drive Wheel Motor Maintenance Replacing the Motor Brushes 1. Remove the Drive Wheel Assembly described on page 118. 2. Remove the Drive Wheel Motor described on page 120. 3. Remove the Cap holding the brush in the motor. 4.

  • Page 125: Specifications

    Service Manual – SA40 Wheel System - Traction Specifications Shop Measurements The following table lists measurements taken from one SA40. While these are not “specifications”, they can help you recognize abnormal vs. normal conditions. Note that the black voltmeter lead is on B- unless otherwise indicated. E1 Curtis 1210 Speed Controller –...

  • Page 126: E1 Curtis 1210 Speed Controller - Output

    Service Manual – SA40 Wheel System - Traction E1 Curtis 1210 Speed Controller – Output Ref. Measurements FWD low speed 12.6v FWD high speed 23.4v REV low speed 11 v REV high speed 3.9v FWD low speed 11.2v FWD high speed 0.17v REV low speed 12v REV high speed 20v FWD low speed 1.5v...

  • Page 127: Special Tools

    Service Manual – SA40 Wheel System - Traction Special Tools Curtis 1311 Handheld Programmer, p/n 56409441...

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